Builds Roma's 78 fj40 gets a refurb

[roma042987]

Thanks guys the comments go along way in keeping me motivated on this thing. Tom its always refreshing to hear your feedback on things. Got a bit more done this evening. Working at a Honda/acura dealership has a few SMALL perks lol. I have boxes of new Japanese hardware.

Since taps are a bit harsh on threads and I didn't have a thread chaser handy, I made my own by cutting two grooves in a spare bolt. Worked pretty well.

I chased all the roll bar weld nuts before installing with new hardware. I will remove it and powder coat it at some point but for now I'm trying to get back on the road for a road trip.

New side markers installed out back as well.

Fuel feed and return hole drilled.

 

[roma042987]

I guess I missed that thread, but interesting reading. That being said I would correct it, and no offense Roma but I would paint that rear crossmember black. Doesn't look right to me.

None taken. I believe it would look better black as well but not many good ways to paint galvanized. And I'd hate paint just the crossmember when its part of the frame.

 

[hobbes]

Are you worried about the fuel lines chafing where they enter the trans tunnel?

 

[roma042987]

Are you worried about the fuel lines chafing where they enter the trans tunnel?

I had planned on using rubber grommets but the two layers of linex are so thick they won't work. It's roughly 1/2" thick. I need to find a grommet that will work but the linex is pretty much like a hard plastic so I highly doubt it could ever realistically rupture.

Didn't get as much done this evening as I hoped because I had to pick these guys up from the sand blaster. I'm going to try to get them to the powder coater this weekend.

Got the front doors installed.

I also bolted on the spare tire latch and support block. I'm leaving the tire carrier off until I set the top on so it doesn't get in the way.

 

[RattleCan]

Looks great dude, keep it up!

 

[roma042987]

Looks great dude, keep it up!

Thanks man!

 

[roma042987]

Drove to Kentucky Sunday and picked up a 3b for my blue bj40. Thanks to wileycoyote! Rained the entire 400+ mile trip there and back.

Moved my vapor tube on the filler neck and had my friend Brett TIG weld it in.

I welded on a straight piece in place. Not pretty but after my road trip I plan on removing this along with every other bracket I can remove and send them off for CAD zinc plating.

Filler and vapor tube in. Still need to run the vent lines.

New Japanese hardware with some stainless flat washers. Funny I didn't powder coat the door. It's still blue may install it as a momento.

Heater and ducting is installed along with heater valve on firewall, still need to plumb rear heater after seat frame is made.

New operator decal

 

[roma042987]

Thanks for the constructive critisism
Found a pcv valve grommet

 

[Weber Sarge]

Excellent fit and great idea , those grommets have a pretty thick wall so it should work well for years .
Sarge

 

[roma042987]

Thanks to Gary (Mid TN) got my wheels powder coated and have some tires on the way.

Picked up some goodies last week and my electric die grinder arrived yesterday its almost like opening Christmas presents.

 

[roma042987]

New rubber in the 33x10.50 variety. I'll get a fifth in a week or so.

Factory seals ready for the top.

Surprisingly enough I can still pull under my garage with less than 1/2" of clearance IF I pull in at an angle. But my new tires look about an 1.5-2" taller than the 235-85-16s currently on it. Maybe the tire carrier, spare, ambulance doors and seats will weigh it down a bit more.

 

[roma042987]

Excitement got the best of me had to drive to a gas station with some lights for a proper look.

Still need to build a seat frame, install my new front calipers, wheels, rear heater and work on a secondary battery tray.

 

[roma042987]

Got the new calipers on. Axles will be the next.

Finally got the new wheels on as well.

 

[Mid TN]

Looking good Roma, you have been busy! You been wearing the welder out yet? You have the caps for the tires?

 

[roma042987]

My friend Brett has been kind enough to let me use his welder and shop to work on my seat frame. I haven't purchased a tank and regulator yet and as far as that goes don't even have a place to plug it up yet. (220v)
I have three hub caps that are in pretty rough shape. When funds ease up I will get some new ones from Toyota.

I still have to finish my seat frame but am driving it on a daily basis again. I turned in my notice for my vacation today so leaving Alabama on the 15th of February headed for Death valley national park then on to see the redwoods and possibly Kings Canyon np before heading towards the coast. My girlfriend has never been to California so pretty excited for her to see it. Anyone up for a trip across Death Valley around the 18th 19th would be nice to have a convoy.

 

[roma042987]

Well a man-a-fre long range tank and factory seats don't mix too well because the factory seats have roughly a 2" rake. After three designs ended up with this. Moved driver seat up as little as possible and back as far as possible

 

[roma042987]

Got the rear heater installed this evening as well as a center console. Also made a rear cargo mat from horse stall mat from tractor supply. I put my old dash pad in just to make it a bit more cozy for my trip. Wish I had time to make a cup holder, hinge my console lid and install my front floor mat. I have some new rubber brake hoses coming tomorrow for it and hopefully that will fix my brake issues. Hitting the road Friday night!

 

[roma042987]

Wired an led for the glow plug control.

Ratty dash pad and elcheapo thermometer clock compass trio

Need to put a cup holder here.

Rear heater console.

Got some new hub caps from a mud member.

 

[hobbes]

That thing looks great. Love the detail. Have fun on the trip.

 

[roma042987]

That thing looks great. Love the detail. Have fun on the trip.

Thanks!

Had a delivery from Toyota this morning so I installed three new rubber brake hoses up front and some new factory wiper blades. Couldn't believe the blade were only $7. And look much better than the aftermarket ones that they replaced. Also replaced the illumination bulb in the headlight switch I'm sure that bulb has been burned out for 30+ years. Going to hit the road late tomorrow night! Bringing plenty of tools and fluids along. I will need to change the oil in 700 miles which I think will put me in Texas somewhere. I hate to change it now because it will need changed before my return anyway.