Builds Slight Change of Plans--A BJ42 Build

[Crazjtk]

Well, I finally did it. I took the plunge after over a year of agonizing and planning and searching. Last weekend I was kicking around on eBay, and found the OBO ad. The truck was close by, so I sent the seller an offer, pending an inspection. He accepted and my dad and I hopped in a car to go check out what may be a huge mistake, or may be the truck I keep forever. It's a 1980 BJ42, Right-hand drive, P.O. imported it from New Zealand. It's rusty, to be sure, but the frame is solid, and the original motor starts right up and runs like a top. Our test drive of it was an hour of chugging past cabins and offroading through a national forest. I was hopelessly sold. We came back the very next afternoon with a tow vehicle, trailer, and a stack of cash. Here's what we brought home:

I'm wildly excited to start working on it! It filled all but one of my wishlist, for half what I was planning to pay. (for the savings, I can add an H55 myself, if I want)

It even has the exact same roll cage installed I was planning to put in

I ran out of things to say! It's late at night! Here's more pictures!

This is some of the worst of the rust. Nothing we can't fix.

Engine shot!

If you notice the rear hubs, this one has full-floating rear axles! The original 2-piece rims, too.

Out of the garage at home, now it's parked at its winter home, the shop where we'll be working on it.

The work starts Saturday. Stay tuned! Or don't, I'm not your boss.

 

[chappohj47]

Looks like a good starting point

 

[cult45]

Splits for life!

 

[Disasterman]

Good luck with your project, looks like a good starting point after you steam clean it. Nice shop space, I have seen two of those VW van pick ups this summer in your shop space, though rare, they seem to be popping up. My body man is working on one and a fellow PCA member has one.

 

[Crazjtk]

Thanks guys! I hope it's the start of something good too!

Yeah, rust removal and prevention is first and foremost. The P.O. did a pretty good job preserving it, but it's spent at least a handful of winters here in Michigan. I'm hoping that by taking drastic measures from the start we can get it truly clean, and then genuinely rustproofed.

That's not the shop space, actually. That's the garage at home. The shop has a 10-ton crane we're guessing will be handy for getting the tub off the frame, plus a better air compressor and welding setups that aren't completely junk. And a loading dock, on the off chance we end up having a tub shipped in. (Hoping it doesn't come to that)

The VW is a 1964 double-cab. That's dad's other-other-other project. He got a good deal on it from a guy who did a pretty shoddy "restoration" on it. Literally an inch thick of bondo in places. Dad's kind of burned out on it at the moment. Maybe working on the LC will reignite the spark...

 

[Disasterman]

The VW double cabs require a good metal guy, just like the FJ40. Your truck looks pretty darn good. Michigan is tough on trucks with the salt, wash it often underneath. Rustproofing is whole different game which I have lots of experience.

 

[winnie]

looks like you have a keeper there ... love the sound of BJ's ... enjoy, driving and the refurb project ...

 

[78fj40mg]

Congrats nice BJ42!!

Keep in mind that everything is fixable, these rigs are a labor of love for most of us, with your enthusiasm I have a feeling this will turn to be a beautiful cruiser!!

 

[Varty Yo]

Nice man!!! Mine is a 82 bj42 and i love it! I has issues as i knew when i bought it but i will fix them up as i go!

hopfully it wasnt too big of a stack of cash haha

 

[alberta mac]

interesting ? looks like you have the dash plate from an 83/84 ! Do you have power steering ?
Post up some more interior photos ! split bench seat ? Fuel tank inside or under cab ?

 

[FJ404345]

Nice truck ! Welcome to the Madness 1

 

[Crazjtk]

No power steering. Yeah, split bench and it had long jump seats originally. Fuel tank is under the cab, not under the seats.

 

[Crazjtk]

Here's a dash picture. I didn't see the interior shot request until after I had stripped the interior, by which I mean pull the seats out.

Here's where I got to by the time I got done working around 3:00 this afternoon.

Seats out, doors and hood off, snorkel removed, roof and sides disassembled and removed. (Oh, and Yakima bike holder on bumper removed)

I'm sure that's no great accomplishment for you old salts, but I'm pretty pleased. Next time we'll know what we're doing, and the bolts won't have 36 years worth of rust holding them in.

I've got to say, working on this thing is WAY more satisfying than working on modern cars. It feels like you can get so much DONE in a morning of working on this thing.

Unfortunately, with the holidays fast approaching, I probably won't have an opportunity to work on it much until after new year's. In the mean time, I'll be scouring the forums for info on rust repair panels.

 

[Crazjtk]

Well, I got the chance to work on the truck for a while today. More teardown mostly. Trying to evaluate what all this project is going to need is daunting. A rear half-tub is probably going to have to happen.

More pictures though!

That bumper WOULD be off if that last stupid bolt would comply.

More empty tub shots.

And the front stripped down.

 

[Crazjtk]

Teardown day 3: the part where it pretty much stops looking like a Landcruiser for a while.

I got a few more hours of work in today. All just taking things off. There is an ever-expanding pile of parts amassing just out of frame on all these pictures.

Partway through the day. Radiator drained, radiator and frame removed, radiator fan and frame removed, bumper removed, wiring disconnected, air cleaner removed.

the data/VIN plate, after a bit of cleaning. I'll have to find the MUD thread on deciphering these things.

After we got the fenders and fender frames (with the aprons still attached) off, dad felt some degreasing was in order.

And here's a second angle, pretty much how she sits at the moment.

I'm going to start ordering parts shortly here. Since the frame will be fully accessible, it's a perfect time for suspension replacement. (OME heavy duty is the plan)

 

[Crazjtk]

Teardown Day 4 (2 Saturdays ago) doesn't have much for good pictures. most of it was pulling pieces off the rear bumper, and some of the body bolts.

Day 5 though, (this past saturday) We have LIFTOFF!

Thank God (and the tool and die shop that used to be in this building) for the 5 ton gantry crane. Made this stuff EASY.

I had to cut a diesel line to get it free. My hoodie will never be the same. And I might have stunk up the washing machine. (sorry, mum)

And here's how we sit now, (or as of 1/14/17) with the tub resting on a harbor freight utility trailer.

Now comes the part where I start spending money again. Old Man Emu is getting ordered tomorrow, replacement body panels shortly thereafter. Also gonna give the engine a degrease (like 8 bucks in quarters at the u-blast-it carwash) then take the frame to the local sandblaster.

 

[alberta mac]

Suspension : go 4'' but will have to shim the rear leaf pack, Mine has a 4'' above stock lift with shims in rear leaf pack to prevent blowing the rear end. I ran 33'' tires. To me it is total kick ass ! A friend runs 34'' which also look good.

 

[Crazjtk]

Suspension : go 4'' but will have to shim the rear leaf pack, Mine has a 4'' above stock lift with shims in rear leaf pack to prevent blowing the rear end. I ran 33'' tires. To me it is total kick ass ! A friend runs 34'' which also look good.

My plan is the Old Man Emu heavy duty suspension lift, which is in the 2.5" lift range. Since I don't plan to run super wide tires, I should still be able to run 33's without rubbing. (according to various MUD threads)

 

[Honger]

Looking forward to seeing this build progress. Nice truck man!

 

[Crazjtk]

Hi guys! It's been a while, but I finally got to work on the truck again! A vacation a couple weeks ago, and prepping for the Superb Owl ate my last few Saturdays. I worked for a good while today though!

First, we loaded the frame onto a trailer.

Then we took that trailer to the local self-serve car wash and cleaned it down thoroughly.

Then we brought it back to the workshop and moved the tub to a more convenient place.

So we could pull the rear axle off.

From here, we're going to be grinding on the frame to clear off the surface rust, applying POR-15 followed by paint everywhere we can reach, and then reinstalling the axle with the new Old Man Emu suspension (which you can see in front of the doors in the last picture) Once that is finished, we're going to give the front half of the frame the same treatment.