Which part of Ontario, wow, you are brave, they sure look sweet when all put back together. Am going to follow along on this, looks like you can do a lot yourself which will save some big dollars in the build.
Saving a ‘79 Fj40 in Ontario, Canada
- Thread starter a meal
- Start date
This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.
1MOA
SILVER Star
Stunning work so far!
Please spend some time and make a detailed post on fitting a Aqualu tub to a fj40.
I can't believe that over the years no one has put together a good step by step for fitting and preparing a Aqualu tub to a 40.
If you are going for a stock look please detail how you need to set up the blind nuts for things like the hard top, side and rear doors and interior fittings like seats rear heaters and roll bars.
I have always wanted to do a aqualu tub on mine but the "details" part of the build eludes me.
- Thread starter
- #44
Thanks! I’m from the Newmarket area. Are you from Ontario? And yes, it definitely helps doing a lot yourself. But most importantly, it means everything is done exactly how I want it done
- Thread starter
- #45
Thank you! Yes, that’s the plan. There’s a couple things I’ve been suggested. I’m definitely going for a stock form and function. I will be sure to post details on what I’ve chosen to do for everything. Unless I can find a better solution, I think my main plan of attack for the blind nuts is to use yellow zinc plated rivnuts. Preventing corrosion is the trickiest thing here. I’m thinking I’ll put a generous amount of sealant (sikaflex) and then paint over everything to seal it better. (I’m actually going to powdercoat the whole body). Ambulance door hinges will probably end up being a plate I’ll make for the inside. I will detail all of this in another thread in the next couple months and put a link here to it.
Cheers
Great work so far love seeing the progress. Congrats on finding a job that you are passionate about and will enjoy! I’m looking at going the aqualu tub route within the next couple years. This is huge to see your write up and follow along with the design changes as I work towards getting to the tub phase of my build.
suzuguru
SILVER Star
Awesome build! I love watching a true craftsman who isn't afraid to go all the way. Looking forward to see the rest of the build!
- Thread starter
- #48
Thank you. I feel very lucky to be able to do what I love
that’s great! I am making changes and improving the aqualu tubs along the way. Please do follow along with my aqualu thread when I make it. I’m really hoping to give people on here a detailed look into how it works and I’m hungry for feedback especially on the tub design!
- Thread starter
- #49
Thank you. This means a lot to me! I will get it done in my somewhat painfully slow and meticulous way
but am enjoying every step as I hope everyone with cruiser builds can
Very, very nice work mate! Inspirational actually.
- Thread starter
- #51
Hi all, a much needed update after about 2 years!! The truck is finally done! Aluminum body completed, painted with aircraft single stage paint, stainless exhaust made and all assembled carefully over the past couple of years. Over 8500kms put on the truck already, with no issues and lots more kms to come! I'll dump some photos below and add some context in for them. Thanks all that have followed along
Fitting aircon components and door switches. Checking alignment of steering column and other small bits before taking apart for paint.
Lookin good! Some panels painted to protect from flash rusting while transporting. Side panels were later replaced with replacement panels since inside edges were quite rusty.
2.5" Exhaust. I TIG welded this all together and routed it in just the right spot to avoid heating up the floor while keeping it from getting hit by rocks. Straight section is in place to allow me to put a resonator in at a later date if the truck is too loud. This picture was taken before I welded the hangers on.
Aerospace grade epoxy primer after a chemical etch and alodyne finish were applied to the aluminum panels. Homemade paint booth made it possible to paint in the winter months and allowed me to bake the paint.
Fitting aircon components and door switches. Checking alignment of steering column and other small bits before taking apart for paint.
Lookin good! Some panels painted to protect from flash rusting while transporting. Side panels were later replaced with replacement panels since inside edges were quite rusty.
2.5" Exhaust. I TIG welded this all together and routed it in just the right spot to avoid heating up the floor while keeping it from getting hit by rocks. Straight section is in place to allow me to put a resonator in at a later date if the truck is too loud. This picture was taken before I welded the hangers on.
Aerospace grade epoxy primer after a chemical etch and alodyne finish were applied to the aluminum panels. Homemade paint booth made it possible to paint in the winter months and allowed me to bake the paint.
Last edited:
- Thread starter
- #52
High build epoxy over the green anti-corrosion primer. This stuff was a joy to use! Some spot putty used to fill some areas, but I tried to keep filler to a minimum. I want all the imperfections to be kept so I don't have cracking filler one day!
Hood looks very good with some filling here and there. Original panel was in very good shape, only needing me to do a small repair to the hood prop hook.
Door switches added in. This means I needed to add blocks to the doors. Also added original door limiter holds instead of the thin reproduction ones. Main benefit for these doors to me, is the E-coating inside and out. Hopefully they'll never rust on me.
Undercoating done to all under surfaces to stop paint chipping and some sound deadening.
Single stage paint came out amazing! Colour chosen from an industrial catalog. I think this is a Westjet colour.
Hood looks very good with some filling here and there. Original panel was in very good shape, only needing me to do a small repair to the hood prop hook.
Door switches added in. This means I needed to add blocks to the doors. Also added original door limiter holds instead of the thin reproduction ones. Main benefit for these doors to me, is the E-coating inside and out. Hopefully they'll never rust on me.
Undercoating done to all under surfaces to stop paint chipping and some sound deadening.
Single stage paint came out amazing! Colour chosen from an industrial catalog. I think this is a Westjet colour.
- Thread starter
- #53
Fitting parts! I couldn't contain my excitement and had to gently test fit a few parts to see how it would all look. Getting those vin tags on was extremely satisfying.
Looking so good!
A good friend made custom shifter boots. Leather for in the cab, and vinyl layer for the underside.
Wiring was one of the last steps. I needed to move to a storage unit for the last stage of the project. Worked on battery tools for the summer, getting the last few things done.
Engine bay coming together nicely! Still some piping to figure out before it's road worthy
Looking so good!
A good friend made custom shifter boots. Leather for in the cab, and vinyl layer for the underside.
Wiring was one of the last steps. I needed to move to a storage unit for the last stage of the project. Worked on battery tools for the summer, getting the last few things done.
Engine bay coming together nicely! Still some piping to figure out before it's road worthy
- Thread starter
- #54
Rear side looking great!
Fitting the electrical. Tested everything, pulled harness out for wrapping, re-installed. It looks like a mess going together, but it all works out. This is one of those moments whereI had to trust the process. There was definitely a moment doubt right around there where I couldn't help but ask how the hell I got here!
And finally, it's all done! Already enjoying trails, and splattering the underside with mud.
A 2000mile road trip to Normal, IL and back. I had to make a stop in Warren Dunes State park, MI to admire the view...
Fitting the electrical. Tested everything, pulled harness out for wrapping, re-installed. It looks like a mess going together, but it all works out. This is one of those moments whereI had to trust the process. There was definitely a moment doubt right around there where I couldn't help but ask how the hell I got here!
And finally, it's all done! Already enjoying trails, and splattering the underside with mud.
A 2000mile road trip to Normal, IL and back. I had to make a stop in Warren Dunes State park, MI to admire the view...
HOLY F…..ing J40!!!!!!!! I hope women and men throw themselves at your feet and worship the cruiser savior that you are.
So, when you starting your next project?
Wow
- Thread starter
- #59
Haha Thank you! Proud of this one. Fixing up the little things, making seat covers and road tripping is going to keep me busy for the next year at least... It's been fun, but holy sh** I need to get my life back! Won't be taking on another project for a little while. May or may not have an FJ25 in storage for a project with my dad... Hoping to document that built a lot better and preserve as much originality as humanly possible. Definitely a cruiser addict for life now.
- Thread starter
- #60
Thank you! She's a beaut. I met the right people who know paint. It's quite the process, but I couldn't get that primer off the metal if my life depended on it. Would highly recommend Tristar coatings to anyone doing this type of stuff
