Builds Project Pikachu: 1977 FJ40 (3 Viewers)

[wngrog]

Awesome.

 

[cbmontgo]

Now I'm going to dig into the electrical system. I have one brake light and the hazards will blink on the front lenses. NOTHING else works. I'm also direct-wiring the idle solenoid to the battery to drive it.

There's a total jumble of trailer wiring spliced into the rear tail lamps, completely covered in mud with loose ends everywhere. So, this is where I'm starting. I'm going to cut all of this crap and out replace the tail light housings.

 

[wngrog]

Yeah just run new wires and get new lights.

 

[cbmontgo]

I ordered a new soft top through @Trollhole today. Pikachu needs a white top, and these aren't easy to find. I could've found any other color on the used market, but I really think that the mustard yellow and white pinstripes will pop with the white top. Maybe I'm crazy, but I'm convinced nonetheless.

 

[KingAir Driver]

Now I'm going to dig into the electrical system. I have one brake light and the hazards will blink on the front lenses. NOTHING else works. I'm also direct-wiring the idle solenoid to the battery to drive it.

There's a total jumble of trailer wiring spliced into the rear tail lamps, completely covered in mud with loose ends everywhere. So, this is where I'm starting. I'm going to cut all of this crap and out replace the tail light housings.

View attachment 1423750 View attachment 1423751 View attachment 1423755

Looks like mine when I pulled them. Replaced OEM on right and Cruiser Outfitters on the left.

 

[wngrog]

I ordered a new soft top through @Trollhole today. Pikachu needs a white top, and these aren't easy to find. I could've found any other color on the used market, but I really think that the mustard yellow and white pinstripes will pop with the white top. Maybe I'm crazy, but I'm convinced nonetheless.

Hell yes it does.

 

[kcsmithson]

I agree. One of my favorite all time color combos. I think the white wheels were a great touch.

 

[cbmontgo]

I replaced one of the crusty headlights with one out of my stash. Also decided to leave the OEM bumper on, and finished up the frame rails and factory tow hook. Scrubbed 40 years of grime off the bottom of the besel as well, dolling her up nicely. I'm getting closer to not being written up by the HOA when I taxi out into the driveway.

 

[cbmontgo]

I have spent a little bit of time on the rear of the 40 this week too. New tail lenses are en route, old hitch wiring cut out, the horrible 3/8" steel angle-iron hitch assembly is gone after a ton of grinding, and I scored a couple of OEM tailgate latches on eBay. Now I'm measuring and prepping to drill holes for the hinges.

Electrical troubleshooting and searching for a windshield in between.

 

[cbmontgo]

Rear bumper is sanded and rear wiring cleaned up. New lenses also in place.

I have rear brake lights on both sides and hazards on all four corners.

 

[cbmontgo]

I took a piece of the hard top to English Color & Supply in Dallas to have them match Toyota 532 and tint it as needed to catch the exact color as it has faded over time. I'll be spraying the rear of the 40, the tailgate, and both side doors. So, I have started to clean up the surface rust on the hard doors and bring them to bare metal. The old steel from the door set I picked up is actually in quite nice condition. It wasn't sure what I'd find underneath the non-OEM black paint.

 

[cbmontgo]

Spent a little time on electrical stuff today, as the weather has been rainy and no good for paint prep. Still no power to head lights or running lights after removing and cleaning all of the grounds that I have read about. However, both head lights work when I direct-wire the battery to the circuit at the head light base. I am beginning to lean towards a bad head light switch. When I turn the rheostat, it feels like it is full of grit.

Also pulled the original mustard hinges off of the old Kayline half doors in preparation for mounting on the hard doors.

 

[samc2447]

Those switches are pretty easy to rebuild. There is a thread here somewhere that details it, but basically you bend the tabs back and it comes apart. You have to do it carefully though as there are springs and a few bb's to make contact. Clean it all up, lightly sand the contact points, use some dielectric grease and put it all back together. Cleaning out almost 40 years of grit made all the difference for mine.

 

[cbmontgo]

Those switches are pretty easy to rebuild. There is a thread here somewhere that details it, but basically you bend the tabs back and it comes apart. You have to do it carefully though as there are springs and a few bb's to make contact. Clean it all up, lightly sand the contact points, use some dielectric grease and put it all back together. Cleaning out almost 40 years of grit made all the difference for mine.

Good to hear. Thanks.

 

[wngrog]

Bad ass. Not the plan of it being a beater but I get it

 

[cbmontgo]

My paint supplier did a great job mixing a match to the original mustard 532 paint. I nearly forgot to spray the pillar for the soft top bows behind the doors. The hard doors and tailgate are done as well. Coming along.

 

[cbmontgo]

Tire carrier next. This is my old trick to softening up stuck hinges. Bolt it to a large piece of lumber (4x6 in this case), douse in oil, and work it back and forth until it has the looseness that you want.

 

[cbmontgo]

Still fiddling with electrical. I installed a used headlight switch (thanks, @Drewk). Now have running lights, which is a big step in the right direction. Still no headlights, turn signals, or cluster lights/gauges though.

 

[cbmontgo]

Took a swig of gin, cried a little, and drilled 6 holes into a rust-free c-channel.

 

[sokoloka]

Shakedown run.

Drove Pikachu about 5 miles. Went better than I could've hoped. She's coming together for sure.

View attachment 1409517

Love the stuffed look with the 33's and stock suspension / steelies. How badly does it rub when driving it as is?