Builds TheAmigo's 1981 FJ40 Build Log (1 Viewer)

[theamigo]

I've been waiting for months to start this thread. I'm very happy to have the chance to do so now.

I picked up my '81 in January with plans to begin the restoration this summer once the garage was renovated and ready for action. The garage is almost done so I'm moving into the prep phase for tear-down.

 

[cruiserkev]

Nice 40!

 

[theamigo]

It looks relatively nice on the outside, but inside there are some issues.

It spent some time in Colorado, so:

• I can see through the floorboards on both the driver and passenger sides.
• The diamond plate was a bad idea by one of the POs.
• The wheel wells aren't exactly solid.

I also picked up a hard top and ambulance doors. The doors are in GREAT shape:

But, the hard top and associated hardware comes with some rust:

 

[theamigo]

My goal for this build is to completely tear it down while tagging, bagging, and photographing everything. I'll then start to repair, repaint, and renew every single piece. I'll do most of the work myself, including the preliminary body work and welding.

• I've settled on sand blasting the frame followed by something like POR-15 for protection.
  • Had considered galvanizing it but given the work I need to do on the frame I think it would be too onerous to work around/with the galvanized frame.
• I'm keeping the factory engine, gearbox, and transfer case.
• Buying new suspension components. I believe it has a 3" lift right now. I'm not sure if I'll keep that height or possibly drop it down a bit.
• New wheels and tires.
• Adding air conditioning.
• Adding power steering.
• Upgrading the lighting systems.
• Adding a rear tire carrier system.
• Adding an audio system with unobtrusive speakers.
• Tinting all windows.
• Adding front and/or rear diff locks (likely rear only).

For the final body work and paint I'm going to pay a professional to do it right. I'm not settled on the color yet, but it will likely not be the original color. I'm leaning heavily towards a factory blue or green. I may go with some other Toyota color. I don't know yet, and I'm having a hard time deciding. But, color will be one of the last choices I have to make, and it's at least a year away.

Timeline? I would LOVE to have this thing finished by summer of 2018. But, I know life gets in the way, so I look forward to the adventure. And, that's really what this is about.

 

[Racer65]

Looks like it still has all the smog equipment. Is it going to stay that way?

 

[rrv333]

Good looking 40 and sounds like fun times ahead

 

[theamigo]

Looks like it still has all the smog equipment. Is it going to stay that way?

That's my intent.

 

[theamigo]

Since the start of my build is contingent on having a nice place in which to perform it I want to throw in some shots of the "barn-age" renovation.

We have a variety of animals so the building has pulled double duty as both a barn and garage. It will continue to do so, but with some mods. I've wrapped up a complete rewire, to include the addition of 3 separate runs of lights, 3 separate circuits with GFI outlets, plus 2 circuits with 240v plugs for a heater and welder or compressor. I'm covering up one of the stall doors to give me more wall space. And I've added a TP-Link power-based WIFI extender since my house is about 50 yards away.

All I need to wrap up this weekend is the insulation, and then the sheet rock. I'll post a nice finished photo before I start breaking the FJ40 apart.

What's behind door #1?

Goats. Goats are behind door #1.

 

[theamigo]

Had a chance to verify (rough) fitment of the new-old hard top today. I love 'em with ambulance doors.

 

[airon23]

Looking good there. Subscribed to keep watching the progress.

 

[theamigo]

Ok! My garage renovation is finished. I've got real walls, insulation, shop air and power reels, lights, and outlets galore.

My kids are certainly going to be a part of this whole process, even one of the littles.

I bought an industrial shelving unit from Costco and am using that to store the bagged and tagged items as I remove them.

One of the first steps was removing the pre-lube system one of the POs installed, along with the Jacobs ignition system. So much poorly done wiring and hardware shoved in the glove box. Also, if anyone is interested in the Tuffy box make me an offer.

One of the POs also bought the wrong Steel Horse seats. They're not wide enough so the PO just drilled another hole and used a smaller screw to hold the inboard rails in. I'm sure that was safe. So, it looks like I need seats. Anyone have a use for these? I believe the rails are good, but the seats are too narrow.

AND! They went the hockey puck route to raise the driver's seat. They went the "home depot counter top sample" route for the passenger's seat.

My goal at the moment is to get it down to the frame by the end of August so that I can safely have it prepped and back in the garage before it starts raining.

 

[cbmontgo]

Good stuff.

Looks very similar to a 1980 that I had several years ago.

Was one of my favorite rigs ever, but had an idling gremlin that finally drove me crazy enough to sell it.

 

[Helipilot]

I think you will need more shelving, lots of parts in bags when you do a resto. Ask me how I know.

 

[Burbot]

Love the 50/50 rear doors. Coolest style in my opinion. Good thread. Keep them lil grease monkeys involved eh. Big smiles there. And those lil hands can go where dads don't fit!

 

[theamigo]

I think you will need more shelving, lots of parts in bags when you do a resto. Ask me how I know.

Heh. We'll see. This thing is supposed to hold thousands of pounds. I'm starting top left and going right and down in sequence to give it a bit of chronological history. Or something. I'm piling the bags on pretty good. I do have other shelves and work areas in which to hold stuff.

 

[dad4x4]

Nice 40 and candidate for a restoration. Subscribed

 

[theamigo]

Blast cabinet assembled, radiator out, fenders off, and carb cooler off. Everything tagged and bagged. Also sprayed PB Blaster on nuts and bolts in prep for future work.

Anybody know what kind of brush guard is on the front? Wondering if I should keep it or sell it. I kinda like it, but it weighs a lot.

 

[tucker74]

Anybody know what kind of brush guard is on the front? Wondering if I should keep it or sell it. I kinda like it, but it weighs a lot.

Looks like a 4plus brush bar that Dave Gore used to make, I'm interested if you decide to sell

Tucker

 

[theamigo]

Engine OUT! Fun time. Had to take the driver side tire off due to the brush bar on the front combined with the length of the hoist legs. Slid it out to the right no problem.

 

[theamigo]

Ok, so these seats I removed are definitely not FJ40 seats. No idea what they are, except some type of Steel Horse seat. Anybody interested in these? I'll put a for-sale ad up, but wanted to document.