Builds Project Old Blue Eyes

[pb4ugo]

Im guessing that's to the wheels?

 

[jesus888]

Im guessing that's to the wheels?

That is correct... I didn't get a video of the dyno run, but once we swap out the exhaust manifolds/piping, he's going to touch up the tune and I'll get it then!

 

[Mike Shull]

212hp/270tq on 87 pump gas…
And the maps are nice and smooth, gas smell is all but gone… he said with very little cost, can add 100hp… for now, I’m fine. Maybe later if I ever get tired of the current power which feels like a rocket ship compared to my other vehicles

Power delivery is smooth and consistent, I’m stoked to keep moving forward!

View attachment 3920945

I’m just curious what work was recommended to add 100hp…not that I need more hp.

 

[jesus888]

I’m just curious what work was recommended to add 100hp…not that I need more hp.

He said 50lbs injectors, a truck cam (his preference is Brian Tooley Racing truck cam stage 2 v2 - $199), some BTR valve springs and a tune, should be closer to 330hp…

He said you def could spend a lot more money on a lot more stuff that’s nicer but for for 5.3s he’s very happy with this setup…

 

[jesus888]

Finally got a chance to give the old girl a wash and set her up for shuttle duties for a bit before going back into the spa…

@DirtDauberGarage is gonna take care of the rear sill, widen the rear wheel wells in anticipation of flipping the springs, and give the frame a nice cleaning/painting once I get my patch panels from CCOT, probably starting beginning of next week.

I’m stoked because I have lots of parts that I wanna install and things I wanna do but the metal work is definitely the first step.

Keeping all the patina, but just focusing on extending her life, and sealing things up with all the weatherstripping in the back, since there’s currently none present…

 

[DirtDauberGarage]

I have started working on project Old Blue Eyes and aim to complete the metal work, along with the sill, rockers, and paint the frame in a week or so. I began by thoroughly cleaning the underside. I used compressed air and a shop vac to get the initial debris logged on the inside of the frame rails. I realized that by parking it on a steep hill and working my way down the frame hole by hole with a pressure washer, I can clear out all the debris trapped inside. I forgot to take a pic when I was finally done, but a ton of dirt, rocks, even a piece of copper tubing came out. The pic here is just from one side of the frame. This isn't even counting the stuff initially vacuumed up with the Shop Vac.

 

[DirtDauberGarage]

The plan...

1. Clean, seal, and paint the frame. Including coating the inside with a rust encapsulator.
2. Replace the rear sill and sheet metal cover.
3. Replace the lower rear corners of the rocker panels.
4. Fix two small spots on the rocker panels.
5. Widen the rear wheel arches to accommodate a spring flip. I will add five and a half inches to the wheel well. See the pics below.

@jesus888 wants to keep as much original metal and patina paint as possible.

Here is the pic of the rear sill before I started. I took off the spare tire and the bumperettes.

 

[DirtDauberGarage]

Got a lot done today!

I could NOT find a good "How to Replace a Rear Sill" thread that is step-by-step and has lots of pictures. There are many threads where people have done them, but not a good "step-by-step" thread. Do you guys know of one? If not, I will write one up when I am done.

Here it is...

"HOW TO" - Replace the Rear Sill on an FJ40 – STEP BY STEP

There are many threads about sill replacement here on MUD, but I could NOT find a comprehensive “step-by-step” guide on how to do it. Therefore, I decided to create one in hopes it might help someone in the future. It was my first time replacing a sill, and I took my time to ensure I did the...

forum.ih8mud.com

I sealed the inside of the frame with rust encapsulator and then painted the frame. I applied the product generously, moving the paintbrush back and forth in every hole in the frame.

Next, I removed the rear sill and installed a new one. Here are a few pictures.

 

[DirtDauberGarage]

More Pics

 

[DirtDauberGarage]

A few more pics... sorry that they are not in order

 

[DirtDauberGarage]

More progress...

I installed the new body mounts and I am finishing up the sill.

I need to do a little bit more cleanup on the sill,and then I can move on to the quarters.

 

[DirtDauberGarage]

Got a little bit more work done today on "Old Blue Eyes". I was hoping to finish the sill, but found a rust spot that needed to be fixed. This was not in the plan but needed to be done. I found some blue paint that was close but not perfect. At least it looks better than gray primer.

Usually, I would recommend replacing the entire quarter panel with rust like this, but @jesus888 wants to keep as much original metal and patina as possible. I agree, it looks pretty cool!

Here are a few pics.

 

[DirtDauberGarage]

A few more pics...

Found this 9mm shell casing when I flushed out the inside of the frame. I guess Old Blue Eyes has a story or two...

The patch is from CCOT and was of nice quality... thick metal and fit perfectly.

 

[DirtDauberGarage]

It was a long day, and Old Blue Eyes is making me work, but I am progressing slowly.

Here are the latest pics...

 

[DirtDauberGarage]

Almost done and can move on to the other side...

 

[cruisermatt]

Looking good.

 

[DirtDauberGarage]

Sill = Done!
Passenger side wheel well = Done!

Moving on to the driver's side tomorrow...

 

[DirtDauberGarage]

I am almost done with Old Blue Eyes....

Moving on to the rocker panels. This area is prone to rust due to the bracket located behind it. It tends to trap water and dirt, which encourages rust development.

I had to fabricate a new bracket using some scrap metal left over from the CCOT patch. The metal was nice and thick, and I think it turned out pretty well.

I coated everything before and after with a good rust converter and some flat black paint.

 

[DirtDauberGarage]

More pics...
Again, I used the leftover metal from the rear quarters from CCOT. It is super thick and nice metal. I would definitely recommend them!

 

[DirtDauberGarage]

@jesus888 wants to keep the rough patina look, so I am not making it look too good. I am really good at making things NOT look too good

A little more grinding and primer. I also had to drill out and retap all the rear hatch bolts that broke. That was painful!!