I found it easier to leave the holes open and just re-tap them.
Builds Project 2027: 1977 FJ40 Rebuild
- Thread starter Jetlander
- Start date
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Dunbar
SILVER Star
What about cutting off the thread sticking though on the inside that got galvanized? I'll learn from your experience though and put them in thread deep.For those who have been following the frame galvanizing debate about putting in sacrificial bolts, the outcome is less than stellar. I tried to remove about 12 bolts and have snapped 5 of them. I think putting the bolts only in deep enough to cover the threads would have been a better plan. Live and learn I guess. Looks like I have a ton of work ahead of me now...
- Thread starter
- #163
Not pissed at all, it’s my favorite too by a long shot.View attachment 1672757
Ahhh... hope you won’t be pissed when I say, after reading through your thread and impressive work detail/pics, that this is my favorite!
My previously buggered steering setup is dangerously close to yours (although I’m toolin around surprisingly well) so I’m looking forward to how you improve yours!
Great work...
- Thread starter
- #164
Been busy extracting bolts from the frame. There was a learning curve but getting a torch on the backside threaded portion of the bolt and heating up the thread and galvanizing is doing the trick. They then zip right out with the impact. I’m a little slow sometimes and I managed to snap a bunch before I figured it all out, so I’ve been busy drilling and retapping about 10 bolt holes. Oh the joys...
- Thread starter
- #165
It’s officially a roller again! I had an idea of the work involved to get it to this point, but man did I underestimate it. Regardless, it’s getting so close I can already feel the vibration of the trusty 2F!!!
And a celebratory Orval Trappist beer to make the moment all the better.
And a celebratory Orval Trappist beer to make the moment all the better.
You're making some great progress!It’s officially a roller again! I had an idea of the work involved to get it to this point, but man did I underestimate it. Regardless, it’s getting so close I can already feel the vibration of the trusty 2F!!!
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And a celebratory Orval Trappist beer to make the moment all the better.
I was just saying to a buddy of mine this weekend that my time estimates for truck projects are off by AT LEAST a factor of 4. 1 hr. project in my mind = 4 hrs. or more, in real life.
Epic man. That frame should only last a few hundred years lol. Never seen that beer b4. Is it a Texas thing?
Same here, except not only do I underestimate the time needed, but I also likewise underestimate how much of my bank account will get eaten in the process.
ZACTLYEpic man. That frame should only last a few hundred years lol. Never seen that beer b4. Is it a Texas thing?
Same here, except not only do I underestimate the time needed, but I also likewise underestimate how much of my bank account will get eaten in the process.
- Thread starter
- #169
It’s actually a Belgium beer brewed by monks. By a mile it’s my most favorite beer of all time. Nothing tastes like it. It’s a special order type thing and very pricey... Orval Trappist AleEpic man. That frame should only last a few hundred years lol. Never seen that beer b4. Is it a Texas thing?
Same here, except not only do I underestimate the time needed, but I also likewise underestimate how much of my bank account will get eaten in the process.
- Thread starter
- #170
Epic man. That frame should only last a few hundred years lol. Never seen that beer b4. Is it a Texas thing?
Same here, except not only do I underestimate the time needed, but I also likewise underestimate how much of my bank account will get eaten in the process.
Yes, and yes. I’m a bit behind what I thought my schedule would be, mainly because of the powder coater being epically slow. But I’ll keep plugging away with the hopes of having it done by November as originally planned. It’s still very ambitious.
As far as the $$$, I’ve been buying parts a few at a time for months. I’ve got quite the collection going in my office.
Posted this elsewhere but it fits better here!
*Rest of your 40 comes out nice as the frame..... The FJ Company has competition
@Jetlander How is progress coming?
- Thread starter
- #173
Wow! I can’t believe it’s been that long since I’ve done an update. Progress is moving along nicely but not as quick as I’d have hoped. Spent a couple weeks on vacation, then came home to a significant promotion at work that has me more of a 9-5er than I’ve ever been before. Gone are the days of hanging out at the house 70% of the week with nothing better to do than wrench on the Cruiser.
Anyways, here are some photos with updates.
I managed to get the engine put back together after replacing the push-rod side galley, front crank, rear main, fuel pump, oil filter with new OEM seals and gaskets. This was after I did a thorough cleanup, media blasting, and painting of the engine block. The ol’ trusty 2F is now resting securely back in its forever home, sitting atop brand new OEM engine mounts.
I then replaced the nearly worn out clutch assembly with a new one. With the rear of the engine exposed as it was, it didn’t make any sense to put the old one back in even though there was still a few years of life left in it. Piece of mind is well worth the extra effort when it comes to things like this.
So that brings me up to where I’m at right now. The replacement of all seals and gaskets on the transmission and transfer case... I don’t have the knowledge to do a full rebuild on either, but then again, other than leaks, both worked perfectly before the tear down.
So I’ll throw the dice on these and just fix leaks.
I think the hardest part is getting the damn things clean. I literally spent hours with wire wheels and brushes to get it to this point of cleanliness. I didn’t want to open it up and get crap inside.
I was excited to see the blackmagic, which is a transmissions heart, was damn near perfect! There doesn’t appear to be any heat marks or any wear for that matter. Not bad for 40 years old. I wish I was in that good of repair...
One small hiccup though. The seal and gasket kit I got from Cruiser Outfitters was perfect in every way, except one. This gasket doesn’t fit properly.
I talked to Kurt and he says this is the first time they’ve seen this. He’s going to stop selling the kit until some fixes can be made. I’ll have to elongate the bottom two rows of holes to make it work. Shouldn’t leak though. I’ll put some sealant on just to make sure.
Anyways, here are some photos with updates.
I managed to get the engine put back together after replacing the push-rod side galley, front crank, rear main, fuel pump, oil filter with new OEM seals and gaskets. This was after I did a thorough cleanup, media blasting, and painting of the engine block. The ol’ trusty 2F is now resting securely back in its forever home, sitting atop brand new OEM engine mounts.
I then replaced the nearly worn out clutch assembly with a new one. With the rear of the engine exposed as it was, it didn’t make any sense to put the old one back in even though there was still a few years of life left in it. Piece of mind is well worth the extra effort when it comes to things like this.
So that brings me up to where I’m at right now. The replacement of all seals and gaskets on the transmission and transfer case... I don’t have the knowledge to do a full rebuild on either, but then again, other than leaks, both worked perfectly before the tear down.
So I’ll throw the dice on these and just fix leaks.
I think the hardest part is getting the damn things clean. I literally spent hours with wire wheels and brushes to get it to this point of cleanliness. I didn’t want to open it up and get crap inside.
I was excited to see the blackmagic, which is a transmissions heart, was damn near perfect! There doesn’t appear to be any heat marks or any wear for that matter. Not bad for 40 years old. I wish I was in that good of repair...
One small hiccup though. The seal and gasket kit I got from Cruiser Outfitters was perfect in every way, except one. This gasket doesn’t fit properly.
I talked to Kurt and he says this is the first time they’ve seen this. He’s going to stop selling the kit until some fixes can be made. I’ll have to elongate the bottom two rows of holes to make it work. Shouldn’t leak though. I’ll put some sealant on just to make sure.
- Thread starter
- #174
So here is a pic of the engine remounted on the frame. I really should push it into the drive to get some better pics.
Not sure about the white paint on the fan. The fan was in good condition but was stained from years of dirt buildup. I tried cleaning it with everything I could think of, to no avail. So I sprayed it with white epoxy hoping it’ll stay on. I couldn’t bring myself to putting on a fan that looked ratty, especially with everything else looking so pretty. I may end up just buying a new one, strictly for cosmetics.
And finally, the reason my build has been moved off the “fast-track”.
I’m thinking a November finish date is now beyond any reasonable expectation. Having 70+ pilots to supervise takes up A LOT of time...
Not sure about the white paint on the fan. The fan was in good condition but was stained from years of dirt buildup. I tried cleaning it with everything I could think of, to no avail. So I sprayed it with white epoxy hoping it’ll stay on. I couldn’t bring myself to putting on a fan that looked ratty, especially with everything else looking so pretty. I may end up just buying a new one, strictly for cosmetics.
And finally, the reason my build has been moved off the “fast-track”.
I’m thinking a November finish date is now beyond any reasonable expectation. Having 70+ pilots to supervise takes up A LOT of time...
9-5 job whats that???? lol
Im used to 7-13s for 5-6 weeks straight then maybe a week or 2 off. REally hurts the cruiser time but i usually get Dec-Mar off so thats cruiser time.
Congrats build looks good so far
Im used to 7-13s for 5-6 weeks straight then maybe a week or 2 off. REally hurts the cruiser time but i usually get Dec-Mar off so thats cruiser time.
Congrats build looks good so far
- Thread starter
- #178
Been a helluva couple of days working on the cruiser. She was my main mistress for a long time and now she’s been replaced by work. Sucks to only get the weekends to wrench on it.
Anyways, managed to get the transmission and transfer case all sealed up new hardware. Been waiting for a few weeks to get the transmission painted but the Houston humidity has been killer. Not conducive to painting, that’s for sure.
While moving about the garage I managed to knock over the transfer case. Damaged the damn thing but was lucky I didn’t crack it open.
Managed a reasonable redneck fix but I’m still pretty perturbed about it.
Had to grind and smooth out the area to prevent it from cracking down the road.
Once mounted to the transmission I filled the bolt hole area that was exposed with ultrablack rtv. The gasket area is still in good shape so no worries about leaks.
Drivetrain is almost done! Still need to overhaul the parking brake and bolt it up, but the heavy lifting is more or less done.
Anyways, managed to get the transmission and transfer case all sealed up new hardware. Been waiting for a few weeks to get the transmission painted but the Houston humidity has been killer. Not conducive to painting, that’s for sure.
While moving about the garage I managed to knock over the transfer case. Damaged the damn thing but was lucky I didn’t crack it open.
Managed a reasonable redneck fix but I’m still pretty perturbed about it.
Had to grind and smooth out the area to prevent it from cracking down the road.
Once mounted to the transmission I filled the bolt hole area that was exposed with ultrablack rtv. The gasket area is still in good shape so no worries about leaks.
Drivetrain is almost done! Still need to overhaul the parking brake and bolt it up, but the heavy lifting is more or less done.
- Thread starter
- #179
Haven’t really done a lot of work since the last update, but I REALLY needed to clean the garage out. So, for the first time since November I pushed the ol’ girl into the driveway. I took some pictures of the cruiser in some natural sunlight. Here’s a bit of eye candy for you guys.
thecrazygreek
A.K.A. TheCraftyGreek
Great work!
You planning on painting the frame black? Just thinking of the rear cross member, and front end areas...
You planning on painting the frame black? Just thinking of the rear cross member, and front end areas...
