So I brought a FJ45..Without the misses permission..

[Shagger1]

Interior going back in, luckily the factory floor matt is in ok condition

 

[Shagger1]

Next to attach is the doors..
There was a fair bit of time spent on these as they are going to open/close a lot in their new life!
I also splash out on the genuine weatherseals, window runners, and wiper seals/dust seals for the windows.
Cost abit more, but fitted/seals soo much better!i used 3m weather strip adhesive, messy &struck your but seems to be holding well.
(Note the pegs holding the seals in place while I seal, and the sealer sets)

 

[Shagger1]

With the doors complete, and once they were hung I could then plan on getting the old to work to attack some mechanical stuff, but instead decided to do the disc brake front diff conversion at home(unable to be away from home for too long- swivel hubs at home are messy!!)

 

[Shagger1]

All the part numbers I used for the front diff over haul.
Spent more than I wanted to, but brakes are important!

 

[Shagger1]

Once the front diff was rebuilt, I bolted up some wheels and rolled it under, bolted up the leaves with some new bushes and shackles, and plumbed up the brakes(new hoses) and was able to drive it to work(only 15min drive).
Had to bleed the brakes as the kid was pretty bad!
Managed to run out of fuel on the way

 

[Shagger1]

Lucky I have access to a hoist at work, as I then discovered the handbrake wasn't holding, and the rear brake shoes were cactus.
Those rear twin slave cylinder setups are tricky to adjust!!

 

[Shagger1]

You may notice that I haven't fitted the ARb bullbat that had had previously reconditioned, and that is because I have also picked up a complete TEQ PTO refurbished and want to fit that-but unsure how the winch and bar will bolt together, and it's in too good of nick to be cutting up to "make work"-so in the meantime a Landrover Defender factory front bumper I picked up free works, and keeps the truck looking nice n legal

 

[Shagger1]

So from the start of the rebuild, or at least during the strip down, I knew I hated they way the tray looked that come with the truck.
And opportunity come up to straight swap it for a better looking one of a later model Hilux ute, so I did-but didn't realise the dimension difference till later on!
So inlised a friend to cut 300mm out of it, and get it mounted nicely

 

[Shagger1]

He also repaired the rear chassis cross member, as the OP must have over loaded the trailer, and the towbar had damaged it both sides.he cut out some fancy looking plates that mimic the holes in the chassis rails-come out looking mint!

 

[Shagger1]

After having the chassis repaired, and tray all fitted up, I decided to get a brand new Hayman Reece towbar to fit, as they mount differently to the one that caused the damage, and double as a good rear recovery point..

 

[Shagger1]

The ute was looking soo much better, but the split wheels that were on it were doing it no favours, so I sourced some far better condition ones, with near new tyres.
I also have some 16x8 black rims with some Cooper tyres fitted, but kinda wanted to keep it looking pretty "original" so will see how they drive

 

[Shagger1]

So now that it's looking better, it was time to concintrate on getting it road legal, which requires a road worthy inspection here in AUS, and as I planned on "club registering it(limited drive use, but far cheaper for registration)
The old girl didn't fail on much.
*handbrake not working
*adjust rear brakes
*brake light staying on(adjust switch)
*playvin steering idler arm
*wiper blades!
NOT BAD FOR A 40YO ute!!

 

[Michael B]

Looks mint mate! Great job!!

 

[Shagger1]

Whilst trying to get this roady worth certificate, on the way back to be re-inspected, would you know it, the clutch slave cylinder gave up the ghost!
Had to limp it back to work and replace that, and after test driving that and adjusting, I noticed green on the slave cylinder, as I followed it to its sourced I barely brushed the heater tap and it snapped clean off and dumped its fluid!!!
I guess luckily it did it in the workshop not on the road I suppose!

 

[Shagger1]

Finally all repaired, I got it re-inspected and it passed!!
No better feeling!!

So the last step is to get it to the registration place and do the paperwork now.

 

[Shagger1]

Well, after 3years the old girl is back together, looking as good as it should and now road legal!!

 

[Shagger1]

Well, I didn't build this thing up for it to sit in the shed, so the first chance I got we went bush!
It did happen to bucket down rain on me, a good test for the weatherseals amd wipers(which failed on the way home!!)
Went very well, but handles pretty badly above 80km an hour.
Need to look into that..

 

[Shagger1]

The next morning was no drier!!

 

[Shagger1]

Ok so that just about puts us up to date, and as far as the build up is concerned it'll only be minor repairs, minor detailing, and probably some additional items/future plans(canvas canopy etc)
Hope this insipires someone one day!!

 

[jim land]

I notice it is common pratice down under to remove the windshield hold down hooks on the hood , why ?