Builds Project 2027: 1977 FJ40 Rebuild (4 Viewers)

[Krondor]

Looking awesome! Hope you didn't have much trouble with those body mounts.

 

[fjdiesel]

Looking good!! What kind of pad are you using under the bib hinge?

 

[White Stripe]

Haha you already have a cooler on the back. Nice

 

[Jetlander]

Looking awesome! Hope you didn't have much trouble with those body mounts.

Thanks! I have all the body mounts bolted but not tightened. I’ll do that towards the end of reassembly when I add the fenders and aprons.

 

[Jetlander]

Looking good!! What kind of pad are you using under the bib hinge?

After realizing the bib hinge pad is basically unobtainium I scrounged around the garage and found some compressor floor mount vibration pads I had extra. I think they’ll do the trick. I haven’t cut them to size yet. I’d prefer OEM but over the last 3 years I’ve adopted more of an adapt and overcome philosophy.

 

[Jetlander]

Haha you already have a cooler on the back. Nice

Priorities my friend... Priorities...

 

[Jetlander]

Something I had zero intention of actually doing, but guilted into by another Cruiser Head. The wiring and electrical system was working perfectly when I started my resto, so I intended to put it back in as I took it out. Yes it was dirty, yes it had grease on it, but it’s mostly hidden, right? Well, I unwrapped, inspected, and cleaned the entire main harness. This is what 19 hours of labor looks like...

Now for the rear harness.

 

[05CTD]

great work looks amazing congrats

 

[Jetlander]

Have a question with the wiring harness. Installing today and I have a connector labeled “parking brake”. It’s right behind the gauge cluster right next to the parking brake. I labeled everything I disconnected as I took it apart. Thing is...I don’t see where it connects to the parking brake. Any ideas or info would be greatly appreciated.

 

[zerotreedelta]

Here's mine with the parking brake lever dropped down, wiring attached - '76 model:

 

[Jetlander]

Here's mine with the parking brake lever dropped down, wiring attached - '76 model:

Okay, that helps a lot. Now I have another issue. Mine doesn’t have any wires coming out of there. I removed the switch and I’m not even able to tell where wires would actually connect. What’s the chance you have a picture from the inside?

 

[zerotreedelta]

I don't have mine apart, but it looks like it's just a pretty typical momentary push switch...hopefully they help a little. My main wiring loom needs the same clean-n-rewrap treatment though, I'll be feeling your pains shortly...at least my rear harness is all patched up and rewrapped.

 

[Jetlander]

Well, things are coming together nicely. Sitting at the exhaust shop as I type this and my mistress is getting some love from a strange man.

May actually have this ol’ girl running before the weekend is over!!!

 

[Jetlander]

Woke her up from her 3.5 year “nap” and she sounds and runs perfect! So damn excited!

 

[CruisingSned]

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...

View attachment 1856114 View attachment 1856115 View attachment 1856116 View attachment 1856117

Just found your thread.
Awesome work. It seems a shame to hide the drive train with body panels.
Hope I get to do a rebuild to this level one day.

 

[Jetlander]

And may I present to you my newly finished (last night) self-restoration 1977 FJ40.

Before:

After:

She’s not perfect, there are many like it, but this one is mine. And I did everything myself, minus the leather upholstery.

And it only took me 3 years, 5 months, and 6 days...

 

[fjdiesel]

Great job!! Looks awesome!!!

 

[Kerby J]

Might have missed it in your build thread but are those the Racer65 headlights?

 

[White Stripe]

Congratulations man that turned out great. Paint looks really good. How does it drive? Looks like it's ready to go anywhere! Its a good balance of resto mod and stock fj40. Make sure you add some anti theft devices of some sort if you haven't already.

 

[Jetlander]

Might have missed it in your build thread but are those the Racer65 headlights?

They sure are. Plug and play, look great, and work even better. They seem to be a high quality product and a huge improvement over stock headlights. You’ll actually be able to see!