Tortuga2 2 Indy/Caballo Build Thread

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Just picked up a 79 FJ40 from AZ and towed back to Indianapolis with my amazing girlfriend Brittany, want to use this to document the trip/build/travels with it as I wasn't very good about doing so with my last.

First I'll start with a bit of background on how I ended up back in an FJ40. My love for cruisers started with my dad buying a 71 when I was 9. He had it a couple years, not really turning it into too much of a project (solely keeping it running was project enough at the time!):

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A few years went by with us cruiser-less, when we decided to get one as a project to work on together/first ride for me (can't thank my family enough for this...directly lead to my livelihood today and was involved in what are easily my fondest memories as a kid). Cruiser two in hindsight started with few redeeming qualities other than a healthy 350 and lack of rot. Unfortunately don't have many pictures of how it started, 33s, inch-thick add a leafs and Peterbilt bubble-gum blue :princess:. Through HS built it into a very capable rig, and sadly had to sell it in college:

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Went several years without any sort of off-road rig, dabbling in cars. With my last project starting to come to a close, I initially planned on getting something that would be a good daily/weekend trail rig. Tacoma and Jeep JK were at the top of my list, the Tacoma not fitting my want to be able to drop the top/doors, and the Jeep simply not being acceptable being a cruiser guy.

Long story short I decided to start looking for a new FJ40, something more original than the others I had involvement with. I stumbled upon pbr streetgang's 79 which seemed to be very much what I was looking for; fairly original, not necessarily perfect body ($$$), but solid mechanically and with a good history. Biggest problem with this rig was the distance/inaccessibility, I'm in Indy and it was in Southern AZ. Ultimately, I looked into several other rigs that seemed interesting, even significantly increasing my purchase budget, but pbr's 79 remained a front-runner.

Finally decide I needed to go check it out...and ultimately end up buying it sight-unseen to avoid losing it! With that out of the way, Brittany had the amazing idea of towing it back via the Grand Canyon and Moab (both of which neither of us had been). Ended up being the trip of a lifetime!

We had 4 days to fly out, pick up Tortuga2 (John [pbr streetgang]'s name for the 79), drive up through the GC and Moab, and then straight-shot it to Indy.

We flew into Phoenix, grabbed a Uhaul in Tuscon, drove down to Elgin, grabbed the cruiser, and headed back up to Flagstaff in day 1. Totally kicking myself now, didn't even get a single picture at John's place. I know I was too thrilled to be back in the possession of an FJ40 and overwhelmed with John's fleet (amazing 80 with pretty much everything you could need from the sahara to the hammers, two FJ40s, a Tacoma, a 100...all armored out and in various levels of build), I don't know what Brittany's excuse is :hmm:! Actually, Brittany did get a pic of my s***-eating grin on the test drive:

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Here it is in tow shortly after picking up:

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Woke up very early the second day (our big day, GC sunrise, drive to Moab, and hopefully a couple trails all planned) and got to the Grand Canyon which was amazing:

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We then quickly hit the road and made our way up to Moab, amazing sights along the entire route. Had a run-in with a wild horse on this leg, hence Brittany renaming Tortuga2 el Caballo. He'd actually walked away by the time we grabbed a camera, we could have reached out and pet him!:

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Made it in time to hit a trail or two...ended up doing Gemini Bridges given we'd driven the cruiser a total of about a mile and hadn't made a full assessment of reliability yet:

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Had an absolute blast on that, got to teach Brittany how to not only drive off-road, but how to drive stick (she did awesome!). But with that out of the way, and the reliability tested (somewhat!), had to do a little bit on a real trail so hit the first part of Metal Masher:

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Cruiser did absolutely awesome, wish we would have had better circumstances that would have allowed us to spend more time on some more challenging stuff, but had to grab a quick bite and a pint at the Moab Brewery and head toward Grand Junction.

The first half of our drive the next day was absolutely amazing, going through Western Colorado and seeing some of what it has to offer. Still can't get over stopping at a rest stop and seeing this:

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Made it to Denver by lunch and stopped at Station 26 Brewing (a pretty cool place built in an old fire house) for another bite and a pint:

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Unfortunately the rest of the drive was pretty uneventful, ended up pulling into Uhaul with loads of time to spare Sunday afternoon:

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Absolutely awesome trip, over 4 days did ~2700mi, caught the sunrise at the Grand Canyon, hit some trails in Moab, went to 5 breweries in as many states, and got to do it all with the most amazing girl in the world! As if that weren't enough, I also ended up with an awesome cruiser at the end of it all!

Again thanks so much John, so awesome to meet you, your wife, and the dogs. Hope to one day have a collection of cruisers half as impressive as yours!

Have started to tear into a few little projects, will update tomorrow, also have a few questions about factory skids and things.

Chase
 
Congrats, nice pics. We travel the western slope frequently for my sons soccer and the scenery never gets old! When I purchased my 82, I took my father for the trip from Sandpoint, Idaho to Tulsa. We drove the new cruiser home and it's something I'll never forget.

Great memories these cruisers create!
 
Nice Chase! I was seriously tempted by this rig (The distance was killing me and does anyone really NEED two 40s? Want, yes, but need?) and to tell the truth bummed when I saw it sell, but glad it went to a Mudder. Looks like you have a long history with 40s. That trip was awesome. Keep the updates coming, so I can watch el Caballo and kick myself for not pulling the trigger. What are your plans for it? Good luck!
 
Chase,
Great pics!
Diana and I really enjoyed meeting you and Brittany as well, and we're stoked that Tortuga 2/El Caballo found a great home!!
Looking forward to following your build and you guys have a place to stay anytime you're in SEAZ.
Cheers!!
:beer:
 
I came THIS close to renting a tow bar and doing an overnight trip to check it out myself (whew, that was close). Glad it's staying in the community, Chase, and keep the postings/pics coming.:beer:
 
Wow sounds like I'm lucky to have jumped on it! Spent yesterday afternoon doing a few easy things: fixed the park position on the wipers, straightened the steering wheel, and threw in a blingy $30 Bluetooth stereo and some speakers to fill in the dash holes!

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For the time being I plan on just doing simple things like that and slowly cleaning things up a bit. Honestly it's a great rig as-is and will benefit from just a little tidying. Functionally an 8274, some armor, and locking both ends are all that are on the short list.

Longer term I envision either OME or SOA, some sort of further gearing reduction, and a metal tech half cage to go along with it most likely. Really love the classic vibe/patina of the rig as-is though so intend to strive to not hurt that too much. Definitely not going the way of my last with massive weight reduction and big stretch and the sort.

Have a few questions that I'm hoping you guys might have some insight on for me. First, this rig formerly had a 4+ rack on it and has the crossmember damage to show for it:

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In keeping with the style of the rig I really would like to install the dang boat anchor, but know some reworking of the attachment needs to be done. Any suggestions on how to make it passable? The leverage it induces is pretty awful so I'm not completely sold on mounting it back on, but I'm thinking if I were to grind/drill/weld the cracks then box the crossmember with sleeves for the bolts I might be alright?

Also, how is the factory skid? Worth tracking down or would I be better served to build my own?

Chase
 
I'm thinking if I were to grind/drill/weld the cracks then box the crossmember with sleeves for the bolts I might be alright?

That was my plan, I think it would work great.

Also, how is the factory skid? Worth tracking down or would I be better served to build my own?

IMO the OE ones aren't very impressive...

I'd build one or pick up something like this.

Iron Pig Offroad FJ40 Skid Plate

Fun build!!
 
Thanks for the input John...seeing how little tcase hangs down in stock configuration almost makes me want to look into a flat belly :doh:. Do you by chance know or can you ask your buddy what paint he used on the rig? Looks like it could just be rustoleum camo tan or something, but figured I'd check, I'm going to do the dash and touch up the chipped stuff.

Tcase question reminds me...the factory crossover under the frame from the exhaust manifold needs to change, anyone have any pics of what they've done?

I figure as long as I tuck everything up as much as possible I'll make it much more capable without having to do away with how it looks/feels too much. Or at least that's what I'm telling myself.

Also, forgot to tell a little bit more about the re-setting of the park position of the wipers...fairly self explanatory once you get in there, but I wasn't able to find anything about exactly what it entailed.

The motor (at least on 76+ I believe?) uses a set of 3 contacts which hit a timing wheel to set the park position. To stop the wipers at the proper stop position you pull the plate with the three wires attached to those contacts and simply run the motor to where you want it. At that point it looks like this:

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Pictured above is the orientation the wheel needs to be to get the wipers to stop. To set the rotation of the wheel, you unbolt the wiper assy from the ws frame and detach the 10mm nut from the linkage that attaches on the backside. The wheel can then pop out from the motor and be rotated without moving the wipers. Bolt all back together with the wheel in the orientation the pic shows and with the wipers parked at BDC and park position should be set.

Chase
 
Been too busy enjoying el Caballo and have failed to post any updates...it's been an absolute blast and hasn't missed a beat, even on the 1400mi weekend excursion to Hot Springs ORV Park Brittany and I made this past weekend!

Quick update before that...

So about a month ago we went to the Badlands, quickly discovered that prior to being concerned about getting the front and rear locked I need to be concerned about getting some rocker protection for it.

Brittany got a few action shots:

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I was very impressed with how point-and-shoot it was...biggest hindrance was certainly clearance and my lack of interest in bashing the hell out of the rockers and steps. It will definitely go anywhere I need it to at this ride height/level of body armor.

Unfortunately despite my concern for the rockers I managed to eye up a climb that led to what I'll call a combo of el Caballo and myself running out of talent; got to the top after threading the needle between two trees, didn't quite make the crest and slid down hooking the windshield frame:

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The windshield frame is salvageable...the glass not so much. Also going to have to piece together the left hand dash-to-frame knob assembly too. Needless to say I was unhappy with myself, but didn't let that slow down the fun for the day-these things can be fixed!

A couple weeks later, with the cold weather setting in, we decided we better make a quick trip down to Brown County to knock around the park and find some gravel roads to get Brittany behind the wheel on again. After our trip out West to say the sights were a little underwhelming would be an understatement, but it was still fun to get outside:

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Brittany back behind the wheel!:

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Around this time I decided to put the 4+ tire carrier in the classifieds (I mocked it up and couldn't get past the additional weight), and rc6340 on here ended up buying it. He was located in Nashville, TN...we assumed we'd end up shipping it down. Also around this time I was looking for either doors or rear half doors as an excuse to go on one last little trip before winter totally set in. Ended up winning a set of doors on ebay for a steal that were located just south of Hot Springs, AR. Ultimately this worked out perfectly because it gave me the opportunity to swing by Nashville and drop the carrier off to its new owner en route to AR to pick up the doors.

At first we had planned on driving my truck (the thing with doors, heat, nice ride, a top, etc.) down to do this, but at Brittany's nudging started to entertain the idea of driving the cruiser. The gears started turning (well, I've never been to Hot Springs Off Road Park...it looks like it's not going to rain [much] those days...I Uhauled it back from AZ, wonder if it would have made it that distance on it's own...), and Brittany and I ended up deciding to load up the tools, a tent, the 4+ carrier, and as many layers of clothes as we could fit on at one time and hit the road in the 40!

We drove down to Nashville Thursday night and got a hotel there to get a head start on our long weekend...here's Brittany modeling her beautiful garb:

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Early Friday morning we met up with Rick (rc6340) to drop off the carrier, then straight-lined it to Little Rock. Grabbed lunch there then made it into Hot Springs just in time to set up camp before dark:

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The next morning got an early start and checked out 'bath house row':

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It was pretty cool, hot water is still piped to many places in town:

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Then hit up a few hiking trails that led up to some lookout points and a lookout tower:

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Went to pick up the doors and believe it or not, Keith (sold doors to us) had a windshield and frame for me as well!:

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We then went to Hot Springs Off Road Park for the afternoon...really good and vast system of trails, excellent markings, good facilities...it was an awesome place. Unfortunately with a 600mi drive home the next day in the back of my mind didn't hit it quite as hard as I would've liked to, but still had some serious fun:

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And the next day we loaded up everything and drove back (bonus shot of night-before-trip temporary tailgate):

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...took about 10 hours in 45-50 deg temps @ 75mph (!)...Brittany is an amazing co-pilot and I could not appreciate her any more! Can't begin to imagine how long a drive that would have been without the act of driving to occupy my attention...she's a trooper.

Now the tally of failures over the course of the trip:

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NOTHING! The only thing we had to Macgyver was the windshield for fear it wouldn't sustain 75mph speeds...absolutely in awe at how great a rig this is. Can't wait to now take the downtime over winter to give it a proper once-over and refresh of oils if nothing else! As a sidenote to this...I actually had to use the cruiser to jump my other fun (and apparently less-reliable, cracked me up) vehicle because I'd left it sitting so long while driving the 40!:

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So now on the short list of projects is getting the glass in, a complete refurb of the doors I picked up (they definitely need work [full rebuild]), gauge cluster rebuild/dash refurb, install of new seats (currently en route via Fastenal), and install of a Metal Tech half cage. Can't wait to get to it!

Chase
 
A couple of things. The name Tortuga 2 intrigues me. Yes, I know what it means. But, there was a fella that lived in Bahia de Los Angeles (Baja) that had a FJ40 also named Tortuga. Coincidence?


Brittany is a keeper.
 
What size lift and type are you running? Also, what type of tire and size? Your set up looks sweet!
 
I'm not sure if the previous owner used to live in that area...he's actually already got tortuga3, a very cool red 78. And yes, Brittany certainly is a keeper!

Love the 930! What year is it? Mine is currently in a bit of a state of disrepair awaiting my finishing the interior after a big diet...hope to finally finish it up this winter, my work caused it to be a several year diversion unfortunately. Did get it together enough this summer to enjoy it without an interior though, total blast down about 300lb.

Suspension-wise it is completely stock...though I would say they are surprisingly healthy spring packs, don't think they've sagged quite as much as others often do. It has 32x9.5 TSLs, can't believe it's the first I've owned a set of Interco tires (or bias ply tires at all for that matter), but I'm loving them. Couldn't imagine a better option for a stockish rig for someone who wants something a little more aggressive than the standard 33x9.5/10.5 BFG ATs.

Sadly put it away for the winter this past weekend...going to get on the rust repair of the doors over thanksgiving break. Still waiting on my seats, not exactly been the smoothest transaction ever...will try and reserve judgement a little longer in hoping they show up!

Chase
 
Been a long time since I've updated this thread....have made slow but steady progress I'd say. First thing I went about doing while it sat in the garage was fixing the odometer. Unfortunately that proved to be a non-starter, upon disassembly I found one of the worm gears that runs it to be missing one of the pins that locates it:

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I had some thoughts about trying to drill the gear and add a dowel, but because I have too many other projects going I opted to buy a NOS cluster from 96Newf:

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It looks amazing, and is right at home with the dash post-refurb (following). Because I bought that, I have a cluster that has seen better days (looks suspiciously like it lived the last 30+ years in the desert...), but aside from the odometer and the temp (which I can't account for because it was disconnected) is fully functional. If anyone could use it for parts let me know I'd be happy to box it up and send it your way:

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In addition to the cluster I did the typical knob refurb with some simple green and nail polish (is hazard supposed to be red?):

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Also installed the ashtray-mounted cb and painted the dash tan (it was previously still it's factory white). I somewhat begrudgingly (as there are much better ways to communicate) installed the cb to fill the hole in the dash, but it looks too at home so I ordered a firestik and coax and am waiting on that. I actually painted the speakers when I painted the dash as well, I figured I wouldn't be hurting the audio quality enough to matter and think it turned out pretty cool:

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Second is a pretty bad pic and is before I finished up the glovebox knob, but shows the cb mounting better:

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I'm really pleased with how much the dash actually cleaned up...I need to get an upper dash pad to round it out.

My seats finally also showed up, so installed them with new belts from specter. Don't mind the ratchet strap bending the windshield frame back so glass could be reinstalled!:

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I am very very pleased with the seats...feels much more proper and puts occupants probably 6" lower, should be much safer and allow Brittany to actually reach the floorboard! I do have one question with respect to factory seats...what dictates whether they have a sheetmetal back or not? I thought it was a year thing, but I swear I've seen 79+ with the sheetmetal seatback. That's one thing I would like these seats to have which they do not, I think they look cooler plus are quite functional with respect to mounting things.

Shortly after getting the seats in I finally fit a new windshield...I got the windshield frame 'tweak' down to about 1/8" so I opted to not use one of the others I've picked up in my now two parts hauls (more on that in my next post):

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Must say, despite the glass being a flat pane and fairly straightforward to install, I am pretty happy to have it in. Between this and the 911 (which still isn't really sorted as the lexan rear isn't an awesome fit) I am fxxxing over glass installs.

While I did the dash refurb I pulled the heater and blower and disassembled for rebuild...they look like they've been to hell and back and then some!:

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Found a fossilized wasp nest in the blower and again 30 years or so of desert in the heater. I'm a little torn on doing a full-on refinish on the heater itself...it has a pretty cool rust-not-rot patina on it from the time it's spent outside. My original intent to keep the cool patina that the whole rig had has started to falter already, starting with the dash clean-up. That said, I don't mind the idea of cleaning everything up as good as possible with the hopes that I can preserve it for another 35+ years. With that in mind, does anyone have suggestions as to what paint I should use on the sheetmetal and plastic parts of the heater? I'd prefer to not have to paint the plastic, but as the pics show, I think it's probably too washed out to save with anything but.

In getting things tidied up this hole has been bothering me more and more, does anyone have a good source for a plug or something to fill it in? Is it for a factory antenna? I almost remember the same hole bothering me on my 78...I think I just resorted to using a bolt and fender washer to plug it:

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Also, I'm excited to say that John hooked me up with a replacement Smokey Bear sticker (the last went with the 4+ tire carrier when I sold it)...need to repair the crossmember before I can place it!:

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@orange45 was collecting cluster parts for rehabilitation of complete clusters.

Nice work on the 40, keep the updates coming.
 
Curious about the windshield - when you tweaked the frame to within 1/8", what did you do, and why was that necessary?
 
Cool I'll have to see if orange45 is still looking for clusters. The windshield frame issue was caused by me threading the needle between two trees on a climb at the badlands, then failing to make the climb and sliding back down and hooking one of the trees on the way. You can see in this pic the frame is too upright:

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Oh and to fix the frame (I think this is what you were originally asking after rereading) I just pulled the glass, wrapped a ratchet strap around the most whack corner and tightened it beyond where it originally should have been. This allowed it to spring back to being basically flat/square. The passenger side was fine as it was, I actually pushed forward by hand on that corner (while the ratchet strap was hooked to the other corner) to help massage it all into place.
 
Mine's bowed 1/8" in the middle of the top of the frame, so I've got it clamped in the opposite direction to get it straightened. I don't know how much flex a new w/s gasket would give between the glass and frame as is, so I'm gonna keep tweaking until it's straight. Ratchet strap probably would be faster, but pipe clamps are what I've got, so clamps it is.
 
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