Builds Roma's 78 fj40 gets a refurb

[roma042987]

If I decide to linex the inside I think i will still be in it cheaper than a good paint job. It certainly will not have the shine and luster but id rather have the abrasion protection anyway. If I remember correctly I purchased a 10lb. box which was 125 dollars and was more than enough for the whole job.

 

[roma042987]

Thanks to "clutchee" here on the board I picked up five factory steelies and three factory hub caps today! As soon as my cruiser account recovers a bit I will order some 33-10.5 bfg all terrains. Looks like next week will be a mad rush of throwing this thing back together so I'm trying to go through everything in my mind that may still need to be done. I'm a bit concerned with how the rear heater plumbing will work with the larger long range fuel tank. I still need figure out something to paint the tub side door hinges with, I couldn't powder coat them because the seal is glued onto the hinge really well. I'll also have to recruit my friend Brett "smracing" to help me fab up some seat brackets and a proper battery tray.

 

[roma042987]

Got the tub back from linex today not too bad. As always things take longer than planned I got the tub unloaded off the trailer but looks like it will take three people to set it on the frame.

Got the bottom of the trans tunnel lined as well

I'm using energy suspension body mounts excellent quality but I hate the fact that it uses sae hardware.

Here is where I'm at at the moment. Got some friends coming over tomorrow to help me set it in place.

 

[roma042987]

Oh almost forgot got a 5 gallon stainless jerry can today to match my 2.5 gallon can. Holders are compliments of a military friend I'l have to find somewhere to mount these guys.

 

[roma042987]

Riveted the Vin plate back on

And what the hell put this back on too.

 

[eazzrider]

VIN plate is backwards from mine. Great work...maybe mine is backwards.

 

[roma042987]

VIN plate is backwards from mine. Great work...maybe mine is backwards.

Thanks! You know I put a lot of thought into that before I riveted it back on. I have seen them both ways and decided it was probably meant to be read from the outside not by someone sitting in the driver seat. Would be interesting to know how it was done originally assuming it was uniform.

 

[roma042987]

Well got the tub sitting on the frame. I'm shocked at how much higher this thing is sitting with only a 2.5" lift. These body mounts are kicking my ass I think I'm going to have to use some longer bolts or at least some with a fixed flat head washer to help get them started.

 

[roma042987]

Noticed something this evening that is making me boil. First pic is the day the tub went to powder coater second pick is when I picked it up.

Now notice the big ass dent in the cowl above the vent on the pass side.

 

[roma042987]

Here is a better picture of the damage. Also noticed the rocker is tweaked a bit.

This thing is starting to resemble a school bus more and more.

 

[roma042987]

Looks like the body mount issue is isolated to two body mounts, same location on both sides.

So off with the weld nut!

Took a 10mm x 1.25 nut and smoothed a bit for a press fit in the plate. As soon as I can verify the fit it will be tacked welded in.

 

[MScruiser]

I like this thread. Keep up the amazing work. I have subscribed. BTW, Clutchee is a great guy.

 

[roma042987]

I like this thread. Keep up the amazing work. I have subscribed. BTW, Clutchee is a great guy.

Thanks! He sure is.

Ok well finally got all my body mounts on and installed despite the recent cold spell we are having in my area. I decided to improvise a bit for light so I put a charger on my car battery and left my lights on while I worked on the cruiser.

I also sand blasted my body side door hinges so they should be dry for reassembly tomorrow. I hated to rattle can anything but I guess I didn't have much choice here. Ironically enough the color is called school bus yellow.

 

[roma042987]

Here are a couple if shots of the body mounts installed.

These have to be the hardest bolts to install/remove on an Fj40. After some blood shed the hard part is done.

Color matched up pretty good too.

 

[antFJ]

why is it that companies think it is easier to lift things with a fork lift or some other contraption... all it takes is three people to move a tub without damaging it :/

looking really good though!

 

[roma042987]

why is it that companies think it is easier to lift things with a fork lift or some other contraption... all it takes is three people to move a tub without damaging it :/

looking really good though!

Yep that's exactly how they moved it and I suspect damaged it.


Pedal bucket assembly installed.

Upon installing the dash harness I came across several of the retainers which had lost there rubber sleeves to dry rot and then the oven at powder coating.

Not wanting to cut and ground out a wire on the sharp retainers I decided to use heat shrink tubing on all of the retainers.

Worked like a charm so I went ahead and done the rest in the cab and on the firewall in the engine bay.

 

[roma042987]

Different size shrink tubing can be used for different size retainers.

Cluster in

 

[PRFJ]

That was a good idea, keep it coming.

 

[roma042987]

Steering is done.

 

[roma042987]

That was a good idea, keep it coming.

Thanks!

Couple of quick questions.

Im assuming this is a ground does it bolt to the fuse block?

Where does this connector go?

Also have this extra spring. The spring goes inside the sleeve. I allready have the spring on the clutch and brake pedal.
Thanks for the help in advance.