The rebuild is 99.9% complete and will be bringing my truck, 78 FJ40LV-KCJA, home today!!!!
Started out with a 78 chassis and a 67 body (couldn't find anything else here in Maine that was not rusted out 2003).
Started the rebuild May, 2017.
Swapped out the rusted 78 frame with a good 63 frame. Bought an Aqualu 3/4 aluminum tub and paid shipping from British Columbia to Maine. I had a fair to good 78 cowling and we restored it to mate with the Aqualu. Was going to paint it Toyota FJ Cruiser 6V7 but decided instead to paint it a FJ40 color Olive Green 637. Bought Nason Fulthane single stage paint and the color match to the Toyota 637 paint chip chart was way off but after using some of the gallon could not return it. So it's not exactly what I wanted but ok. Everything is now 1978, except the wire harness which is from a 77. There are differences between the 77 and 78 wire harness so some connectors have to be re-pinned ie. windshield wiper motor, combination instrument panel, horn circuit and headlight/highbeam flasher switch.
The 78 cowling is different than the 67. I was running a 34/34 progressive Weber carburetor but it would not fit next to the Brake master cylinder with the 78 brake booster. So I bought a Trollhole Carburetor.
(I forgot to mention that an old style 19.5 gallon gas tank will not fit in the Aqualu 3/4 aluminum tub with the different transmission hump cover it will only take the newer 16.5 gallon gas tank-had to buy a new tank.)
I had heard that Trollhole carbs were good to go right out of the box, so we installed it and fired her up. Much spitting and coughing out of the carb. So I came back here and searched for indicators of the problem. a lean indication with possible intake vacuum leaks. Checked pcv and brake booster and their hoses-OK, Also read about possible crossing of spark plugs.....but that couldn't happen to me....how would anyone be so stupid to cross plug wires??? Well, number 1 and 6 were crossed, ran much better after THAT was corrected. Started dialing the Trollhole in and found the idle mixture screw 4.5 turns out, just had to start over from scratch. 7 degrees BTDC @ 650 rpm. It runs pretty good now but not 100%. With the Weber, once it was dialed in I could just hit the ignition and the truck would start immediately, can't seem to get the Trollhole to do that. Some pictures of the engine compartment with more pictures of the truck coming.