Rejuvenation Treatment for Old Girl LJ73 / build (1 Viewer)

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Joined
Dec 2, 2018
Threads
5
Messages
110
Location
Bucharest / Romania
Hello Everybody,

This is my first post on this forum, although I am quietly following it for some years. Since I found here some nice ideas during this time, I decided to give something in return and share with you some of my projects.
This thread is about a full scale restoration of a 1992 LJ73. Actually it is more than a simple restoration, it's a rebuild with some improvements, following my experience with the J7 model.
But enough introduction, let me begin with the story.

About 3 years ago I bought from France an LJ73 with the intention to use it for parts. At that moment I was working at a different project and I needed some parts. The car was not in a very good shape, the previous owner(s) did not took too much care of it. Anyhow, this is how the car looked like when I got my hands on it:

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At first I did not pay too much attention to it and as my other project stalled for a while, the car was simply parked near by my garage for half year. One day I checked the French registration documents and realised that the car was homologated as "2 places fourgon" (commercial vehicle with two seats) which made it quite interesting for registration in my country (Romania), due to taxation reasons.
So I took it inside the garage, put it on the ramp and took a better look at it. At this moment I realised that the car was in a much better shape than I thought, and had in fact very little rust. What looked like rust was in fact a reddish dry mud sticked very well to the chassis and underneath the body.
But other than that, it was a complete nightmare, the engine was leaking everywhere, the turbocharger was dead, the electric harness was cut and tied. It looked like it was serviced by a drunk mechanic for the past 10 years.
The interior was equally bad, the seats were torn and especially stinky, everything was covered with a dark sticky grime.
So I started to dismantle it, while thinking how will I rebuild it. My first ideas was to swap the engine for a 3.0 1KZ-T that I had already, together with all the necessary parts like clutch housing bell and some other items. The 3 litre 1KZ-T engine is a much better alternative to the 2LT engine which is heavy and quite weak.
 
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Eventually the body was "divorced" from the chassis and we prepared the installation of the 3 litre engine. Although both engines were available for this model, the 3 litre 1KZ-T has different engine mounts and they come in a different position to the chassis, about 5 cm or 2 inch behind the 2.4 litre 2LT engine mounts
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As soon as everything was dismantled and my garage was full of TOY parts, I introduced my friend, the Kaercher...

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This was not rust, it was mud that looked like rust. I turned the Kaercher to "steam" and it came off right away.

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Hi , what gearbox will you use. We dont get many LJ73 on here and most of them are newer models with the 3L non turbo engines
 
Hi , what gearbox will you use. We dont get many LJ73 on here and most of them are newer models with the 3L non turbo engines

This is a R151F transmission with manual T/case. The gearbox fits both 2LT and 1KZ-T engines, only the clutch case is different.

Coming back to my storyline; The original undercoating was stiff and cracked, so we took it off. We applied a new layer of fresh undercoating.
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The body had some dents and some spots that needed to be fixed.

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Next stop: paint shop. I made no compromise here and I took it to a painting company specialised in such projects.

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As soon as I got rid of the body parts, I took care of the chassis. Everything was dismantled, the chassis was cleaned, sandblasted, recoated...

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In my opinion the success of such a project, lays in the degree of detail you are willing to go. So I took time for details.
All the nuts and bolts, all the assembly parts, everything was cleaned, sandblasted and re-galvanised.
Sandblasting was done with very fine glass particles which left a very smooth touch on the surfaces.

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We had a very good time sorting back everything... :)
In the end I was able to identify almost every nut and bolt and where was their mounting position... :grinpimp:

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I stop for today, I will continue my thread tomorrow or the following days. Meanwhile, if anyone has questions....
 
Amazing work! Looking forward to more pictures and details!
 
Well, yes it was a lot of work, but the satisfaction following each small result was really high in comparison with the amount of work.
When you are able to place a finished part, on a clean piece of cardboard in front of you, and you know that you rebuild this part by yourself, this is highly motivating and driving you further.
Below there are some examples of parts and assemblies that were rebuild:

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I could share more pictures, but the settings of this forum only allows me to upload 5 pictures / post. If a moderator would kindly like to consider changing this setting to 10 pictures / post, I could share more pictures.

Anyway, coming back to my storyline, it has to be said that this work was carried out by 2 people, myself and a friend of mine - the guy who appears in some of the pictures. And both of us have full time jobs, so we actually worked during our spare time. Therefore the project lasted for some months, almost a year.

We followed some really simple principles
- pay attention to details
- work as clean as possible
- try to improve every bit and part you handle
 
At the beginning of this thread I mentioned that beside the rebuild, I also planned some improvements - following my experience with the J7.
I was trying to mend some of the problems that I have encountered over time.

- the side steps; TOYOTA's original side steps are made of aluminium and they are fixed on the inside of each rocker panel. As soon as the floor and the rocker panels are not rusty, they are good enough to step on it. That's it. But the very first time that you hit something with it, you damage the step, you damage the rocker, you may damage also the body. Therefore lot's of people who are seriously off-roading their car, are putting them away. I did something else - I made some side steps out of steel tube, and they were mounted directly to the chassis.
This is how a chassis mount looks like - the part sprayed with grey zinc.
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- another issue that I wanted to mend was the steering gear. The LJ73 is a light duty truck, therefore it's steering gear it's not so tough. I have a history of 2 broken steering gears, out of which one a severed axle. So I replaced the original assembly with the steering gear from a NISSAN Patrol GR Y60. Unfortunately I do not have any picture of that operation. But it fits on 3 out of 4 mounting holes. The 4the has to be relocated.

- seats are also a problem with this model. I remember very well driving longer distances, having my knees, my ass and my back really hurting me. I am quite a tall guy, so even with the seat pulled back at max, I still had a very bad driving position.
So we took off all these parts:
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We build two frames that are going directly on the floor:
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and we fitted some very nice VW Passat Comfortline seats :D
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- I also installed air-conditioning, this was quite challenging (and not technically) due to the low availability of the a/c parts.
- At the end of the project I remade the upholstery, to a much better level than the original, but I am going to show these pictures later on in the thread.
- I added ARB airlockers, back and front.
- I coated the hard top with Line-X. For the glass fibre hard top this was quite an improvement.
 
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I also bought lot's of new parts:

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And from this point we slowly started to put everything back together...
 
But before going further, I would like to say few things about the fuel tank. I discovered that my tank was full of rust, so I decided to tackle the problem directly

First thing, I cracked it open. I actually did not cracked it, but I made a surgical cut along it's welding line. The result was that:
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Inside it was full of rust and heavy fractions from the fuel.

I cleaned it, and cleaned it, and cleaned it until it looked like that:
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there were some holes that needed to be brass coated...
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Afterwards I put it together and remade the side welding. This picture shows it right before welding.
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In the end it was Line-X coated
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