Restoring 1983 FJ40 Esmeralda in Colombia comments needed

[CHAS404]

Heater came in from Summit. Going with modern one not to cut the firewall up. Plan to take it down to Colombia with me and install it along with the AC. Looks pretty low profile I think it will turn out OK.

Not original I know but I didnt want to have to pick up 10 used pieces and install them all in the USA. I think this is a good compromise. Atleast I can say I have all new heat and AC.

 

[CHAS404]

Picked up the smittybuilt today. Hope it fits. plan to do the cushion in matching vinyl same as the interior.



Got the stereo one to add some flexibility. maybe for a CB.

 

[CHAS404]

Engine getting detailed. All new paint and gaskets. Not rebuilding it because it doesn't need it. But we are replacing plenty of items like water pump and fuel pump etc.



I love straight sixes!

Idea is to get to as new a truck as possible.

 

[CHAS404]

installing new hubs too. AVM brand.

 

[CHAS404]

Recoring radiator!

 

[ColoradoFJ40]

Your manifold gasket is on the wrong way. That tiny little tab or ear that is showing on the last hole needs to be closest to the radiator not the firewall as it is shown in the photo above. Looking good and moving fast.

 

[CHAS404]

Thanks Colorado. Duly noted. I have it turned over to the mechanics we will see how it turns out. It moves fast bec the same shop has mechanics on one side and body/paint guys on the other. So there are 3 or 4 guys working on the truck at any time. I can really see now the benefit of doing a body off frame so that parts are accessible for repairs. Hopefully the truck will be put together in a week or so then I have to take it to the interior guy, the rollbar shop, the heat/AC/stereo shop and the exhaust shop. Then I have to ship it.

I have a Lexus/Toyota independent mechanic in Tampa I may have him go through the truck here on our end too.

I hope this all works out I am contracting land cruiser fever and nearly bought a 1962 FJ40. I missed out on it unfortunately (or fortunately depending).

I hope to do a FJ43 next we will see.

 

[CHAS404]

Figured I would give a list of the upgrades/tasks/items so far in this project and talk a little about my experience in finding and restoring a FJ40. I have spent thousands of hours on this forum looking at other people's projects which has helped me alot and maybe now that I am knee deep in it I can give back a little and share some of my limited knowledge.

This is my first project and I am not a mechanic but I am a car enthusiast and have some experience in business so here goes...

First thing we can set aside I found the truck in Colombia just to make the conversation easier but I did have the advantage of being able to see maybe 25 FJ's and BJ's now over a period of 3 months down in Colombia before selecting mine. I have seen also 2 FJ40s in the US that looked great curbside but upon closer inspection were maybe sub $10,000 trucks.

I give my perspective here bec I think a lot of new people falling in love with these trucks may think hey I am going out to buy a decent one now for $10k to $15k. I would say that while there is nothing wrong with that I think it is important to know what you are getting into. At that price range those are OK quality driveable trucks you can have fun with but I would say 90% have hidden rust and body work plus a bunch of deferred mechanical maintenance items. Again nothing wrong with that but you better have some plans to put money in them.

80% of the trucks I saw in Colombia had rust in the 2 front floors and some rust in the rear sill. Remember this is in mountainous middle Colombia with temperatures between 70 and 85 degrees all year round with no road salt and no ocean sea breeze salty air! This is the achilles heel of these toyotas. I am getting pretty good at even looking at a photo of a truck on the internet and seeing that shiny paint and just KNOWING where it has rust etc! I would hate to see a truck from PA or NY in the US!

The truck I bought here was an above average truck when I bought it. Setting aside it is a 1983 which is rare in the US I would estimate that when I bought it that it would be worth about $15k or so in the US for an equivalent late 70s 2F model with hardtop etc. What I mean is that the Esmeralda here before the restoration if found in the US would be a $15k or so truck (maybe more for being an 83). She ran great and had a nice hardtop, shiny paint from 20 feet away and decent tire tread etc.

I am happy with my purchase and happy with the project. I just think it is important to take a close look at some of the issues we addressed like the rust in the body and now some mechanical items.

These trucks are 30 years old and hide rust and mechanical issues. The upside is that they have strong reliable drivetrains and all parts are mostly available and not too too expensive. The other big upside is that they hold their value and even now are appreciating.

 

[CHAS404]

Body work upgrades so far?

one month of 2 to 3 workmen working 6 days a week..
all body parts removed from chassis.
replaced rear tub due to cut fenders, some dents in the floor, some rust in the sill and a small HIDDEN pocket of rust in the rear of tub (we found only upon tearing into it)
adjusting tub took a while for 2 men working on it
front floor pans cut out and replaced with new
all detail show areas like cowl and dash and other areas hand sanded to bare metal
some door bondo removed. doors refinished. no rust was found in the doors.
no bondo in the body
chassis was fine too but cleaned sanded and painted. rear drum brakes sanded and painted.
painted all parts separately 6 total coats of paint and lots of sanding
fiberglass top sanded and repainted
metal hardtop sidewalls had some surface rust addressed
5 wheels need to be sanded and painted
painted the seat frames

 

[CHAS404]

Mechanical work (in progress)? and more new parts...

paint engine block
replace gaskets
tune carb
braking system inspected new parts replaced including disc pads and drum shoes
hubs were shot replaced with new
radiator recored
new fuel pump
new water pump
still reviewing the engine and trans and transfer case but should be OK
engine bay to be detailed
4 new shocks plus steering stabilizer
new body mounts
new weatherstripping
new exterior stainless steel bolts
new front and rear lenses
new emblems
new antennae
5 new tires
new exhaust soon
new headlights
new battery
new suspension bushings ( the leaf springs are retained. they had replaced some at some point they are fine )
new steering bushings

 

[CHAS404]

Interior items....

new custom roll bar
new heat
new AC system
6 new seat belts
seat frames sanded and repainted
all new seat foam and custom new vinyl
new headliner
new sun visor covers
new door panels
new head unit and 2 speakers
new floor covering (have not decided yet)
new metal console/ armrest
all gauges removed, sanded and repainted
new stickers soon
need the OEM jack

 

[CHAS404]

Missing original items I had to hunt down (my driver helped a lot)...

OEM jack
rear spare tire carrier
5 OEM 15 x 6 steel wagon wheels
still need a plastic ashtray!

 

[CHAS404]

Final clearcoat added. 6 total coats of PPG paint.







I think it looks pretty close to toyota code 681 green.

 

[CHAS404]

Electric green has really grown on me. Thanks to Landpimp for advising me to stick with this original semi-rare color. Can't wait for them to put the truck back together!

 

[Chamba]

Agreed. Looking really nice.

 

[CHAS404]

Hey thanks Chamba! here is your rear door opening detail. not 100% perfect to my eye but pretty darn close. the rear doors were prefitted should turn out well. FYI I did see a 1982 rear tub for a soft top that had a totally different rear tub/door detail. it was squared off on the bottom.



The main issue is it looks like the original paint color/shade.

 

[CHAS404]

The body work and paint work has been easily the most stressful part of this project! Next project I want to do a lifted macho offroad modern truck. Haha. "Original" is hard to do! I can't imagine what the guys that did the 1960s models went through.

 

[RWBeringer4x4]

"Original" is hard to do! I can't imagine what the guys that did the 1960s models went through.

Guys with trucks from the 60's have it easier when it comes to paint color - no color photography back then, so nobody can call you a liar! "Close" is close enough!

 

[CHAS404]

haha. funny. I love the old colors. Fashion Green etc. I really do want to do a little bit more modern truck etc. we will see.

yeah the old trucks did not have the color on the tag plate either i hear. let's you chose.

 

[CHAS404]

Did I score a period correct 1983 bottle jack?