Build Project Pork Roll - 1970 FJ40
- Thread starter bulldog77
- Start date
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that is correct, the anti rattle clip should be on the bottom slid pin.
you are just hammering through this despite the 3 or so feet of snow in march
.
- Thread starter
- #63
Two steps forward and one step back. Since I received my new hardware kit from @davework (overland metric) I decided to take the fenders off to replace the old crusty bolts. About three of the bolts snapped and two of the welded nuts broke free as well. I'm going to try to remove the broken ones today but for the others I'm going to attempt to use steel rivet nuts. I had a feeling that removing them wouldn't go smoothly but I just want to get this sorted out now so that disassembling at a later time would be easier.
I received 5 OEM wheels through the mail the other day and my tall and skinny Coker tires should be delivered today! I'm hoping to get a couple of them mounted so that i can get them on the front end. That will allow me to start working on the rear axle disc brake conversion from poser. I'll also clean up the frame and rear axle while I'm back there.
I received 5 OEM wheels through the mail the other day and my tall and skinny Coker tires should be delivered today! I'm hoping to get a couple of them mounted so that i can get them on the front end. That will allow me to start working on the rear axle disc brake conversion from poser. I'll also clean up the frame and rear axle while I'm back there.
purrty!
- Thread starter
- #65
Pretty much have the front end back together, so I'm moving on to the rear. I'm planning on cleaning up the frame (wire brush, flap wheel, rust killer, paint) and installing the rear disc brake conversion.
I started out by trying to remove the axles but unfortunately when I removed the diff shaft pin it was broken! I searched a few threads and I'm going to attempt the method that @Shark56 used in his thread from back in 2008 -- Rear Differential Shaft Pin
I'll post an update once I give this a shot over the weekend.
I started out by trying to remove the axles but unfortunately when I removed the diff shaft pin it was broken! I searched a few threads and I'm going to attempt the method that @Shark56 used in his thread from back in 2008 -- Rear Differential Shaft Pin
I'll post an update once I give this a shot over the weekend.
- Thread starter
- #66
Received some wiring stuff from @Coolerman yesterday. Thanks for the quick delivery and quality parts! I changed out my alternator connector since the clip was broken on it, also needed new leads on the transfer case switch, and put in a new fuse holder with longer leads to replace the one under the cowl vent which had seen better days.
Still need to work on getting that broken pin out of the diff, but for now I'm just chipping away at a long list of stuff to get done.
Still need to work on getting that broken pin out of the diff, but for now I'm just chipping away at a long list of stuff to get done.
if the diff pin isn't hardened maybe you can try to drill it and use a spiral extractor to get it out, I think that their only torqued to about 30 ft/lb so might be a good option
- Thread starter
- #68
Finally was able to get the diff pin out! I drilled a hole through the original bolt using that as a guide to drill into the broken pin. I then attempted to back it out using an easy out...well it wasn't so easy. I resorted to the pound the crap out of it method. The pin finally broke before the housing did so I lucked out.
I'm still working on cleaning up the frame and now with this out of the way I can start changing out the rear axle seals and install the disc brake components.
I'm still working on cleaning up the frame and now with this out of the way I can start changing out the rear axle seals and install the disc brake components.
- Thread starter
- #69
I was able to get the rear back together and new axle seals in. Thanks to the search function I learned how to get those spider gears lined up again. 
The bearings and axles looked fine so thankfully nothing to do there. I was able to install @Poser rear caliper brackets and discs. Very high quality and everything fit as it should. The only issue that I came across was that I had to cut off a small section at the bottom of the casting on my Monte Carlo calipers in order to have them line up properly (see pic). After searching this site I came across somebody who posted about the same issue/resolution.
Calipers/discs installed!
New Tires and rims are on all four corners now:
Next up on my list:
. I have faith that he can work his magic and get it working properly again. I really appreciated the knowledge that he shared on our short phone call.
The bearings and axles looked fine so thankfully nothing to do there. I was able to install @Poser rear caliper brackets and discs. Very high quality and everything fit as it should. The only issue that I came across was that I had to cut off a small section at the bottom of the casting on my Monte Carlo calipers in order to have them line up properly (see pic). After searching this site I came across somebody who posted about the same issue/resolution.
Calipers/discs installed!
New Tires and rims are on all four corners now:
Next up on my list:
- Finish painting the frame.
- Fully install fuel tank and run new fuel line.
- Run new brake lines to front/rear.
- Reupholster front seats (already prepped and painted the frames)
. I have faith that he can work his magic and get it working properly again. I really appreciated the knowledge that he shared on our short phone call.
I really enjoyed this post. I’ve got a 69 that looks about the same but it’s been sprayed in primer. I really like the interior red primer you used, I’ll be following the overall theme of this build.
Clean and repair as needed. Very interested in this.
Another Ratty 40 series: Project Primer
Clean and repair as needed. Very interested in this.
Another Ratty 40 series: Project Primer
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Yes, that's how to mod caliper & get it mounted up at a good angle. The GM caliper is oriented correctly when the banjo bolt is going vertical into the bottom of the caliper.
Now might be a good time to flip those around so caliper is behind the axle, then it's not the first thing to find the gravel, boulders, parking block, etc.
I gave @FJ40Jim a call today to check the status of the carb rebuild. I learned a lot about the process and he provided great insight to the condition of my 40. Apparently a (rodent) feces packed carb is a bit of a challenge
So yeah, that was nasty enough to warrant a picture.
- Thread starter
- #72
I was already was following your thread! I thought the same when I saw the pics of your 40. Good luck!
Thanks!
Have you tried moving the motor since you put the MMO in?
Have you tried moving the motor since you put the MMO in?
- Thread starter
- #74
Yes, I have a new battery and it turns over as it should. Compression across the cylinders is good and consistent as well. I did see some oil making it up to the head while I was cranking but not much. From what I read that seems to be normal but that is still in the back of my mind to double check. I may attempt to manually spin the pump with a drill to see if all is working properly.
- Thread starter
- #75
A little more progress but then a step back. I turned over the engine just to see if oil was making it up to the head. The good news is that it was, but the bad news is that it didn't seem to be making it down the rocker tube and through the weep holes, especially to the front half. Most of the oil was dumping out at the ends of that banjo fitting piece. I concluded that it either the tube was clogged up or the two o rings were bad. I disassembled it and ordered new o rings. I didn't find much gunk build up at all so for now I'll just wait for the parts to arrive. I'm glad that I took a look at this now and hopefully get it resolved
As I was taking the rocker stands off I noticed that one of them had a very loose bolt. I think a PO may have stripped it out. It was holding but just wouldn't tighten all the way up the way it should. I installed a helicoil in that location and it should be ok now. First experience with one of those and it was a lot easier than anticipated and took less than 10 minutes.
I was able to finish cleaning/painting the frame and run the new fuel line. I didn't strap in the new tank yet because I think it will need to lift up a bit to get the tunnel cover back on. I also installed the cluster and the repainted glovebox and ashtray. There are a few extra holes in the dash from a PO. I'm just going to plug what I can for now, If I ever take the body off to do a proper restoration I'll address them then.
Learning a lot, but further down the rabbit hole I go.
View attachment 1693453
As I was taking the rocker stands off I noticed that one of them had a very loose bolt. I think a PO may have stripped it out. It was holding but just wouldn't tighten all the way up the way it should. I installed a helicoil in that location and it should be ok now. First experience with one of those and it was a lot easier than anticipated and took less than 10 minutes.
I was able to finish cleaning/painting the frame and run the new fuel line. I didn't strap in the new tank yet because I think it will need to lift up a bit to get the tunnel cover back on. I also installed the cluster and the repainted glovebox and ashtray. There are a few extra holes in the dash from a PO. I'm just going to plug what I can for now, If I ever take the body off to do a proper restoration I'll address them then.
Learning a lot, but further down the rabbit hole I go.
View attachment 1693453
- Thread starter
- #76
Progress! ...or at the very least the illusion of progress. Either way I will take it. I ordered and received the rocker stand bolts/studs that I needed along with the o rings. The whole assembly is back on and I'm seeing oil weep out of all the holes now!
Finished off a bunch of other stuff:
Finished off a bunch of other stuff:
- Sourced and installed bumper gussets and side brackets as well as tow hooks
- Installed rear shocks
- Installed new rear lights/brackets and side markers.
- Replaced the oem window regulators with CCOT reproductions. I'm going to try to recondition the originals but just wanted to get working ones on there for now. I was surprised at the color of them they seem to be more on the golden side.
- Installed a fusable link that I ordered from coolerman
- Reupholstered the front seats. (I'll get pictures of these up soon)
- Did a bunch of other crap that I can't remember right now...
- Welding - tombstones for brake lines, random holes drilled on the trans tunnel cover, seat frame.
- Make hard brake lines
- Thread starter
- #77
There are some things that I still need to source. If you have a lead on any of them please PM me.
- tire carrier (passenger side mount)
- oem rollbar
- windshield
Cutting it close on space with the garage door! Build is looking good
- Thread starter
- #79
I ended up biting the bullet and getting a new oem radiator. I found a crack in the neck of the original that looked like it was jb welded together so I really didn't want to rely on it.
I installed the radiator today and also welded the brake line tabs to the axle. Man I suck at welding. I practiced and can lay a decent looking bead on a flat surface but once I'm in an awkward position it comes out like crap. I definitely need more experience before I attempt to do the rear sill and quarter patches. I also filled in the numerous holes on my trans cover.
I finished the reupholstering the seats which came out ok (SOR foam and cruiser corp covers). The frames and backs were stripped and repainted the pewter silver color (jtoutfitters). I was rushed for time when covering them so I may go back and fix some minor things. They were A LOT easier to do than the seats in my 80!
Next on my list:
I installed the radiator today and also welded the brake line tabs to the axle. Man I suck at welding. I practiced and can lay a decent looking bead on a flat surface but once I'm in an awkward position it comes out like crap. I definitely need more experience before I attempt to do the rear sill and quarter patches. I also filled in the numerous holes on my trans cover.
I finished the reupholstering the seats which came out ok (SOR foam and cruiser corp covers). The frames and backs were stripped and repainted the pewter silver color (jtoutfitters). I was rushed for time when covering them so I may go back and fix some minor things. They were A LOT easier to do than the seats in my 80!
Next on my list:
- Weld PO random holes in the front heater and paint it
- Start making brake lines (not looking forward to this)
- I need to bend a new fuel line from the pump to carb - waiting on the carb to do this.
- Thread starter
- #80
The carb should be coming in by the end of next week so hopefully I'll be able to fire it up next weekend. I managed to get the bib back on an sort out my rear light wiring. Everything was there and working but I had to replace some connectors and clean up where the PO attached a trailer wiring harness. I painted the transmission cover and plan on installing it this week along with strapping down the fuel tank and putting back the front seats.
I've also been thinking about picking up some rear seats like these from a Sprinter. They have integrated seatbelts. Of course the base would have to be modified. They come in configurations of 2 and 3 but I'm not sure if 3 would fit across. I'm going to try to get to a place in Queens NY that has a bunch of them for sale so that I can measure and figure out if it is worth it. I'm trying to come up with a safe way to transport my kids on the occasional local ride in town.
I also had a cigar and a couple of beers while staring at all of the work that I still need to do.
I've also been thinking about picking up some rear seats like these from a Sprinter. They have integrated seatbelts. Of course the base would have to be modified. They come in configurations of 2 and 3 but I'm not sure if 3 would fit across. I'm going to try to get to a place in Queens NY that has a bunch of them for sale so that I can measure and figure out if it is worth it. I'm trying to come up with a safe way to transport my kids on the occasional local ride in town.
I also had a cigar and a couple of beers while staring at all of the work that I still need to do.