Builds Project 2027: 1977 FJ40 Rebuild

[Kevin Pratt]

UPS more or less stops by the house everyday now, delivering new parts. I have quite the collection starting to build up in my office including:

Clutch Kit
Water Pump
Tail Lights
Engine mounts
Front Indicator/marker Lights
All engine seals and gaskets
Pitman Arm
Speedometer Cable
All rear drum cylinders
Brake lines
Firewall grommets
New quik hinges for front doors
Coolant Overflow bottle
Bump stops
JIS bolt kit

Just to name a few...

Here’s the bolt kit I got from @davework, which is super nice and should replace almost every bolt and nut bumper to bumper. Additionally, I dropped off all the brackets and hardware from the engine bay and cab to be cad plated. Should be nice when it’s all done.

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How much did that bolt kit set you back? Thanks

 

[Jetlander]

The kit worked out to be about $173 to the door, if you use the code YZKIT on checkout. That included the assortment box which I believe was an extra $18 or $19. You won’t be disappointed in the box as it’s super sturdy and will definitely serve other purposes for me.

 

[Jetlander]

Got some goodies back from the platers. Now to try and figure out where it all goes.

Also, finished up removing the old rusted out rear leaf spring hangers and tub mounts. Bolted new ones on with some Grade 8 flange bolts. Tightened them as much as I dare and then tacked the nut to the threads so I don’t have to worry about it loosening.

 

[Jetlander]

Well, after a few months the frame is officially ready for galvanizing. I put sacrificial bolts in all the places to hopefully prevent me from having to re-tap all the threads. Dropped it off and should have it back in a couple of weeks.

Now to finish cleaning up the axles and engine for paint while I have the extra room in the garage. So excited to begin reassembly!

 

[1MOA]

will the galvanization process bond the bolts to the frame?

 

[Jetlander]

will the galvanization process bond the bolts to the frame?

They won’t back out easy if that’s what your asking, but they shouldn’t be “bonded”, at least I hope not!

From the reading I’ve done putting bolts in helps prevent all the threads being filled with the zinc coating, unless you know something different?

 

[1MOA]

Not sure,I know we have to chase threads after galvanizing but not re-tap them only in extreme cases where the galv solution did not drain out and hardened up into a mass.

 

[White Stripe]

Is the galvanizing weak enough that the bolts won't break off due to the bonded galvanizing?

 

[Jetlander]

Well heck! Now you guys have me worried about breaking bolts! Lord knows I snapped enough during disassembly, that I DEFINITELY don’t want to have that nightmare again.

 

[White Stripe]

I honestly don't know, that's why I asked. It would stink if they did snap off. Not to hard to run a tap through vs breaking a bolt. Your way is definitely better if the galvanizing isn't that strong.

 

[Jetlander]

Spoke with the galvanizer and he said he’s never experienced or heard of bolts snapping as long as they aren’t run all the way in with the head flush to the frame.

Anyone else experienced this?

 

[mdsims]

Zinc melts at 790 degrees F. Worst case, if a few bolts are too stuck, a little detailed torch work on the bolt should soften the zinc around the threads enough to back the fastener out without breaking. Since zinc is a soft metal, I think you'll be fine.

 

[Jetlander]

Now that the frame is off getting galvanized I have enough room in the garage for some axle finishing work...

In case you’re wondering, blasting in the garage is messy business. I was wearing all the protective gear, but damn, what a mess...But this is the end result of the first axle.

Before...

And after...

 

[Jetlander]

So I’ve talked to two local galvanizers, and both recommend putting bolts in all the threaded frame holes. On guy did say there is an high temp (1200*) caulking that Lowe’s sells that will prevent any zinc from getting into the threads. They both said that if a bolt does get stuck to take a torch and heat it up to extract.

 

[fj40fillet]

A lot has happened since my last post. I managed to get the engine pulled and put onto the stand.
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So now to addressing frame issues. Besides the rear spring mounts, the half-@ss Saginaw conversion done by the PO is starting to show its ugly head. The front crossmember was completely and utterly a hack job. It’s a mess. But I’m determined to keep the frame and I have seen the magic other MUD members have done on frames that were in FAR worse shape. Regardless, I have my work cut out for me. I see many hours of cutting and grinding in my future. I’ll be ordering a new Saginaw bracket mount from @orangefj45 today, along with a complete knuckle rebuild kit.

View attachment 1582893 View attachment 1582894 View attachment 1582895

I never liked the Signaw hack the cross member install on an FJ40. Your new solution looks much better.

 

[fj40fillet]

Now that the frame is off getting galvanized I have enough room in the garage for some axle finishing work...

In case you’re wondering, blasting in the garage is messy business. I was wearing all the protective gear, but damn, what a mess...But this is the end result of the first axle.

Before...

View attachment 1644433

View attachment 1644434

And after...

View attachment 1644435

View attachment 1644439

You are correct sir. I blasted in my garage and have now stopped half way back on the frame, and will never do it again. I didn't disassemble my axles, trans, etc. Frame rails were full of sand, even after blowing it out. I am now finishing my frame by scraping off undercoating, treating with Corroseal Rust Treatment, then coating with Eastwood Frame primer and paint.

 

[Jetlander]

You are correct sir. I blasted in my garage and have now stopped half way back on the frame, and will never do it again. I didn't disassemble my axles, trans, etc. Frame rails were full of sand, even after blowing it out. I am now finishing my frame by scraping off undercoating, treating with Corroseal Rust Treatment, then coating with Eastwood Frame primer and paint.

Yeah, really the ideal garage setup would be an empty garage to blast in. It would make cleanup and reusing the media a lot easier. Although I was able to salvage most of the media, it’s basically on everything. I thought about doing it in the driveway but I’m already certain the neighbors hate me from all the grinding and wirewheel noise over the last few months.

 

[Jetlander]

I never liked the Signaw hack the cross member install on an FJ40. Your new solution looks much better.

Thanks. While it’s not perfect, and certainly not as clean of a job as I’ve seen on other rigs, it works, and the strength integrity of the crossmember is much, much better than before.

 

[fj40fillet]

Yeah, really the ideal garage setup would be an empty garage to blast in. It would make cleanup and reusing the media a lot easier. Although I was able to salvage most of the media, it’s basically on everything. I thought about doing it in the driveway but I’m already certain the neighbors hate me from all the grinding and wirewheel noise over the last few months.

LOL. I can so relate. I've been toxifying my neighbors spraying epoxy and 2 part urethane paint. An pulling my firewall on the tree out front with a chain fall.

 

[velillen]

Yeah, really the ideal garage setup would be an empty garage to blast in. It would make cleanup and reusing the media a lot easier. Although I was able to salvage most of the media, it’s basically on everything. I thought about doing it in the driveway but I’m already certain the neighbors hate me from all the grinding and wirewheel noise over the last few months.

I did mine in the driveway in a sort "pit" made out of tarps. 3' high walls caught most of the debris. But man the fine dust still went everywhere. My truck was covered (it was a good 30' away downwind) and im sure my neighbors got a dusting too even through some trees. Thankfully my neighbor is a car guy and never said anything about it. He was out re-roofing his home after I'd painted the frame and dropped the engine back in....heard him telling his friend how I'd been doing things right and blasted it, cleaned it, POR-15 and top coated it. So even if I did make a mess at least he understood!

I haven't decided if ill blast the body or not. But if I do Im thinking Ill buy one of those 10x16 type portable garages to contain the dust and debris a lot better. And not have to worry about rain.