Builds OL'BETSY ZX: 1991 HZJ77 (40 Viewers)

[JDM Journeys]

Oh man door handles were tough. Decided to go into the scoop below the handle with the stripe. Some conservative heat gun action did the trick.

RHS is now complete.

 

[Fiddy5000]

Oh man door handles were tough. Decided to go into the scoop below the handle with the stripe. Some conservative heat gun action did the trick.

RHS is now complete.

View attachment 3294079

View attachment 3294080

That looks good!

 

[Rigster]

Oh wow this is painful. If anyone ever decides to tackle stripes, think long and hard about putting it at the beltline. Door handles, badges, intakes... It's all in the way. I think aesthetically it's the right place, but holy crap what a giant pain in the...

View attachment 3293994

Front fender on RHS is done. Working on the door now.

Man... I hear you. My wife will often comment to me about my patience, but I am 100% convinced that this would test mine.

That said, I will be honest - I wasn't sure about the whole idea as I don't even like stickers or dealership stickers, etc... I spent hours when I got my land cruiser removing them.

Looking at the one fender done, I have to admit, that looks really good on there bud!!

 

[JDM Journeys]

I definitely think stripes are a hit or miss, but in this case, the two tone always seemed to be crying out for something to break up the belt line, which always looked too low to me where the silver started.

I think this little add on will allow me to accept the two tone, until such time as I get a full respray. But that might be a long time coming, if ever. I'll redo the hood and roof, finish the wheels, and call her pretty enough for now.

Also, everybody knows that stripes add horsepower.

 

[JDM Journeys]

One side is now fully done, plus fender on the other side is completed. Hope to finish it tomorrow and then get her out in the light and see how acceptable it is.

 

[coldtaco]

Keep thinking about doing some stripe kit for my Ute, but haven’t decided one way or another

 

[JDM Journeys]

Oh wow the corners were tricky... Bottom radius is different from the top so some pulling and stretching was necessary. Still not quite to my satisfaction but I only ended up with about 3 inches of excess material when it was all finished so I couldn't take too many chances. It's so so.

But overall I'm happy with the retro vibe. It might be more leftover 80s than early 90s, but I'm old enough to be considered ummm... experienced in both. As well as the decade before.

For those wondering. The side badges are pinned and easily removed with a plastic tool.

But the zx badge on the back is taped.

Overall I'd put this job up there with bodywork. Finicky, unforgiving, and endlessly time consuming. Even after you lower your standards, turn the lights off and squint ever so slightly.

Time to take her out and put on some c&c music factory. No. Maybe van Halen. Pre-Sammy.

 

[Rigster]

Oh wow the corners were tricky... Bottom radius is different from the top so some pulling and stretching was necessary. Still not quite to my satisfaction but I ended up with about 3 inches of excess material so I couldn't take too many chances. It's so so.

View attachment 3294768

But overall I'm happy with the retro vibe. It might be more leftover 80s than early 90s, but I'm old enough to be considered ummm... experienced in both. As well as the decade before.

For those wondering. The side badges are pinned and easily removed with a plastic tool.

View attachment 3294771
View attachment 3294772

But the zx badge on the back is taped.

Overall I'd put this job up there with bodywork. Finicky, unforgiving, and endlessly time consuming. Even after you lower your standards, turn the lights off and squint ever so slightly.

Time to take her out and put on some c&c music factory. No. Maybe van Halen. Pre-Sammy.

Nice work bud. So you shouldn't need the turbo now, I am guessing? After your test drive, how much HP did you add?

New top speed to report?

 

[JDM Journeys]

Lol! Well, I've worked a new bubble into my viewport after the "speed run". I did in fact pass a street cleaner (true story) so definitely some gains were made. But tomorrow I go back in for some more diesel aroma-therapy, as I change out another line. Might throw a clear line on that little jumper by the filter too just in case. I did the primer last year but not the drain part. Stupid me. And then there's the line at the back.

After that it's tank drop time unless I can find someone to smoke test it. Maybe they won't be able to resist the stripes?

 

[Rigster]

Yeah, this brings to mind a wonderful tale of when I first bought my 2005 Jetta TDI. Not long after I purchased it, it started going into limp mode and throwing turbo boost value errors... thus began a slow and arduous task of going through the entire vacuum system. Ended up replace most, if not all vacuum lines, and 2 actuators.

And despite the codes thrown in computer, nothing I fixed or replaced in the vacuum system had anything to do with the turbo system. But, once I fixed all the leaks, the codes went away as well. All that said, I suppose what I am trying to imbue upon thee is it is likely that due to the age, there is air getting into the system from more than one spot? Eventually you will get to them all.

Love that diesel cologne though eh??

 

[JDM Journeys]

Well, I replaced the rear most rubber lines, then started her up. Suddenly I had way more foaming bubbles coming through my clear line. What?!? Went back and looked for leaks. Nothing at the new rubber lines, BUT there was wetness at the top of the tank where there hadn't been before. Guess my suction tube lines were probably rusty and compromised enough to let air in as it cooled down. Once I put a little strain on them by changing the rubber lines, the gap got bigger. Now it won't even run without priming the filter every so often. And a milkshake is coming from the tank.

Tough way to find the leak, but at least I found it. There was no actual weeping before but I didn't disturb the lines that much coming out of the tank, so they had to have been pretty corroded... a little movement in getting the new lines on was enough to finish them off.

The part is now 7-10 days from the warehouse, and then UPS hopefully gets it to me quickly.

If anyone is looking for it, its this one:

7724060190

TUBE SUB-ASSY, FUEL TANK SUCTION

Bolts onto the top of the tank, two little barbs come out of the top. Dips down into tank, and a plastic filter sits down in the bottom of the tank. Probably pretty dirty by now too?

And so now I get to drop the tank. Luckily I just filled up the other day, so there's probably about 70 litres of fuel onboard. LOL Oh joy. I'd like to say this saga is likely solved, but I won't promise anything yet.

I'm pretty sure a lot of folks with older rigs have air leaks but just accept a bit of startup smoke as normal and go about their day. Maybe that's what I should've done?

 

[Rigster]

Well, I replaced the rear most rubber lines, then started her up. Suddenly I had way more foaming bubbles coming through my clear line. What?!? Went back and looked for leaks. Nothing at the new rubber lines, BUT there was wetness at the top of the tank where there hadn't been before. Guess my suction tube lines were probably rusty and compromised enough to let air in as it cooled down. Once I put a little strain on them by changing the rubber lines, the gap got bigger. Now it won't even run without priming the filter every so often. And a milkshake is coming from the tank.

Tough way to find the leak, but at least I found it. There was no actual weeping before but I didn't disturb the lines that much coming out of the tank, so they had to have been pretty corroded... a little movement in getting the new lines on was enough to finish them off.

The part is now 7-10 days from the warehouse, and then UPS hopefully gets it to me quickly.

If anyone is looking for it, its this one:

7724060190

TUBE SUB-ASSY, FUEL TANK SUCTION

Bolts onto the top of the tank, two little barbs come out of the top. Dips down into tank, and a plastic filter sits down in the bottom of the tank. Probably pretty dirty by now too?

And so now I get to drop the tank. Luckily I just filled up the other day, so there's probably about 70 litres of fuel onboard. LOL Oh joy. I'd like to say this saga is likely solved, but I won't promise anything yet.

I'm pretty sure a lot of folks with older rigs have air leaks but just accept a bit of startup smoke as normal and go about their day. Maybe that's what I should've done?

Well... I suppose I should not be surprised. This is exactly what I ended up having to replace. Might as well replace all rubber while your waiting for the pickup part. I also ordered a new screen for the end.

Nice to finally have the definitive problem resolved, once and for all. I prefer this, keeping it OEM, as it should be. Rather than what some people have suggested, like putting in a supply pump, or a stop-valve to prevent leak-back.

These measures may work, but all they do is mask the problem until it gets worse. Way to go bud! Guess I should have just ordered a couple of those pickups when I did mine, lol.

 

[ATL Cruiser]

Make sure to clean out your tank while you have it out. Vinegar obliterates whatever is in there.

Also BIG CONGRATULATIONS on finding it.

What did you do on your 70 series today?

Well... At some point it's not just creature comfort stuff but your actual back and health related issues that come along with that... And maybe good seats are cheaper than physio therapy... And prolong the enjoyment of riding such nice vehicles... I'm happy for your investment!! BTW can you...

forum.ih8mud.com

 

[JDM Journeys]

So the good news is that the tank is clean inside. No rust at all! The bad news? I just got fuel the other day. So I had to somehow find a place for 80L of the "good stuff", and I also had to get it out of the tank. My shake siphon ended up in the bin. My fancy new vac-siphon sucked up fuel and then dumped on the floor. Finally, I resorted to the drain plug and a bucket.

So my afternoon was as follows: Fill bucket. Drain into jerry can. Repeat. Repeat. Repeat.
Also got all the lines except the main fill tube off the tank. Sending unit is out. But the mini-highway of tubes, valves and pipes coming off the fuel filler is in rough shape too. So much so that I'm worried I may not be able to get the rubber lines off without damage. I couldn't find this item when I ordered my suction tube etc yesterday. So today I did some more digging, and supposedly stock exists in japan? I'm waiting for confirmation from the supplier, and then it'll also be on the way. Fingers crossed.

While I was babysitting the buckets, I decided to take advantage of the empty space in the back (all my drawers, elec system, third battery, water tank/pump, carpet, insulation, etc are out and sitting on the table in my garage) and do some more sound deadening. I had planned for this all along, but didn't want to pull everything out at the time to do it. Now that I had to? Well, may as well make the most of it...

Right rear wheel well is now covered in Kilmat. Back in Dec/Jan I put some on the inside of the outer walls in the back, if you recall.

Tomorrow I'll do the other side and then see how much I have left for the floor. Still want to put a square in each door, but I have enough apart right now as it is.

AND, I'll attempt to drop the tank, without, you know, dropping the tank!

 

[Rigster]

Well, may as well make the most of it...

That right there is wisdom talking.

Speaking from (recent) experience, you are going to love how well it runs and drives once you get this nicked.

 

[Felde]

Great you found the culprit. Sorry it was the hard way.
The suction tube is notorious for rusting at the bend. I suggest to give the new one an additional coating right from the start.
The lines from the filler neck are standard straight lines, but there are two sizes involved. The big rubber filling pipe is readily available.
I installed the new filler neck with the tank in place.
Good Luck Ralf

 

[ATL Cruiser]

Beno was selling a tank over in the Classifieds if yours is too rusted out. I think you can also buy them new still? At least that's what I've heard.

For Sale - 7x Fuel Tank (used)

Came off of a BJ70. Rearmost position. Check your application/consult with a parts professional to confirm fitment. $400 + UPS shipping

forum.ih8mud.com

 

[JDM Journeys]

Beno was selling a tank over in the Classifieds if yours is too rusted out. I think you can also buy them new still? At least that's what I've heard.

For Sale - 7x Fuel Tank (used)

Came off of a BJ70. Rearmost position. Check your application/consult with a parts professional to confirm fitment. $400 + UPS shipping

forum.ih8mud.com

Thanks. Mine is 100% clean on the inside. We'll see how the outside fares tomorrow hopefully, when I take it down.

Meanwhile, parts are on the way from Japan. Got the filler neck and the venting spaghetti factory coming. I LOVE that this stuff is still available.

 

[Felde]

You might find this thread to be helpful...

remove fuel tank

I wanted to get the fuel tank off to see if there was rust on the top side which is invisible. The skid plate has a dent in it and I wanted to make sure it was not rubbing the tank. Top of the tank needs some help. After straps and hose connections, you have to get the filler tube disconnected...

forum.ih8mud.com

It has the procedures on installing the filler neck, hose diameter etc.
Good Luck Ralf

 

[ATL Cruiser]

You might find this thread to be helpful...

remove fuel tank

I wanted to get the fuel tank off to see if there was rust on the top side which is invisible. The skid plate has a dent in it and I wanted to make sure it was not rubbing the tank. Top of the tank needs some help. After straps and hose connections, you have to get the filler tube disconnected...

forum.ih8mud.com

It has the procedures on installing the filler neck, hose diameter etc.
Good Luck Ralf

That post helped me IMMENSELY. Thank you again for it.