Operation Olive, My 1975 FJ40 Ground Up Restoration

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Ignition wiring help with a DUI distributor real time help!

I am attempting to start my 40 after being in pieces for the last 18 months. I recently re-wrapped the wiring harness in new tape, but other than that i have made no mods. I am attempting to reinstall the harness the same way it was before it all came out. The previous owner de-smoged it and installed a DUI distributor. the ignition is run through a switch on the passenger side fender pictured below. It is a five prong switch/relay. The bottom red wire attached to the bottom prong on the switch below my finger runs to 12V 30A fusible link hot off the battery. The middle prong on this switch is now hot 12V where I have the black and yellow ignition wire connected. The left prong has a black ground wire attached that runs to a ground on the fender. the right side prong has a red wire attached that runs to the DUI distributor. Does this all make sense? The top prong is empty. I am unsure if this is how it was all originally connected, but this configuration is the only way the key works to turn the starter and all the accessories work. So here is the problem......I crank it over and everything works except that I only get about 6 volts coming from the red wire to the distributor. The distributor requires a minimum of 10.5 volts according to the manufacturer. The battery is fully charged and I checked the voltage off the battery during cranking and it gives nearly 11 volts. I have also checked the ground and tried several different places in the frame as a ground. Same result. All the wires have been replaced with new 12 gauge wires except for the black and yellow wire that runs back into the harness and back to the ignition switch. I have also tried a new switch. what am I missing here? Should there be a 5th wire? Can I bypass this switch? It seems like there has to be a better way to do this.:bang::bang::bang::bang::bang:
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I got it started!!!! I got the relay switch wired up, but I am only getting 10.5 volts to the distributor so no spark. I decided to just run a jumper from the battery directly to the distributor and jackpot she fired right up! Here is a link to the video.
http://www.youtube.com/watch?v=0Vlo_dfY3yA&feature=youtu.be
 
Awesome! Now you can smell the finish line! I can't wait to do this to my rig one day. - JP
 
Wow that looks good. What brand and color is that. Is it a close to orig desert tan or just a color you liked?
 
Thanks for the compliments guys. I still need to figure out this ignition wiring issue, but I am close. I also discovered that it only runs with the choke on. as soon as I push the choke in it idles faster then dies. Any ideas?
Always working: The color is a Toyota color code Dune Beige 416 and I used PPG shopline paint
 
Man I've been through this entire thread tonight anticipating the climax of seeing pics of your finished rig and all of a sudden everything stopped. No post in a month. What happened?
 
X2 on the idle solenoid, also whats up with your accelerator pump arm spring???? thats definitely not stock
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Epic Restoration

Well, I must say that you have done a fantastic job and have inspired me to do my 67 FJ40 restoration .....hopefully, half as good as yours. I hope you get this thing together soon so we can all drool. My big question is how much in parts do you estimate you have in it so far? I won't tell my wife!
 
I have been on a hiatus since my last post. The holidays really took the wind outta my sails and my budget!
The issue has been solved and it runs great now. Not sure what was happening, but it is running great now.

91 4 runner .....Yeah that spring was there when I bought it. I guess I need to track down the correct one, but it seems to work for now.

FJjohn67.... do you really want to know? Since I have bought it I have dumped,,,,,,,,,,,,,,,,,,ready,..............13k into it!!!!!!!! The upside is that I know it has all been done to my standards and is better than new. I guess I could sell it for more than I have into it when I am done, but that wouldn't include my labor. nearly 2 yrs worth now.
 
1975 FJ 40 daily driver

I don't think that cost is bad at all, in fact I was thinking $18k. Like you said, it has been maticulously redone top to bottom by your standards. Awesome job and I think that all of us would take your FJ40 over any new Heep any day! Keep truckin and I'll keep watching and reading.
 

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