Builds Roma's 78 fj40 gets a refurb (3 Viewers)

[roma042987]

I didn't do anything to the blower motor. If it ever fails I'll try to find a NOS one.

 

[roma042987]

Foam in the heater box has been disintegrated for a long time. Couple of weeks ago I pulled the box apart and got sidetracked on other projects until this weekend. I have disassembled the heater and with an upcoming work trip was a little worried I'd forget how it goes back together.

The box was in decent shape with the exception of one broken louver on the vent register. Almost no rust, I was a bit disappointed I would have to remove the factory Toyota markings.

 

[roma042987]

 

[roma042987]

 

[roma042987]

Sand blasted and powder coated all the metal bits, and painted the plastic ones. New foam and even repainted the letters for the control. I finished cleaning the core this evening, so will put it all back together tomorrow.

 

[fjc-man]

If you’re interested, @DSB345 sells a new set of zinc coated flap springs for 20 bucks.

 

[roma042987]

If you’re interested, @DSB345 sells a new set of zinc coated flap springs for 20 bucks.

Thanks! I just ordered two sets from him. I still need to redo the heaters in some of my other 40s.

 

[roma042987]

Lots of scrubbing with GooGone and a brass brush to get all the old foam and glue off.

New foam for the sides, I had an adhesive backed foam for this but, the end tanks needed something a little different, so I used an adhesive spray to attach the foam.

I taped the core so as to not get glue on the fins during application.
The adhesive didn't want to cooperate in the temperature of the garage, so I had to get creative with holding it in place as well as bring it inside.

 

[roma042987]

Since I ordered new springs for this unit im going to hold off on installing it back in the 40 until they arrive. It does look like I'll be able to replace them without taking it back apart so I went ahead and slapped it the rest of the way together.

 

[roma042987]

With the ACSD removed, I swapped out this block drain plug which was previously also the ACSD coolant return. The new plug also has a barb but, this one is for catching the coolant when you drain the block. I had a hard time finding this part number and even ordered the incorrect plug first time around so, it felt like a small success installing this yesterday.

I swapped out the fuel cut solenoids with 12 volt variants on the 15bft as well as the 15bf currently in the 40. The 15bf had exhibited a no start condition on several occasions and after some troubleshooting I found the solenoid to be the culprit.

 

[roma042987]

#protip fill the recess for the o-ring with grease prior to installing the o-ring. The grease keeps the o-ring in place while the solenoid is reinstalled.

The megacruiser only has an oil pressure switch here, so I removed it and installed a new 12volt sender.

 

[roma042987]

I decided to rob the register off my spare heater to replace my broken one.

New heater springs

 

[roma042987]

Top water neck modified to left side outlet. I also plugged the radiator cap portion of it.

 

[roma042987]

Not quite done with the whole heater refurb but, I did reinstall the box to clear some workspace on my tool box.

These heater pipes were looking a little ragged, so I cleaned them in my solution and refinished the insulation with heat shrink.

I loaded up the car seats this afternoon and put about 150 miles on it. Drove great but I can't wait to have a turbo on it.

 

[roma042987]

Slowly still working on the heater.i should have it done once the warm weather shows up.

 

[roma042987]

The rear heater pipes cleaned up well. The foam had some scuff marks after nearly 50 years so I used some heavy duty heat shrink to spruce them up a bit.