Saving a ‘79 Fj40 in Ontario, Canada (1 Viewer)

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Joined
Dec 20, 2020
Threads
8
Messages
73
Location
Ontario, Canada
Hey guys! I wanted to make a thread dedicated to my build. I’ve been popping by asking a few questions (everyone been extremely helpful) since I started my project but really wanted to share lots of pictures of the work I’m doing!
To give some background & context, I’ve just graduated materials engineering at university and have been dreaming of restoring a classic. This summer has provided the perfect window of time to start while I look for a good job to get me into the working world.

I was introduced to this sad cruiser about an hour away from my parents’ home where I have access to a machine shop and tools. The truck has been used for many years as a plow truck and the previous owner left a welcome mat in the back that has spent its time eating away at the body :( the truck has also fallen into a pond about 15 years ago but luckily still runs and continued kicking ass for the twelve following years before the owner replaced it with a tractor. When bought, the 2f was purring happily but the clutch slave cylinder was shot, preventing me from taking it for a test drive.

Anyways! I might be naive for trying to restore it but I have managed to buy a complete frame and complete body (yellow) from Wayne Smith with The Original Crushers and the process has begun.
The frame and body are both from an ‘82 (body is right hand drive) and both need to be retrofitted. The process so far has included stripping it completely to the frame, salvaging everything I can and taking out the rivets holding the inner channel since it is rusted out. I am in the process of remaking the channel that will include measuring, laser cutting, welding, forming and hot riveting it into place. Front sections of the main frame channel have been replaced with old ones. I have bought all new rear section of the frame from BTB.
EVERYTHING is being disassembled and will be rebuilt & powder coated.
Since pictures are worth a thousand words, here they are! Thanks for reading this far, I’ll update as I go along. Cheers :)

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rusting in the floor not for the faint of heart 😬
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new (but old) bj42 frame:
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Are you gonna make it red like it was originally, or make it yellow like the tub?
 
Diggin’ the whitewalls- must keep! 🙂 Looks like a lotta work and I really enjoy following along on these threads to see the transformation. Good luck!
 
For those interested interested & following, here’s an update. I’ve made the inner frame sections and have been working on fixing parts of the frame and drivetrain. I’ve cut these sections of the frame on a plasma table, formed the flat edges and welded the curved edges. It’s now ready for a weekend of sandblasting and then powder coating! Notice also some other cleaned parts like the rear axle and steering linkages. I am also painting small parts like driveshafts, brakes, and bits.
Hopefully this week will be full of powder coating and shiny metal! (Mind you, I’ve learned how fast flash rust happens in this humid climate 😬) I will post an update when there is a nicely painted frame. 👍
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Are you going to make a complete reproduction front crossmember? That would be really sweet for fixing hacked up saginaw conversions. I would be in for two at least.
very nice work!
 
Are you going to make a complete reproduction front crossmember? That would be really sweet for fixing hacked up saginaw conversions. I would be in for two at least.
very nice work!
@cruisermatt sorry but I haven’t remanufactured the whole thing. I’ve only cut out & replaced the bottom strip where it’s pressed against the insert. Rust gets really bad in there but the rest of mine is salvageable. With the complicated bend these have in the middle, it would be really difficult to make by hand. Maybe someone’s already tackled it but I haven’t found any you can buy :(
 
Que de superbe reportage photo!
Thank you for uploading and keep up the excellent work!
 
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Your starting point takes the term "rust bucket" to a new level even for a FJ40! I wish I had the skill set and tools to do something like this.
 

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