Papa Smurf - Resto mudded FJ40

[Snicklephritz87]

O boy discovered lots of rust and broken headlight baskets. Most of the bolts are trashed.

 

[Snicklephritz87]

Pile of parts from machine shop. Lots of paint work and assembly in my future.

 

[Snicklephritz87]

Block painted.

 

[Snicklephritz87]

Well i F’d up and broke a bolt on my main caps. I took the block back to machine shop to get the bolt out. I should have purchased new hardware for the bottom end. I think the bolts are over stretched. In addition i think i have a cheap tourque wrench. Time to buy a new one.

Since i have down time. I am fiddling with stuff that’s been hanging over my head.

 

[B y r o n]

You're going to want to take the paint off the serpentine pulley where any seal may rub. If there are grooves than a speedy-sleeve is called for.

 

[Snicklephritz87]

You're going to want to take the paint off the serpentine pulley where any seal may rub. If there are grooves than a speedy-sleeve is called for.

It’s already done. You can tell but it was masked off.

 

[Snicklephritz87]

More updates:
-Headlights restored semi gloss powder coat
-Bid where i discovered rust has been welded. Need to get it painted. Weekend project.

 

[Snicklephritz87]

Engine is Mocked up.

Decided toOrder new rocker arms and push rods for good measure. don’t want to revisit the machinist over $300. Should be able to drop it in next weekend. Also added a steam port kit.

Also started body work on the grill. I hate bondo work. Body shops wanted $600-900 to block /prime and paint single stage. $96 in supplies at my local auto body supplier… time is money i guess.

 

[White Stripe]

Looks nice!

 

[Snicklephritz87]

At the final stretch big thing I want to do is a hard pipe top hose. I need to clear the accessory drive. I am hoping a ridged pipe will handle the clearance issues.

Fj40 punch list

• coolant temp sensor
• Camshaft sensor bolt
• Heat gun - oil temp wire
• Install exhaust & sensors
• Radiator mount
• Ac condenser
• Radiator & fans
• Install air intake
• Wiring connection
• Upper & lower radiator hose
• Water neck selection
• Hose clamp PS return
• Check transfer case mounts. TQ down
• lokar oil tube wire length add
• AC lines - once truck is running
• Install coolant surge tank
• Air compressor bracket and lines
• Install OCC
• Trim air intake
• Install front bezel
• Aim head lights
• Fill break in oil
• Fill power steering
• Top off trans
• Check transfer case fluid
• Check front diff fluid
• Wash truck

 

[jesus888]

Sheesh, that is looking svelt...

 

[Snicklephritz87]

Almost there! Still trying to find an upper radiator hose that fits. It’s a strange shape and proving difficult.

 

[S.CarolinaFZJ80]

Awesome work on the 40.
Would a straight or slightly bent hard tube with rubber elbows on the end work?

Almost there! Still trying to find an upper radiator hose that fits. It’s a strange shape and proving difficult.

View attachment 3461226

 

[Snicklephritz87]

Awesome work on the 40.
Would a straight or slightly bent hard tube with rubber elbows on the end work?

I think I’ve decided on a hard pipe with jumpers.

 

[h82crash]

Almost there! Still trying to find an upper radiator hose that fits. It’s a strange shape and proving difficult.

View attachment 3461226

I've done several engine swaps and custom builds. I usually look up factory hoses with the correct bends and end sizes. Did a 5.3 in mine with a high mount a/c compressor. I had to put one splice in the upper hose.

 

[Snicklephritz87]

I've done several engine swaps and custom builds. I usually look up factory hoses with the correct bends and end sizes. Did a 5.3 in mine with a high mount a/c compressor. I had to put one splice in the upper hose.

View attachment 3461385

Nice. That’s what i did in the past and the flex hose. Bc my large CBR radiator it’s got weird bends. Hard pipe seems like best cleanest option.

Edit: bent a coat hanger to approximate size and found one at auto zone.

 

[Hardhead]

how about the part number on that upper hose? I'm doing a swap myself.

 

[Snicklephritz87]

Autozone - dayco molded radiator hose

#0009743790 E72406

how about the part number on that upper hose? I'm doing a swap myself.

It might not fit for you. I have a custom CBR radiator. It’s not factory spec.

I bent a coat hanger in the shape i needed then went behind the counter and found one that was close. That strategy worked well. Took the idea from @dbbowen LS swap thread in fj60 section.

 

[Snicklephritz87]

My 7 year old radiator was suffering from a pin hole due to electrolysis and improper grounding. New radiator is being made. Fun hicup in the rebuild.

My starting issues were from a corroded fuse box. New fuses and some cleaning are the temporary fix. I wanted a waterproof solution. I chose the bussman 280 - 15303 2-2-4.

I made a quick bracket for the bussman 280 and my ARB compressor. I made some assumptions that will need final refinement in the workshop.

 

[Snicklephritz87]

Photo dump on my brackets and finished engine. Polished up the retune yesterday it runs fantastic with new cam and 30 over pistons!

Fj40 punch list

• Bolt check
• lokar oil tube wire length - call customer service
• AC lines - once truck is running
• Wire up winch
• Top off trans fluid
• Check transfer case fluid
• Check front diff fluid
• Wash truck
• Wire waterproof fuse panel
• Radiator test for electrolysis
• Add more grounds to fight electrolysis
• New 18# radiator cap