Rebuild 74 FJ40 RHD from Down Under - 2F to 2H to 12HT - 40 series Axles with 80 series Coils

[tmarx]

Very nice work ! I think that motor even challenges Marshall's 2F a bit

 

[watrob]

Trollhole's Big Gay 2F Build had a pretty nice engine, remember looking at it awhile back.

 

[chappohj47]

Red calipers make it stop faster

 

[watrob]

It stops the salt corrosion and damage to the calipers because I have to hose down a lot more often due to the beach.

Going to pickup the radiator surround, guard brackets and battery holder from the galvanisers this afternoon and also finish off the front disc calipers.

 

[watrob]

Now have the final pieces back from the galvanisers , radiator surround, the front pieces for the chassis, guard brackets (they are just sitting on the chassis for the photo, I know this not the correct position for fitment) battery holder.

Some of the darker grey areas you see is itch primer test spots to see how it sticks to the gal. Chassis and parts are going to be finished in black gloss.

 

[chappohj47]

Very nice

 

[watrob]

Spent the day etch priming all the gal chassis & suspension, radiator surround and assorted parts. Now ready to be sprayed gloss black.

 

[chappohj47]

Looking good mate I glad you got your left hand side battery tray

 

[AussieHJCruza]

Mmmm, very nice, especially the 12H-T. How do you think the coatings on the engine will take getting hot?

 

[watrob]

Yeh, I cut a lot of excess metal out of the tray, one its not required, and two it had to straddle the coil hats. It also sits about 50mm above the shock tower which worked out quite well.

 

[watrob]

Mmmm, very nice, especially the 12H-T. How do you think the coatings on the engine will take getting hot?

A lot of the coatings are ceramic, the block, sump & head have been painted with a high heat resistant paint which I did but the base coat on these were put on by the company that reco'd the engine after it was chemically cleaned, all the other parts & brackets including turbo have been professionally coated and baked by Revolution Coatings (its not a rattle can job). The harmonic balance is also had a ceramic coating.

The turbo and exhaust manifold are also internally ceramic coated as well, its said it reduces heat by 30%. The only couple of things I have sand blasted and painted are the power steering pump & bracket, alternator, fan clutch and thermostat housing. I cleaned, etched primed and painted every bolt & nut.

The are air intakes that go across the top of the rocker cover (as was every other component, was coated by Revolution Coatings) I just hand painted the red & black "Toyota Diesel" words and they recoated a clear over the top.

I originally stripped the engine, sent the bare long motor off for rebuild, sent off all individual parts to be painted. Ordered a new CHRA for the turbo, then re-assembled all components back onto the engine, including re-installing the IP pump after Diesel Australia did a service on it and I bought new injectors which I coated & installed.

Basically there are no parts on this engine that have not been coated in some way. The current 2H I have which has been running for nearly 7 years on the beach was a rattle can job and is still in pretty good condition. The 2H was never rebuilt but a did paint it, removed and painted the exhaust manifold and heat shields, and then spayed the balance of the engine with heat resistant paint including pullies, power steering pump, IP pump etc.

Its worth doing if you have the engine on a stand, as for my 40, other than the beach its self, its a pretty clean environment, its just the corrosive natures you have to be one step ahead of?

 

[AussieHJCruza]

Thanks for that, very useful information. Sounds like you've done your research on those coatings so she'll look good for years to come.
I think its already been said but it's attention to detail like this that makes a build stand out. Very very well done.

 

[watrob]

Ok, have spent the last week deciding what shocks to run, considering it's going to be running on a chopped up beach at reasonable speed dragging a 475kg jet-ski which is a 40km run the shocks on those occasion will take a beating, so I have decided to run FOX Shocks. Getting the Performance Series as they are alloy compared to the Pro Series which are steel, steel does not last on the beach.

Racing Imports are going to re-valve and also put rubber boots on as well to protect the shaft from the sand. The front shocks are pin top and bottom and the rear set has eye's top & bottom. At this point the shocks will have 10" of travel and accommodate a 2.5" lift. As I have fibreglass sports tub I pickup 1" in height due to light weight, I also pickup another inch in the tub spacers too chassis I use.

 

[watrob]

Have ordered my shocks, will start assembly of chassis & all components this weekend

 

[ozcrusier]

Man you don't muck around watrob keep the photo's rollin along as you start to assemble this great build. I'm keen to hear how the 45 chassis goes with the coil springs but my guess is it will be great for the duties you have planned for this truck.
Cheers

 

[watrob]

My FOX rear shocks arrived today, the fronts are about another week away, so I will start to put everything together this weekend.

 

[watrob]

Got a fair bit done on the chassis yesterday, so the chassis has gone from this?

Chemically cleaned and double gal hot dipped.

To etched primed.

Black gloss finish.

And 80 series suspension components added.

 

[watrob]

Rear.

 

[watrob]

Here are some photos of the front axle assembly.

 

[watrob]

Here's the rear axle assembly.