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rover67
11-14-2009, 06:39 PM
Welp, I decided to go ahead and pull the head on the 40 today. I figured since it had a bent pushrod and a leaky manifold gasket (Found the issues during PM for the 40's only run) I might as well dig in and see what else is up.

Got a lazy start at around noon after a nice brunch with Allison anfter having been out of town for 8 days.

Didn't quite get the head off today since I got caught up in all sorts of other things on the truck I started cleaning. I'm gonna get the coolant pipes, brackets and misc. doodads replated, and am getting the air cleaner powdercoated black again.

Kinda taking my time and de rusting the parts in the tank as I go. It has been working really well. I'll post more pics of the results in the morning. Found a guy that does Cad plating in broomfield, Im gonna give him a buzz monday and take him a box of parts if it seems like a good deal.

Also planning on putting a big order in with Boulder Toyota on monday for all the random gaskets and bolts that are trashed.

Gunn will do the head.

One of the funny things I found was what looked like an old cardboard box peice being used as the thermostat housing gasket. I thought that was pretty funny. There have also been a ton of standard nuts forced onto the metric studs in places. Kinda frustrating but par for the course.

Pics:

1. engine bay before
2, 3.Air rail I got from Elliot. Welded on the last pipe. FIgured I'd fix his and get it recoated. Mine looks like it is going to come off in a billion peices.
4. Power steering pump from a 60. gonna freshen it up since I am taking stuff to get plated. Might as well get a rebuild kit while I'm at Boulder toyota. It is low mileage and is super tight still.
5. Thermostat housing gasket. Nice. This one made me and Allison laugh a bit. Had Hylomar all over it too. reminded me of my British car days.

ElliottB
11-14-2009, 09:37 PM
That gasket is sweet!

Good to see something in my junk pile may actually be put to good use. It was about 5 mins from hitting the trash can.

Mendocino
11-14-2009, 10:00 PM
Marco,
Who is doing the plating in Broomfield?

rover67
11-14-2009, 11:20 PM
I'm gonna give these folks a buzz. Maybe it'll work out. Never used them or talked to them.

http://www.cadplating.com/

Caribou Sandstorm
11-15-2009, 09:13 AM
Hey Marco,

If you get stuck on anything, my buddy Barry from North Carolina just moved here. He rebuilt his 40 from the ground up, it has a Toyota Diesel he imported and installed.

Anyway he might be a good resource also. Not sure if you want a Toyota Diesel but he can get them.

Give me a shout if you want his info.

Jacket
11-15-2009, 12:40 PM
You do more with your rig in a day than I do in a month......

rover67
11-15-2009, 05:43 PM
Got it stripped down to the short block. Camera is dead and the charger is at work. I was surprised, but my air rail came off easily. I guess soaking it in Deep Creep and PB blaster overnight helped everything.

Hopefully tomorrow I can get the head to gunn for a rebuild and a .050 shave, and the parts to the coaters.

The head gasket looked perfect, and the cylinders look really nice.

Matt, I decided I gotta knock it out, so I locked myself in the garage! It's fun now, but i'm sure the honeymoon will wear off soon.. don't worry.

corsair23
11-15-2009, 07:57 PM
You do more with your rig in a day than I do in a month......

x2...Although for me it would be a year, maybe 5 :o

FJ_Mark
11-15-2009, 10:13 PM
Is that a Natural light 12-pack gasket? I normally use a Milwaukee's best.

rover67
11-15-2009, 10:22 PM
Is that a Natural light 12-pack gasket? I normally use a Milwaukee's best.

Dude, I think it might be.. I honestly didn't really look at it that closely. :lmao: :beer:

PabloCruise
11-16-2009, 01:23 PM
Don't be knocking the Natty Light...

rover67
11-16-2009, 02:26 PM
I'm gonna give these folks a buzz. Maybe it'll work out. Never used them or talked to them.

http://www.cadplating.com/


just got back from here. The guy is super nice and does lots of automotive stuff for restos across the country. I'll bring some cards to the next meeting. We'll see what the parts look like this weekend possibly next week. I gave him what totalled out to be 15 pounds worth of stuff.

rover67
11-17-2009, 10:51 AM
Everything is out getting worked on.

Now it's time to clean up what's left over.

Cylinders look nice.

Does anybody know if there is supposed to be a second sealing ring on the exhaust manifold cylinder 1 and 6 parts? Mine wasn't leaking before, but it looks like it should have another ring in there.... see the picture.

-marco

FJ_Mark
11-17-2009, 11:16 AM
It should have two.

rover67
11-19-2009, 07:25 PM
Picked up the majority of the parts tonight. Holy smokes, the cad plated parts look nice. Don't have my download cable (left it at work) so you guys will have to wait for pictures.

rover67
11-20-2009, 11:13 AM
Giggidy..

subzali
11-20-2009, 11:18 AM
you suck.

you doing a full resto on the body? You should so that all the pretty parts can match :D

Jacket
11-20-2009, 11:37 AM
Wow! Impressive.

You should have had those wheels cad plated.... ;)

rover67
11-20-2009, 11:38 AM
I think I kinda have to now. I may have backed myself into a corner.

rover67
11-20-2009, 11:42 AM
Wow! Impressive.

You should have had those wheels cad plated.... ;)

I am from memphis... it would have matched my "roots"

Jacket
11-20-2009, 11:45 AM
What are all the random pieces below your skid plate? Are those carb parts?

wesintl
11-20-2009, 11:46 AM
WOW, bling!

rover67
11-20-2009, 11:54 AM
What are all the random pieces below your skid plate? Are those carb parts?


carb linkage, emissions doodad clips, air injection parts, ect.

Hulk
11-20-2009, 12:05 PM
Wow. Original wheels look super nice, and the cadmium-plated parts look better than new! You are going to have the sweetest 40 evah!

AxleIke
11-20-2009, 12:34 PM
Hey Marco, how were those guys on cost for the cad plating? Pretty reasonable?

rover67
11-20-2009, 01:52 PM
Hey Marco, how were those guys on cost for the cad plating? Pretty reasonable?

It's a minimum of 80 bucks for less than 20#'s of parts plus any heavy cleaning they have to do. All of my stuff was $200 total, and I handed it to them really greasy. You could get it done cheaper if you handed them nice clean parts.

rover67
11-20-2009, 01:53 PM
Wow. Original wheels look super nice, and the cadmium-plated parts look better than new! You are going to have the sweetest 40 evah!

It's cool yes, but now I fell like I gotta keep it up on the rest of the rig. I am stoked about how it will turn out though. thanks everybody for the props :)

60wag
11-20-2009, 04:16 PM
I think some contrast on the 40 is needed. The motor will look like its fresh from Toyota but the rust holes in the body have got to stay. :)

rover67
11-20-2009, 04:46 PM
The seats look nice too....and have heat... except the headrests look dingy now...

FJ_Mark
11-20-2009, 05:21 PM
WOW the parts came out great.

LARGEONE
11-21-2009, 09:03 AM
Hey Marco...those parts look great!!!

I think you're gonna need to change the title of this thread so we can follow the full resto.

MDH33
11-21-2009, 09:55 AM
I've been out of town and missing all the progress. Great Job Marco!! :thumb::beer:

Did you get the powder coating done at the same shop that did the cad plating?

FJBRADY
11-21-2009, 10:14 AM
You are really pimpin that sucka out..........looks great :thumb:

rover67
11-22-2009, 03:13 PM
I've been out of town and missing all the progress. Great Job Marco!! :thumb::beer:

Did you get the powder coating done at the same shop that did the cad plating?



thanks Martin, thanks EVERYBODY!!

aero propeller did the cad plating www.aeropropeller.com or http://www.cadplating.com/ they also apparantly do powder coating, but I went with Powder Coating Specialties in Golden for the powder coating. They had a good price per wheel ($35) and they were close to Allisons work so it was easy.

rover67
11-22-2009, 03:15 PM
Hey Marco...those parts look great!!!

I think you're gonna need to change the title of this thread so we can follow the full resto.


Good point, I was wondering about that. I guess it might make sense to keep it all here instead of doing multiple threads. Can a moderator change the subjet to "82 FJ40 Refresh"?

Hulk
11-22-2009, 08:54 PM
Good point, I was wondering about that. I guess it might make sense to keep it all here instead of doing multiple threads. Can a moderator change the subjet to "82 FJ40 Refresh"?

Done. :thumb:

rover67
11-22-2009, 10:23 PM
Done. :thumb:

sweet, thanks man! Now I won't clutter the board with more threads about the same type of stuff..

rover67
01-18-2010, 08:18 PM
It's been a while, the holidays meant spending time with the 60 so I had to leave the 40 alone for a bit..

Today I started working on it again.

I scored a low mileage power steering pump on mud. Bought a seal kit from NAPA and after losing a spring or two finally got it all back together. Thanks Martin for the pump you gave me to steal parts from! Lots of people say not to rebuild them, but this was a low mileage one so I went for it. The front bushing was nearly new looking so it turned out nice. I'm excited about it.

I also got a stock power steering box from Justin (bruiser) in the club. It was leaking for him so he went the minitruck route. I was excited to get my hands on a stock one so I went for it. I took it apart today and it looked nice and relatively clean on the inside. The only thing that took me by surprise was all those little balls in there. I practiced putting them all back in and finally figured it out. with a little grease it works fine.

I did notice that the teflon ring was damaged a bit so I called our friends at Boulder Toyota to order the rebuild kit. We'll see what it has when it comes in.

In the mean time I got the head all back on and torqued, got the valve train back on and torqued, and stuck on the air rail. It's starting to look like something again.

It's slowly getting there...

Old40Dog
01-18-2010, 10:50 PM
The seats look nice too....and have heat... except the headrests look dingy now...

Marco, did you have these recovered? If so, who did them? Want to have Zach's Pig front seat redone and not sure where to go for reasonable cost but still get quality workmanship.

rover67
06-27-2010, 02:17 PM
welp, I got the whole motor put together finally and started trying to tune it. I finally realized that the intake/exhaust manifold gasket is leaking again. I think I overtightened it all and made the intake manifold flex out from the gasket surface where there are no bolts. Bummer.

I almost have it all the way apart again.

anybody used the remflex gaskets here? I am tempted to try one instead of the OEM one this time..

all that and teh power steering pump started leaking like a seive from the shaft. Got another one from NAPA and it dosen't really seem to pump, I have no poer steering. maybe I messed up the steering gear bod rebuild somewhere.

ick.

RicardoJM
06-27-2010, 02:24 PM
anybody used the remflex gaskets here? I am tempted to try one instead of the OEM one this time..

I used an OEM gasket, put it on dry and have exhaust leak. Yesterday, Air Randy had some 1/2 washer setups that we swapped on - it was an improvement but still an exhaust leak. Randy is thinking that a second gasket and some high-temp copper rtv would take care of it - but I'm going to give the REMFLEX a go. I just ordered one last night. I'll be putting it on as soon as it gets here. From everything I've read, they work great when installed properly.

rover67
06-30-2010, 08:19 PM
So that gasket fixed everything. runs like a dream :) it's the shiz

farnhamstj
06-30-2010, 08:58 PM
congrats

rover67
06-30-2010, 10:07 PM
Yeah man, I'm stoked. It runs really really well.

J Kimmel
06-30-2010, 10:53 PM
have you jumped it yet? looks sweet :)

Hulk
07-01-2010, 11:52 AM
Awesome! Can't wait to hear it in person.

Corbet
07-01-2010, 12:04 PM
So that gasket fixed everything. runs like a dream :) it's the shiz

JT (trapper50cal) tried a pair of remflex gaskets on his 60 down here. They only worked for a while. I hope you have better long term luck. Sorry to drop a turn in the punch bowl:o

subzali
07-01-2010, 01:21 PM
any updated pictures? how's the bodywork going?

rover67
07-01-2010, 07:18 PM
tub is on the way from paul pilgrim, untill then it's on hold... I'm gonna drive it :)

MDH33
07-01-2010, 08:00 PM
tub is on the way from paul pilgrim,

Woah! :eek::D Bling bling. your 40 is going to be soooo nice. :grinpimp:

I would need to sell some stolen organs to afford one of those. :hill:

rover67
09-12-2010, 05:30 PM
Welp, the Remflex gasket is leaking. The thing runs like a turd now.

Project is kinda on hold for a bit. The Tub from Paul showed up with a little damage so i am working on getting some $$ from the shippers which is turning out out be a nightmare. I don't really want to keep moving on it till the tub is ready to throw on there. The tub was expensive but I figure I can get a few years out of this rig when it's done.

I did score a top and ambi doors for it which is sweet.

And, i just got the 2011 registration sticker in the mail last week.. one year since i got it about... I thought it'd be farther along by now, but oh well :)

FJBRADY
09-12-2010, 06:08 PM
Sorry to hear the set backs, hang in there. I look forward to seeing it when you have it all together the way you want it.

subzali
09-12-2010, 09:16 PM
dude, you gotta post pictures...

rover67
09-12-2010, 09:39 PM
You know... honestly I though I had..

here are a few I just snapped :)

Hulk
09-12-2010, 10:54 PM
Wow -- you bought a brand new steel tub?!

RicardoJM
09-13-2010, 07:55 AM
Welp, the Remflex gasket is leaking. The thing runs like a turd now.

Sorry to hear that:(. Reach out to IronGiant on MUD, you are within the "warranty" period. I put mine in about a week after you. We'll see how it holds up.

60wag
09-13-2010, 10:03 AM
I'd change the manifold gasket to a Fel-Pro. That Remflex thing did look awful thick and had no metal support in it. The goal is the thinnest gasket that will accomodate surface irregularities to make the seal.

rover67
09-13-2010, 12:05 PM
Fel-pro over OEM?

I was going to take the manifold assembly to a machine shop and have them plane it all bolted together too.

Yeah, the RemFlex gasket kinda split in between the layers. The truck makes a really cool whistling noise when it idles now.

rover67
09-13-2010, 12:06 PM
Wow -- you bought a brand new steel tub?!

Yeah man, I am pretty stoked. I think it's gonna be nice when it's painted.

wesintl
09-13-2010, 12:07 PM
where did the new tub get damaged?

subzali
09-13-2010, 01:14 PM
Fel-pro over OEM?

I was going to take the manifold assembly to a machine shop and have them plane it all bolted together too.

Yeah, the RemFlex gasket kinda split in between the layers. The truck makes a really cool whistling noise when it idles now.

For the manifold gasket I'm not sure it matters as much as the head gasket. I went with a manifold gasket from SOR and have had no problems...:twocents:

rover67
09-13-2010, 01:23 PM
where did the new tub get damaged?

The front lower parts of the rear fender wells are kinda caved, the front where the kick panels weld to it are bent in, and they drug it around on it's sides and took off the galvanized coating in spots. It'll need to be straightened and refinished prior to paint, not huge I know... and would have needed it anyways no matter what.

The most frustrating one for me is where they drug it around and damaged the coating on it. I was really stoked to have nice galvanized metal to work with, but now the coating is compromised in some of the most visible areas. I was just looking to treat the welded areas for rust prevention prior to paint, but now will just do the tub as a whole. I know I'll have to do body work to fit it all and make it smooth and good looking anyways, but the tubs that didn't come out of the crates look virgin with no surface rust compared to this one. Maybe the shippers can pay to have it re-galvanized or something. I know I'm being picky.

Also, I got some more parts from Paul (Fender, apron, kick panels) and those are dented and scratched from being thrown around after having been removed from the crate. They showed up tied together with bailing wire literally sitting on the floor of the 18-wheeler.

All in all, it is not a lot of damage, it's just frustrating to know it could have been perfect in the crate like the others. If I can get the shippers to toss some $$ my way It'd be nice but I don't have my hopes up. I know that a lot of the work I'd be doing on it would be done anyways, and I have time to work with the shippers to see what I can get since priorities have moved around a little and I won't be getting to this until the winter time.

Paul has been great through this so far and is the one that actually got me motivated to file a claim... alone i probably would have never done it and just moved on. He can't afford to have tubs coming un-crated halfway through shipping.

wesintl
09-13-2010, 01:36 PM
that sucks. I know what you mean though. I got a 4 core rad from a toy dealer in calgary. They didn't repack it and it came in a sloppy box with a couple of dents in the tanks. After trying to deal with both fedex and the dealer I just gave up.

rover67
09-13-2010, 01:50 PM
that sucks. I know what you mean though. I got a 4 core rad from a toy dealer in calgary. They didn't repack it and it came in a sloppy box with a couple of dents in the tanks. After trying to deal with both fedex and the dealer I just gave up.

yeah, that's exactly it... we'll see. Not too bummed about it since I have some down time anyways.

Hulk
09-13-2010, 01:58 PM
Paul who? Just curious where you ordered this. Was it a group buy or something?

rover67
09-13-2010, 02:07 PM
Paul Pilgrim from Costa Rica. No group buy, just bought one straight from him

http://toyotona.com/

Hulk
09-13-2010, 02:25 PM
It's interesting that there suddenly seems to be so many options for new FJ40 sheet metal. For example (in addition to the one you purchased from):

Pacol Online (http://www.pacolonline.com/) (who was at Cruise Moab this year)

Heritage Sheet Metal, sold by Iron Pig Offroad (http://www.ironpigoffroad.com//index.php?main_page=index&cPath=3_25)

I wonder if all these vendors are getting the sheet metal from the same place?

gr8fulabe
09-18-2010, 06:53 PM
Paul has been great through this so far and is the one that actually got me motivated to file a claim... alone i probably would have never done it and just moved on. He can't afford to have tubs coming un-crated halfway through shipping.

Hey Marco,
We met on the road once, my wife & I pulled up next to you in my 65 galaxie & she asked if your Great Dane was named Marco (my fault for not being more specific)...

So anyway, I work in Intl. Supply Chain Management & my wife is a licensed Customs Broker. So what forwarder/broker did you use? If it is one that we have connections with, we might be able to help with the claim. Also, how were the frieght bills signed off? Were they all signed off, "clean" or did someone note the damage to the crate at some point? Lastly, how do you know the crates were damaged in-transit, rather than detsroyed by U.S. Customs? Did Paul, or his forwarder in Costa Rica provide an ISPM cert when they shipped? Was the wood stamped with the official ISPM (Intl. Standards for Phyto-Sanitary Measures) brands? If not, Customs might have removed/destroyed the crates themselves, & you/Paul or the forwarder might end up getting a bill for that.
Anyway, if I can help with insight or connections, don't hesitate to ask.
Best,
Abe

rover67
10-21-2010, 08:14 PM
finally got around to pulling the manifold off. Confirmed that the remflex gasket had basically split in half and started to leak a ton.

Got the manifold machined at Spitfire Automotive in Denver... the only place that I called that was willing to hit it with a belt sander. I called like 6 places including Gunn. I am really happy with how it turned out.

I think it's gonna do the trick.

Picked it up today.

rover67
10-21-2010, 08:16 PM
Ha! sorry that threw me for a loop!!! That was a sweet ride BTW....

Yeah this shipper thing is turning into a weird deal... I may contact you to see what you think...

Hey Marco,
We met on the road once, my wife & I pulled up next to you in my 65 galaxie & she asked if your Great Dane was named Marco (my fault for not being more specific)...

So anyway, I work in Intl. Supply Chain Management & my wife is a licensed Customs Broker. So what forwarder/broker did you use? If it is one that we have connections with, we might be able to help with the claim. Also, how were the frieght bills signed off? Were they all signed off, "clean" or did someone note the damage to the crate at some point? Lastly, how do you know the crates were damaged in-transit, rather than detsroyed by U.S. Customs? Did Paul, or his forwarder in Costa Rica provide an ISPM cert when they shipped? Was the wood stamped with the official ISPM (Intl. Standards for Phyto-Sanitary Measures) brands? If not, Customs might have removed/destroyed the crates themselves, & you/Paul or the forwarder might end up getting a bill for that.
Anyway, if I can help with insight or connections, don't hesitate to ask.
Best,
Abe

gr8fulabe
10-21-2010, 09:11 PM
Hey Marco,
The intake/exhaust manifolds look great! Do you think it is a flaw with the remflex gasket, or something to do with your manifolds? I thought the Remflex gaskets sounded really cool, but I ahve seen some others complain about this type of thing, so I am curious if they aren't all they are cracked up to be...
Let me know what I can do to help on your shipment/import. Even if I can't do anything else, I can at least help to give any insight or advise. Plus my wife Erica has deep connections in the industry, and knows more than I do, so that is a big help too!
Best,
Abe

rover67
11-01-2010, 08:30 PM
The right front hub was leaking goo so I figured it was time to do the front end.

She was treated to a full birfield disassembly, repack, new marlin inner seals, new rest of the seals, some bearings, calipers rebuilt by yours truly, new rotors, new lug bolts, new pads, and some new brake lines.

Also threw on some hubs I had lying around. I totally dig the fact that this is all FJ60 stuff. I get to use my extras on it.

Hulk
11-01-2010, 09:23 PM
That is super clean. When you're done, this thing should go in a museum.

Mendocino
11-01-2010, 09:46 PM
Lookin' good Marco!:thumb:

Caribou Sandstorm
11-01-2010, 09:47 PM
I just re-read this thread, really nice work man!

Melinda walks up and looks over my shoulder as I am staring at your engine...

She laughs and walks away..she asked what I was doing and I said studying..one of these days...

nakman
11-01-2010, 10:29 PM
beautiful!! hey are you using stock shock towers? Are you missing a bolt/rivet on the ds?

subzali
11-02-2010, 08:50 AM
yep, you're missing a bolt for your inner fender support :p:

Looks good Marco! A lot of us 40 owners wish we could swap FJ60/minitruck front axle components with the stuff we have!

Now when you gonna drive it again!?

rover67
11-02-2010, 10:16 AM
Yeah, I am going to drive it again! Trying to get it where I can work on the 60 for a little while. Yeah, it is nice to have all the same brakes and axle components, i really like the compatibility. And yes, there are several bolts missing on the fender supports and the rest of the body.. I haven't gotten there yet :) I stuck with the stock shock towers because I went with an OME suspension after all. I am keeping it low and slow :)

rover67
11-02-2010, 10:18 AM
Also forgot to mention that the manifold is back on. Worked really well so far with the stock gasket from Toyota and the machined surfaces. Idles really smooth and I am seeing about 17.5-18 inches of vacuum. The Idle mixture screw actually did something when we went to tune it this time :)

Trapper50cal
11-02-2010, 10:37 AM
Nice Ride Marco! Impressive level of detail thusfar...

As Corbet mentioned, I did try Remflex twice on my 60 before shipping it off to it's new owner in North Carolina...

both times it failed. The material over the #3 - #4 flanges got pushed up and out. I think the problem is that they state VERY low ft.lb. torque specs...something like 20 ft./lbs and quite frankly an old nut or bolt can hang up well beyond 20 before it's even completely seated. The first install, I know I over-torqued them, the second time I didn't and both failed. It may just be that the specs they require allow the manifold to shimmy around a bit and tear the material, then allowing the manifold to "eject" it slowly upward. Not impressed.

What a shame that Paul's tub got dinged up during shipping...

rover67
11-02-2010, 10:42 AM
Nice Ride Marco! Impressive level of detail thusfar...

As Corbet mentioned, I did try Remflex twice on my 60 before shipping it off to it's new owner in North Carolina...

both times it failed. The material over the #3 - #4 flanges got pushed up and out. I think the problem is that they state VERY low ft.lb. specs...something like 20 ft./lbs and quite frankly an old nut or bolt can hang up well beyond 20 before it's even completely seated. The first install, I know I over-torqued them, the second time I didn't and both failed. It may just be that the specs they require allow the manifold to shimmy around a bit and tear the material, then allowing the manifold to "eject" it slowly upward. Not impressed.

Yep, mine did the same thing.... pushed up and out in about the same spot. It did make a cool whistling noise through the messed up gasket though. Getting the manifold machined seemed to be the trick, but it was hard to find anybody that wanted to machine it. Most folks shied away from it since it was half Al, half cast iron. They were saying that the cast iron manifold tore up their mills. Anyways, the guys at Spitfire Automotive who were recommended by Gunn belted it down.

http://www.spitfireracingengines.com/

Now I'm glad I didn't try the remflex gasket again..

Jacket
11-02-2010, 11:15 AM
Shiny!

I need to get some new lug studs myself. I've got a couple that are stripped since the last tire rotation.