Rebuild Thread ~ 1983 FJ40 LX - Ex Aus

[Achilles13]

Hi. Your BJ-FJ rebuild looks stunning. I've been looking for a BJ/FJ in South Africa for a while now, but can't find any. You mentioned that you've imported your current project FJ from Australia. Could you maybe give me some information on how you are importing them?

Thank you

 

[tlc_4play]

Hi Achilles

You are in Paulshof - just down the road from me
I'm in Randpark/Weltevreden Park, why not pop around and you can check Kermit out as well, the LX rebuild is at the office in Alrode
It'll be easier to explain all the necessities involved in the import rather than trying list them here
If you want call me - Keith - Oh Eight Three 2677726

One of my friends, in Pta, currently has a 1975 FJ40 (imported from Aus) for sale

 

[Littl42]

imports to SA

Hi Keith

I have a 83 BJ42 in Oz that I might want to import to SA too. Any chance of getting the info to me as I am in the Sandpit for a few more? E-mail is littl42@hotmail.com

Thanks
Ben

 

[tlc_4play]

Hi Ben

I'll send you a PM with al the details

 

[tlc_4play]

Its been a while since I updated my rebuild thread.

Work has been progressing albeit slowly.

Lots of wire wheeling, sand blasting welding and painting

We now have a rolling chassis, so today work commenced on stripping the 2F motor
Surprise, , , , surprise, its got 3 bent push rods, and looks like its had some water damage at some point in its life, I still have to remove head to see if there is any damage to pistons, rings and cylinders.

What is the probable cause of the bent push rods ? ?

Today I Ordered 20mtr of 3/16 electro galvanised steel brake pipe and 40 x brake pipe nipples, now to start making up the new brake lines.
I tried to get the plastic coated brake pipe as used on some of the modern cars but couldnt find it anywhere.

I will put up some pics of the rolling chassis tomorrow

 

[tlc_4play]

Well here are the update pics as promised;-

At last here is a long overdue update
The current state of affairs - we have a rolling chassis

Did I mention that "everything" has been rebuilt to new, wheel bearings and seals, steering knuckles, ARB air lockers installed, new fr disk rotors and pads, disk calipers rebuilt, rear wheel cylinders are new, rear brake shoes and springs are new, new diff bearings and seals, birfields were checked and rebuilt.
New leaf springs are Hell Creek 2.5 inch lift with new greasable shackles and PU bushes, new U-bolts.

I also started work on the motor
Removed all the anciliaries and pulled of the head
The pistons and rings look perfect still, and the cylinder wall shows no signs of wear, or grooves or even a lip.

This is the bent push rod.

 

[allana13]

Just read the thread.awesome work man

 

[tlc_4play]

Thanks

I'm picking up the motor from the machine shop today

New Pistons, rings, mains, big ends, cam bearings, valve seats, valve guide seals, skim head 60thou, skim block 30thou, new oil pump, new welsh plugs, and skimmed flywheel.
Then its off for dynamic balancing

 

[Ambrew]

Impressive work.

 

[Slowerthanu]

I bought the same seat belts and they lock up all of the time and get tighter every second. I hate them

Are they mounted in the stock location?

Reason I ask is because I bought the same ones for my 77 and with my custom cage, I had to make brackets and have them absolutely vertical to stop them from locking up.

 

[tlc_4play]

they use the standard mounts.

 

[tlc_4play]

Look what arrived from UK a whole 36sq feet can you believe that Dynamat is unavailable in South Africa

And now for a few update pictures

Reinforced brake hoses.

Some painted bits n pieces

 

[tlc_4play]

Looong overdue UPDATE


At long last I have completed the total rebuild of the 2F engine
All new bearings, new pistons and rings, skimmed head 60thou, skimmed block 40thou, skimmed flywheel, new fuel pump, new valve seats (for unleaded) etc etc
Everything is new

I also had the freewheel hubs powder coated

The cogbox is now just awaiting its final coat of silver and black paint, then it will be mated to engine and FINALLY dropped onto the chassis

 

[baas]

Looking good Keith Can't wait to see this finished

 

[tlc_4play]

The cogbox and transfer box has now been stripped and new bearings and seals are going in together with a new coat of paint.

The brake pipes, where possible have been routed into the chassis and where there is a possibility of abrading the pipe has been covered with a thick wall heat shrink

The stainless steel spring protected brake lines.

The shocks have been fitted - Rancho 9000XL adjustable

 

[tlc_4play]

At last..........

The final assembly process on the cogbox and transfer case
Items replaced, all bearings, all seals, gear lever bushes and 1st syncro.
We even changed the oil seal on the speedo drive ???

Now its just bolting the cogbox to the motor and dropping it onto the chassis, then I can finally put the tub on.

 

[baas]

Some sweet engineering there, looks like this one will last forever! Bet you can't wait to get the tub on, we're waiting in anticipation too

 

[tmarx]

Looking great Keith !

 

[SteveH]

RE: door gaskets - I bought the $80-set-of-4 cheapie gaskets from CCoT. The CCoT rear amb. door gaskets are a disaster. The side door gaskets are ok and seal pretty well.

I then bought OEM ambulance (rear) door gaskets from Toyota and was elated - they fit and seal beautifully. They are a work of art - I thought about just hanging them on the wall and admiring them.

 

[toyman317]

pics no worky for me. Love the thread though.