Project Theseus (aka the 40-40 truck)

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Joined
Jul 14, 2012
Threads
44
Messages
118
Let me start with the background and a trip in the Way-Back Machine...
In Greek mythology, Theseus, the mythical king of the city of Athens, rescued the children of Athens from King Minos after slaying the Minotaur and then escaped onto a ship going to Delos. Each year, the Athenians would commemorate this by taking the craft on a pilgrimage to Delos to honor Apollo. Over time, various of its timbers rotted and were replaced.
A question was raised by ancient philosophers: If no pieces of the original remained in the current ship, was it still the Ship of Theseus? If it was no longer the same, when had it ceased existing as the original ship? Seventeenth-century philosopher Thomas Hobbes further questioned how to consider a second ship that had been built entirely from pieces removed from the original.

Fast forward to Jan 2011 and the start of my 3rd FJ40 project...
I was given the 1966 FJ40 from my father in-law who had it stored at a friends house for about 10 years. It was a true basket case that had been completely stripped down to bare metal allowing the body to turn a nice rust brown color. It came with an F engine, 3speed, transfer case, plenty of removed parts scattered between 2 locations and even more lost to time. This project would be sporadically worked on in small amounts over the next 12 years with the aid of my son who was 3 at the time the project began who called it the "40-40 truck". It was decided early on to do a complete frame-off build due to the amount of disassembly that had already begun.

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Over the years, everything that could be replaced would be. Everything would be given an overhaul...new bearings in everything, brakes and brake lines, complete rebuild of the motor, transmission, and transfer case. Removal and replacing of almost all the body and tub panels from the gas tank/toolbox back to the rear sill. Fixing all of the previous owners (Im sure there were a few) holes, damage, and modifications to the body and frame. Restoring everything possible back to the original stock condition.
Decisions would be made to do many upgrades and modifications...4speed transmission matted to a 3speed transfer case, disk brake front axle, FJ60 power steering, completely new and upgraded wiring loom, 3" lift from springs/shackles, DUI distributor, early FJ40 vent windshield, and many many more.

My hope is to use this thread to document the restoration throughout the years. I will try to keep things sectionalized and not get toooo scattered or throw in unnecessary junk. Thank you to all that have helped this far with tech knowledge, parts, and support. If anyone out there needs pictures or measurements for your builds, let me know as EVERYTHING is, has been, or will be, taken apart.

I couldnt mark this as a "BUILD" in the prefixes. If any of the moderators out there can assist, that would be great.
 
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The front and rear axles were removed and rebuilt. New Bearings, seals, and all brake components.
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Found some interesting black coating on the front axle backing plate. The substance was very hard and coated everything completely and was extremely difficult to remove. It was found on both sides. No signs of a leaky axle seal.
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There was a "ghost" image under the driverside kick vent leftover from what appears to be an old 4x4 club sticker. It appears to be from the VENICE FOUR WHEELERS (possible Venice Ca). I remember seeing this years ago when I was a kid and there was a lot more 4x4 and clubs out here in Southern Ca. In the 2007 SOR catalog on index pg B and in the 2024 SOR catalog on pg5 the image is appears in one of the pictures. If anyone has information on the club, please direct message me.
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This is the image found in the SOR catalogs. Maybe this is an old picture of my rig? The black paint on the exterior of the above picture, could match the black paint found in the engine compartment, as well as on front heater (also painted black but with the pewter grey still visible on the back and inside).
 
So many learning opportunities for the kid. It truly is amazing what some people have done, or not done. Torque values, seals, and gaskets are there for a reason.

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Trying to figure out WHY the shock tab needed such a heavy beef-up with 1" square stock. Those got chopped to make way for original tabs that hadnt been cut and booger-welded.
 
The axle hubs were interesting. One had almost an entire tub of grease in it, the other has plenty of gear oil mixed in with what little multi-colored grease was there. You get an idea of who/what the previous owner was doing (or trying to do) as you get deeper.

Ive never seen a knuckle bearing crushed enough into the race to make the knuckle physically stop at every point of the compass.
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Something about the deep groove cut into the front axle tab washer was another indicator of the thought processes of the previous owner. Very curious.
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Then the axle hubs themselves came into question. One had received a copious amount of RTV sealant when it was placed, the other had some nice race-track grooves cut deep into it.
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Like I said, its been a great learning opportunity for the boy to actually see what happens when you dont do things right and the need to take care of your toys. SUPER EXCITED to see what we find when pulling the 3rd member out. Stay Tuned......
 
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