- Thread starter
- #221
Probably not an issue considering you welded in a 1/4" steel plate! Probably in a another few years mine would have been gone too.
Build Project 2027: 1977 FJ40 Rebuild
- Thread starter Jetlander
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- Thread starter
- #222
Thanks! I've been using 0.030" because I'm too lazy to switch the wire spool over.
That and the fact this should have been a smaller welding job until I screwed it up. I was planning on switching spools though before I replace the bottom of the windshield frame, which has considerable rust on the bottom seam. Thats the next project after the cowl is done.
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- Thread starter
- #224
I haven't even ordered it yet because I've realized I still have a lot of work ahead of me. I appreciate the reminder about the pinch weld, I haven't forgotten, but that would be an epic oops moment when trying to fit the roof back on! Once I have the windshield repaired I will order the tub. What was the turn around time on delivery for yours? Did it come with decent instructions?Did you get your Aqualu tub yet? If so, don't forget to measure to cut that pinch weld back.
That's a big negative on any instructions... It came with one sheet of paper, but vague would be an understatement. I will say, it is pretty straight forward. A couple things myself and other have posted about not liking is the bolts are all SAE. Not metric. The bolts and washers are stainless, the lock nuts are grade 5 steel. So you don't get the gallying effect, the ones that I wanted stainless I changed out.. And the turn around time was just trucking time. They had one on the shelf ready to go.
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Updates?
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- #231
Wow guys! Dang, has it been a year already? I have lots of updates and photos to download. Not a lot of progress throughout the summer but now the weather has cooled in the Texas I've been busy with tub installation, bib repair, mock up, installing A/C...you get the picture. Lots completed but it seems I always have an ever growing list of things to do. Does it ever end?
- Thread starter
- #232
Alright fellas, in an attempt to be all inclusive over the last year I have a ton of info to post. This thread isn't just about my 40, it's also about my life's journey with it. With that being said, life has been more than full, work has been non-stop, and family always comes first. It's been a helluva year to say the least. I will give you a glimpse into why my thread posts have been less than prompt.
So to pick up where I left off...
I continued working on getting the cowl all patched up. As I finished that the Houston summer came with the heat and humidity on the rise, my enthusiasm to work in a sweltering garage dips. I did a few projects off and on during the summer but for the most part, it was a bust.
A new power steering pump bracket from JT Outfitters proves to be difficult. I bought it about 6 months before this pic was taken so when I tried to mount and it wasn't lining up with the head bolts I gave them a call. To say they were less than helpful would be an understatement. Basically, I was told I was doing it wrong. When I sent them pictures JT then said, too bad... Fine, I have lots of money to still spend on this project and I can certainly spend it elsewhere.
I ended up drilling out the bolt hole in the correct position and welding the rest up to make it fit correctly. Definitely NOT how it should have played out.
So to pick up where I left off...
I continued working on getting the cowl all patched up. As I finished that the Houston summer came with the heat and humidity on the rise, my enthusiasm to work in a sweltering garage dips. I did a few projects off and on during the summer but for the most part, it was a bust.
A new power steering pump bracket from JT Outfitters proves to be difficult. I bought it about 6 months before this pic was taken so when I tried to mount and it wasn't lining up with the head bolts I gave them a call. To say they were less than helpful would be an understatement. Basically, I was told I was doing it wrong. When I sent them pictures JT then said, too bad... Fine, I have lots of money to still spend on this project and I can certainly spend it elsewhere.
I ended up drilling out the bolt hole in the correct position and welding the rest up to make it fit correctly. Definitely NOT how it should have played out.
- Thread starter
- #233
As a general rule my wife and I like to take one big trip a year. In past years we have done it without the kids, kinda a refresh on life, each other, and our marriage. For example, we did Italy for 10 days a few years ago and Greece the year after for 14 days. This last summer we decided the kids should go and we planned a 14 day road/camping trip. We had talked about getting a camper for a while and decided this was the perfect opportunity to pull the trigger. We found this brand new 24' trailer online up in Ohio. Before we knew it, I was delivered to our driveway.
Our road trip was planned and now we had the means to follow our own timeline and really enjoy the beauty of the eastern USA. Our plans included eastern Tennessee for Dollywood and Gatlinburg. Then head to Kentucky to explore caves for a number of days, then on to Branson, Missouri, and finish the trip off with a trip to Diamond Crater State Park in Arkansas.
Summer mountain fun in Gatlinburg. Highly recommend the entire area. Kids loved it, we loved it, and honestly my bride and I both feel it would be an excellent area to retire to.
Me trying hard to figure out if life would seem better if I could drink a Heffe and smoke a cigar simultaneously (didn't work), but hey you gotta try.
Cave exploring was one of the cooler things we did. We visited several caves. One in particular cave called 'Lost River Cave' you have to ride a boat into it as it's basically an underground river.
Mammoth Cave National Park
Our road trip was planned and now we had the means to follow our own timeline and really enjoy the beauty of the eastern USA. Our plans included eastern Tennessee for Dollywood and Gatlinburg. Then head to Kentucky to explore caves for a number of days, then on to Branson, Missouri, and finish the trip off with a trip to Diamond Crater State Park in Arkansas.
Summer mountain fun in Gatlinburg. Highly recommend the entire area. Kids loved it, we loved it, and honestly my bride and I both feel it would be an excellent area to retire to.
Me trying hard to figure out if life would seem better if I could drink a Heffe and smoke a cigar simultaneously (didn't work), but hey you gotta try.
Cave exploring was one of the cooler things we did. We visited several caves. One in particular cave called 'Lost River Cave' you have to ride a boat into it as it's basically an underground river.
Mammoth Cave National Park
- Thread starter
- #234
Now I'll sprinkle in some FJ40 stuff to keep it all relevant. The cancer in the windshield frame was always a major concern of mine. Until I removed the paint, I was hoping I could salvage it will a few patches. Not to be. Rust was pretty prolific throughout the bottom of the frame. The seam lip was infected too. More than a patch here and there would fix.
I was on the hunt to find a replacement frame. Apparently a perfect condition '77 frame is rarer then hen's teeth. I manage to find a frame up in Wisconsin that had a mangled top but the bottom is perfect. That's what I plan on using for a patch.
I haven't begun the patching process yet, but it's getting pretty high on the list of things to get done.
I was on the hunt to find a replacement frame. Apparently a perfect condition '77 frame is rarer then hen's teeth. I manage to find a frame up in Wisconsin that had a mangled top but the bottom is perfect. That's what I plan on using for a patch.
I haven't begun the patching process yet, but it's getting pretty high on the list of things to get done.
- Thread starter
- #235
Of course the next big thing was hunting season. I'm most happy outside and hunting is my thing. Managed to harvest a really old buck as a cull on my buddies place and also connected on a stud Blackbuck Antelope.
The blackbuck is actually solidly into trophy size so he will be added to a collection of mounts in my office. Looking forward to getting him back from the taxidermist in the fall of this year.
The blackbuck is actually solidly into trophy size so he will be added to a collection of mounts in my office. Looking forward to getting him back from the taxidermist in the fall of this year.
- Thread starter
- #237
Alright, a final post as to what I've been up to which will bring me back into Cruiser restoration territory. Work has been crazy busy over the last year. Several longish work trips have taken me all over the world. By far the best trip was an extended work stay in Argentina which we do every couple of years. Remember, I'm "working" in the below pictures...
This was in Bariloche, Argentina which is located in the Patagonia area. Interesting fact: There are a ton of very European looking people living there and it took me a minute or two of brain-power to put my high dollar history degree from college to good use... Bariloche is actually the place where a huge number of high-ranking Nazi party official escaped to when they realized the war was lost. They entered in through the fjords of Chile and set up shop across the border. They have even found an old Nazi Submarine there.
REMEMBER... Work...
Mendoza Wine Country.
This was in Bariloche, Argentina which is located in the Patagonia area. Interesting fact: There are a ton of very European looking people living there and it took me a minute or two of brain-power to put my high dollar history degree from college to good use... Bariloche is actually the place where a huge number of high-ranking Nazi party official escaped to when they realized the war was lost. They entered in through the fjords of Chile and set up shop across the border. They have even found an old Nazi Submarine there.
REMEMBER... Work...
Mendoza Wine Country.
- Thread starter
- #238
Alright, that brings me to the last month or so. As you can see life over the last year hasn't been too conducive to spending a lot of quality time with my steel mistress, Wendy.
The lower front bib was hacked up by the PO in his pathetic attempt to add power steering. That along with plenty of rust meant welding a patch was necessary. I've found all of the 'Real Steel' products I've used to be of very high quality. The bib patch was top notch.
My pooch Henry inspecting my handiwork. He approves.
Final product. I have really learned a tremendous amount about welding sheet metal on this FJ40 journey. Slow is in-fact, fast. The quality has improved a lot since my first attempts as well. I moved from .030 wire to .025 wire and that helped a lot.
The lower front bib was hacked up by the PO in his pathetic attempt to add power steering. That along with plenty of rust meant welding a patch was necessary. I've found all of the 'Real Steel' products I've used to be of very high quality. The bib patch was top notch.
My pooch Henry inspecting my handiwork. He approves.
Final product. I have really learned a tremendous amount about welding sheet metal on this FJ40 journey. Slow is in-fact, fast. The quality has improved a lot since my first attempts as well. I moved from .030 wire to .025 wire and that helped a lot.
- Thread starter
- #239
If you've made it this far into my thread you know I have fought rust from day one. It has been the thorn in my side as it has for other Cruiser heads. After tremendous amounts of work removing it from the frame and various other places it was decided early to replace the tub with a Aqualu 3/4 tub. I know the purists are cringing but honestly, ZERO regrets on this decision. The folks at Aqualu are awesome. They had my tub shipped out within a day or two of ordering it. However, the shipper once in made it to Houston was the worst. It took several attempts to get it and was having absolutely no luck at all. I finally called Aqualu and they jumped all over it. It showed up in my driveway the next morning at 0730.
These things are BEAUTIFUL. Wow, the workmanship is second to none. I was so excited I wrangled my neighbor into coming over and helping me at least get it onto the frame. Within an hour of showing up, it was resting peacefully on the Cruiser.
To say this set me on fire to really make a push towards completion would be an understatement. It has been 2 long years in the making to get to this point. I know some take far longer to finish their Cruisers but I'm super eager to get mine back on the road. This scene was the light at the end of the tunnel that I needed.
These things are BEAUTIFUL. Wow, the workmanship is second to none. I was so excited I wrangled my neighbor into coming over and helping me at least get it onto the frame. Within an hour of showing up, it was resting peacefully on the Cruiser.
To say this set me on fire to really make a push towards completion would be an understatement. It has been 2 long years in the making to get to this point. I know some take far longer to finish their Cruisers but I'm super eager to get mine back on the road. This scene was the light at the end of the tunnel that I needed.
- Thread starter
- #240
I've looked at a number of threads on Aqualu tubs and there seems to be an even split between those who like the tranny hump and those who spend the time and energy to make the original one fit. Hands down I prefer the original look, no question, and mine it actually in great shape. It's one of the few parts of Wendy that didn't have any appreciable rust. But my bride really liked the Aqualu supplied one and reasoned with me about spending untold hours on modifying the original one to make it fit. I can't argue with that, so Aqualu it is.
I traced the outline of the factory tranny hump to see the size difference, which it HUGE. That was definitely something I took into consideration when making the decision. Especially with the installation of a Vintage Air air-conditioner, which reduces the amount of room on the passenger side.
With that being said, mock up is in full swing. You may have noticed I welded a filler patch into the dash where the ashtray is normally located. One, cigars are my thing so a tiny ashtray doesn't really work anyways, and two, I planned on mounting an iPad on the dash for a source of navigation, music, and on-road videoing for my Pan-American trip. Practicality is KEY. Function over form is priority number one.
The radio hole will be home to all the accessory switches for lights, winch, CB and HAM radios, and maybe even lockers... Time will tell and I would love to see what other people have installed in there 40's for long-haul expeditions such as the Pan-American.
What is it that I NEED to have and what will make 40 life better for such a long road trip? Let me know your thoughts.
I traced the outline of the factory tranny hump to see the size difference, which it HUGE. That was definitely something I took into consideration when making the decision. Especially with the installation of a Vintage Air air-conditioner, which reduces the amount of room on the passenger side.
With that being said, mock up is in full swing. You may have noticed I welded a filler patch into the dash where the ashtray is normally located. One, cigars are my thing so a tiny ashtray doesn't really work anyways, and two, I planned on mounting an iPad on the dash for a source of navigation, music, and on-road videoing for my Pan-American trip. Practicality is KEY. Function over form is priority number one.
The radio hole will be home to all the accessory switches for lights, winch, CB and HAM radios, and maybe even lockers... Time will tell and I would love to see what other people have installed in there 40's for long-haul expeditions such as the Pan-American.
What is it that I NEED to have and what will make 40 life better for such a long road trip? Let me know your thoughts.