Builds Project 2027: 1977 FJ40 Rebuild

[Jetlander]

That was the original idea when I first decided to galvanize the frame. And honestly, this is not, and never will be, a museum piece. And I’m definitely not after resale value.

So with that being said, the answer is no. The galvanized frame is already starting to grow on me, darken up a bit and should eventually be a medium Greyish color. By time I finish my run of the pan-American it’ll be hard to tell what color it is.

 

[fjdiesel]

@Jetlander How are things going on your build, been able to make any progress this summer?

 

[Jetlander]

Hard to believe it’s been as long as it has since my last update. Work is a real time suck and cruiser progress is, unfortunately, the victim. It definitely doesn’t help that I live in Houston and being in a garage in the summer is unbearable. Anyways, finally cooled down last week and I have resumed my love affair.

Been busy cleaning and reconditioning parts, sorting some things for another powdercoat run, and generally installing new parts. I rebuilt the parking brake with all new hardware. Also had the drum turned to true it up. I also dropped the driveshafts off to have 40 years of grease cleaned out of them and new joints put in. Everything came back looking better than new. All new hoses and belts too.

Blasted the manifolds and painted with high temp paint (the wife played along while I baked it in the oven). Overall, great progress over the last week or so. Posts will start to pick up once again now that it’s under 1,000 degrees outside. Plan is to order the Aqualu tub in January so I need everything ready to go when it shows up. Missed the mark in having it done in 1 year (Nov 7th), but considering all the obstacles over the last 6 months it coming along nicely.

Full steam ahead!

 

[Jetlander]

@Jetlander How are things going on your build, been able to make any progress this summer?

I appreciate you checking up. Like my post above said, summer was basically a bust. Too HOT and too much having to make an honest living. It’s funny really because the wife even said the other day that I needed to spend some time working on the Cruiser. Don’t know if she really meant it, or if she just wanted me out of the house, or she’s tired of not having a garage to park in. Probably all of them. How goes it with yours?

 

[fjdiesel]

Unfortunately kinda the same story here. Summer and work are real time suckers away from working on the 40.. But, like you, I am back at it!! I am planning to have mine on the road next spring. That's the goal anyway. Thanks for asking.

 

[Jetlander]

A quick update. Been doing a lot of busy work on the 40, which takes a lot of time but yields little to show for it. I placed an order this last week with @Rainman for brake line fittings and he pulled through. Package arrived today and I was astonished at the care and thought put into packaging a handful of fittings. Great guy who obviously cares for his customers, and a wealth of knowledge. If it wasn’t for me needing to learn how to make brake lines I’d order his pre-made set I a heartbeat.

Anyways, after replacing the drag link today I had just enough time to cut up an old brake line I pulled off the 40 during tear down, to try some practice runs on doing double flares. After the 5th or 6th attempt they seemed reasonably good so I made my first line.

When I ordered the tubing I also ordered some stainless coil to go over the line. Apparently it’s supposed to help protect the lines. Either way it looks cool even if it’s just a gimmick.

The brown truck also brought me new brake and clutch masters. Next major order will be for the 3/4 Aqualu tub, which should happen next month.

 

[rickpaw]

Just read thru your thread. Nice progress on the FJ40

Quick question and I may have missed it - why are you replacing the tub with aquatub? It looks like the oem tub is in decent shape.

 

[Rainman]

A quick update. Been doing a lot of busy work on the 40, which takes a lot of time but yields little to show for it. I placed an order this last week with @Rainman for brake line fittings and he pulled through. Package arrived today and I was astonished at the care and thought put into packaging a handful of fittings. Great guy who obviously cares for his customers, and a wealth of knowledge. If it wasn’t for me needing to learn how to make brake lines I’d order his pre-made set I a heartbeat.

Thanks for the kudos. Really. I don't have a Cruiser anymore but as I tell my local buddies, working on Cruisers is like therapy for me.

One thing. Can you tell everyone that those flares aren't mine please. I'm a "detail oriented" kind of guy.

 

[Jetlander]

Thanks for the kudos. Really. I don't have a Cruiser anymore but as I tell my local buddies, working on Cruisers is like therapy for me.

One thing. Can you tell everyone that those flares aren't mine please. I'm a "detail oriented" kind of guy.

I’ve seen your work and there’s no doubt the flares pictured in my thread are definitely not yours. Those pictured are the work of an obvious amateur....ME!

Anyways, I seemed to have difficulty getting the flare perfectly symmetrical and I’m not sure exactly why. Plus I’m concerned my 45 degree is too deep. Basically that’s why I posted the picture of my first attempts; to get some constructive feedback. I want to make sure I don’t waste all my time to build a bunch of lines that’ll leak the moment I put pressure on them.

 

[Jetlander]

Just read thru your thread. Nice progress on the FJ40

Quick question and I may have missed it - why are you replacing the tub with aquatub? It looks like the oem tub is in decent shape.

Thanks. Unfortunately, looks are deceiving on the old tub. It’s full of bondo, and I mean full. Virtually every seam was rusted out or nearly so. The rear sill was completely rusted out. I’m sure some who are far more skilled than I could have saved it, but honestly it wasn’t that important to me.

My build is more focused on form and function versus the purist’s eye. It’ll literally be my home for 3-4 months while I’m driving the Pan-American so that’s kinda my starting point. That’s also why I decided to galvanize the frame, to eliminate as many rust prone areas as possible.

 

[rickpaw]

That explains the new tub. What part of Houston are you in? I’m in NE Houston and I just acquired a basket case 74 FJ40, and in the process to researching and planning the build plan.

 

[Jetlander]

That explains the new tub. What part of Houston are you in? I’m in NE Houston and I just acquired a basket case 74 FJ40, and in the process to researching and planning the build plan.

I’m in SE Houston. Clear Lake area. Mine was WAAAAY more of a basket case then I realized when I bought it. I went into it thinking that I knew what I was looking for but really, I didn’t. Lesson learned but honestly I wouldn’t take it back. I’ve learned so much and now I know literally every square inch of my rig. It’ll take the stress level down a notch when driving it north to south knowing if there is an issue I should be able to fix it.

 

[rickpaw]

I’m in SE Houston. Clear Lake area. Mine was WAAAAY more of a basket case then I realized when I bought it. I went into it thinking that I knew what I was looking for but really, I didn’t. Lesson learned but honestly I wouldn’t take it back. I’ve learned so much and now I know literally every square inch of my rig. It’ll take the stress level down a notch when driving it north to south knowing if there is an issue I should be able to fix it.

I'm in Clear Lake once in a while too, maybe I can stop by and check out the truck if you're available?

I'm in the same boat as you, paying too much for too little. I mean I knew what I was looking for, and got no surprises. My truck was already taken apart, so all the rust spots are visible. I'm not new to restoring cars, but 4x4 is a whole new world to me.

Tu

 

[Jetlander]

I'm in Clear Lake once in a while too, maybe I can stop by and check out the truck if you're available?

I'm in the same boat as you, paying too much for too little. I mean I knew what I was looking for, and got no surprises. My truck was already taken apart, so all the rust spots are visible. I'm not new to restoring cars, but 4x4 is a whole new world to me.

Tu

Absolutely. Would love to show you where I’m at with the rebuild. I don’t pretend to be an expert on rebuilding 40’s but I do feel I’ve gained a ton of knowledge over the course of the last year. One tidbit of advice though is pictures. Start searching the web now for as many pictures as possible of a tear down and rebuild. I took over 400 pictures and I still find myself needing to search MUD for reference to location of parts. Probably should have taken 800...

 

[Jetlander]

So after watching a bunch of “how to make a double flared brakeline” on YouTube I realized the way I did the first, and thankfully only, line was wrong. I seemed to be consistently getting unsymmetrical flares and it was aggravating to say the least. Anyways, I pulled the line off and started over. I definitely didn’t want to go through all the trouble of building 13 lines and have all of them leaking when I bled the system.

Anyways, finally seemed to get some consistency after more practice. Using a vise helped with keeping pressure even during the flare. And like virtually everything, prep is the key to success.

For someone as OCD as I am, I found routing and putting in all the bends exhilarating. Sad I know, but dang I love it. I’m really happy with the way the stainless steel coils look. It makes the whole setup look much cleaner.

Hopefully I’ll have the front axle brake lines built before the end of the week. Once they’re done I will see about sourcing new fuel hard lines.

I’ve had the Saginaw powersteering gearbox boxed up for ages so I guess I better get that shipped off for overhaul. Things are coming along nicely and soon it’ll be time for bodywork.

 

[Jetlander]

Still plugging away. Plenty of small projects that take a lot of time but critical in the final result. Finally found a good condition 2F radiator fan shroud. Before the resto I was running around with a F engine shroud and it left a lot to be desired. The as long as I was moving it cooled fine, but prolonged idling in Houston traffic on top of the hellish summer heat, would always make me nervous as the temp gauge slowly climbed. Hoping this takes care of the problem.

Finished the last of the axle and frame brake lines. They look great and time will tell if my work is good enough when I eventually pressurize them. Fingers crossed. I’ve replaced the remainder of the hoses. Everything is new.

In the short term I’m planning on putting the stock alternator back on. However, long term I’d like to replace the underpowered alternator with a more modern 100+ amp solution. Preferably something as close to plug-and-play as possible. By a long shot electrical is my weakest “skill”. Often I rely a lot on guesswork when trouble shooting issues. I will have a double battery set up because I plan on running a winch and extra lights. Anyone have any suggestions?

The only major mechanical work left to do is the power steering. I have a new pump bracket from JT Outfitters that I plan on using. Once that’s done, it’ll be time to strip paint off of the cowl, fender s, and bib while I wait for the tub to show up. Getting closer by the day. Till then, here is some eye candy of the progress made...

 

[samc2447]

In the short term I’m planning on putting the stock alternator back on. However, long term I’d like to replace the underpowered alternator with a more modern 100+ amp solution. Preferably something as close to plug-and-play as possible. By a long shot electrical is my weakest “skill”. Often I rely a lot on guesswork when trouble shooting issues. I will have a double battery set up because I plan on running a winch and extra lights. Anyone have any suggestions?

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I run a GM CS-144 that puts out 140 amps. There are a lot of write ups on here about those and the CS-130 if you search them. Only one battery and I have a winch. Keeps up fine.

You might want to look at changing your starter for a gear reduction starter. One of the better upgrades you can do.

 

[White Stripe]

I installed a upgraded alternator recently, check out my build thread if u wanna see it.

 

[Honger]

Just found this thread... amazing!
I absolutely love that you're going into this level of detail and meticulousness with the intent of using it on a long-distance trek. She may look like a garage queen now, but that obviously isn't the plan. Very cool.

 

[Honger]

Also, agree with the recommendation to upgrade to a gear-reduction starter.