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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?

LXBRADY
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 :)

LXBRADY
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.

rover67
06-13-2015, 01:42 AM
https://vimeo.com/130610451

simps80
06-13-2015, 07:51 AM
Hecks yesses!!
:thumb:

RicardoJM
06-13-2015, 08:03 AM
Nice :D

Rezarf
06-13-2015, 10:45 AM
Way to go Marco.

MDH33
06-13-2015, 07:46 PM
" It's Alive! ALLIIIVE! " - Frankenstein http://mdhuber.smugmug.com/photos/i-xqqB46T/0/O/i-xqqB46T.gif

treerootCO
06-13-2015, 08:52 PM
Awesome!

rover67
11-11-2016, 05:28 PM
Well, after a long hiatus I've started back on the 40 again. Put gas in it and it started right up. It had been sitting since I drove it up to our new place and I took that last video. Allison was impressed (isn't it awesome when we impress our friend/spouses?!) that it was running and exclaimed "I thought that thing was just a fixture in the garage!!!"

I ended up spending the last week welding up some random odds and ends on the body that I had marked as need to do and did stuff like make the hood and doors fit right. It doesn't look like I did a lot when i look at it but it's getting closer. I have also spent time jsut remembering where I was at with everything.

The next steps are to touch up some body seams (where the new tub meets the cowl), take it apart, flip it and redo body mounts, and start the conversation with the blaster and painter. I plan to use the same painter and blast tech like Adam did on his 40.

I'm hoping to get it in paint sometime in the next few months.

I'm off travelling for the next 7 days for work so nothing much will happen for the next week but hey, at least it's going! Consider the post a public exclamation of project re-initiation!! Sometime after November of 2010 I started the tub swap and after getting most of it done I lost motivation (and started biking a lot more instead of working on the 40)

rover67
11-11-2016, 05:35 PM
Oh wow, just noticed there are no shots of the new tub on in this thread and it's lacking a ton of details.. I'll have to update with better pictures sometime.

The majority of the work on the tub has been welding up unused holes, adding nuts for stuff that didn't have any (like welding nuts for jump seats to the tub) and moving things like front seat mounts. Looks like it may have been built left hand drive and for a bench seat. Also took all the fuel filler metal work from the old tub and grafted it onto the new tub. I also have spent a lot of time straightening the tub where it was bent, it ended up being worse than i thought but as with any new replacement metal parts it'll always take some work. Not worried about it.

More stuff that actually happened over the last 6 years:

I got all the grey parts re powder coated. That included roll bar, rear seat frames, and some random other doodads. Finished the rear jump seats with new foam and re cad plated springs and screws.

I also got the front ash tray and grab bar re-chromed.

After trying to salvage the front bib and buying a new used one that also sucked I ended up buying a re-pop new one as well as a new front left fender. Found a new left apron also... that took months

I managed to score a new floor mat for the front. NOS from japan. that was sweet.

I got a new upper dash pad (still need lowers)

I also managed to score a new ash tray for the center console.. mines broken. That happened last year. Some may not think that's a major accomplishment but it was... Adam (With the other 82 40) was just offered a used one for $750. People are starting to take advantage of the desirability of these vehicles, it's frustrating to see that the market has changed from passionate owners willing to help people out to to a market that's in it for the money. Another interesting place this is happening is with emissions parts and other body parts.

Speaking of which, I need a new hood. I have noticed that I have the wrong one for my year.... cringing at what that will cost.

nakman
11-11-2016, 11:04 PM
Dang I am missing that ashtray. $750 huh? Glad to see you're getting back into this Marco.. these 82's need to play together.

simps80
11-12-2016, 01:40 AM
awesome!!
this was one of the threads that I read a lot .. think I found the spitfire place from here too...excited to see it revived!! (your 40 and by proxy this thread)

Crash
11-12-2016, 02:40 PM
Great to read of your 40 project progress, Marco! Will be watching for further developments and I'm glad to report that my 40 project has taken some big steps forward in the last week, too. Got the top and windshield frame off with all glass being removed. Closer to paint. While removing the windshield glass I heard a pop and looked over to see one of the rounded rear top windows had exploded under its own volition - I had removed it from the top panel about an hour earlier. Glass is weird but wonderful. Feels good to get off the snide with projects like this and getting 40s closer to being what they want to be is a good thing. Keep after it! :thumb:

akingf5371
11-12-2016, 08:54 PM
Glad you updated this thread, we might have more 82s than any other club! No smoking for my passengers until I track down a cheaper ash tray.

simps80
11-20-2016, 06:26 PM
Dang I am missing that ashtray. $750 huh? Glad to see you're getting back into this Marco.. these 82's need to play together.

Glad you updated this thread, we might have more 82s than any other club! No smoking for my passengers until I track down a cheaper ash tray.


is it this one?

https://www.cityracerllc.com/products/oem-ashtray-for-79-land-cruiser-fj40-nos

this racer65 guy sources a lot of stuff that's cool

rover67
11-20-2016, 08:57 PM
Naw its the one in the center console...

rover67
12-14-2016, 09:16 PM
Worked on getting the seams where the new body meets the cowl good enough for the body guy tonight. Actually took some work..

http://uploads.tapatalk-cdn.com/20161215/d63c05c9c8e58d66b4caef89d655399d.jpg

http://uploads.tapatalk-cdn.com/20161215/b86efd280b470a145c21f8617ae4e591.jpg

http://uploads.tapatalk-cdn.com/20161215/d9d6e31e82bdf6f9f75cffa19b670be7.jpg

http://uploads.tapatalk-cdn.com/20161215/a491bb722007a433eb27a241ef3e5ce3.jpg

http://uploads.tapatalk-cdn.com/20161215/aff0f9f26196d7e83fd682f922d91c5f.jpg

http://uploads.tapatalk-cdn.com/20161215/35ea18e37357c229f321892488eda375.jpg

http://uploads.tapatalk-cdn.com/20161215/51140a37ebba85fa96c26863ee49316e.jpg

http://uploads.tapatalk-cdn.com/20161215/30a88658fe94cd02f96926965b78fc83.jpg

Also the rear round parts are done. The tub cam with square corners in the rear like the earlier trucks.

rover67
12-14-2016, 09:19 PM
Getting close to taking it apart to do the front body mounts. I think it'll be better to do them with the body off the frame.

http://uploads.tapatalk-cdn.com/20161215/4f33818d9bc344eacc1413e06ac06845.jpg

http://uploads.tapatalk-cdn.com/20161215/1cd3d105553397b931583583b31680b3.jpg

rover67
12-14-2016, 09:20 PM
Old fuel filler cover grafted on:


http://uploads.tapatalk-cdn.com/20161215/a3f0a46eb2c239d0127c8607b240a603.jpg

rover67
12-14-2016, 09:21 PM
http://uploads.tapatalk-cdn.com/20161215/9df96145bab37921174765f95b36fb11.jpg

rover67
12-14-2016, 09:33 PM
Also gotta figure out why my doors seem to low in the openings:

http://uploads.tapatalk-cdn.com/20161215/678e3d51b55eebec1c419fbe8b2eaec3.jpg

http://uploads.tapatalk-cdn.com/20161215/c256604ef6113d614f0a074ee43f2a79.jpg

http://uploads.tapatalk-cdn.com/20161215/04c23d09488170a0c407badb4ba77601.jpg

http://uploads.tapatalk-cdn.com/20161215/4e8bd4d380154141811f596326079566.jpg

The gaps are kinda even all around except at the bottom where it gets smaller

rover67
12-14-2016, 09:37 PM
Other side is similar:

http://uploads.tapatalk-cdn.com/20161215/542f5486aa0fa8cef4372ebe1629cefb.jpg

MDH33
12-14-2016, 09:42 PM
If I recall, aren't the hinges that bolt to the tub on floating -captive nuts that allow for a little up and down adjustment? I seem to remember that when I switched mine to the OEM soft doors.

Looking good!

rover67
12-15-2016, 09:22 AM
Alright, I'm gonna tackle the hinges tonight. I moved the doors up a bunch on the hinges themselves, so if I get a little bit out of where they bolt to the firewall maybe I can get it right. I also just noticed in the picture they aren't square with the body seam.

aprosise
12-15-2016, 10:03 AM
In the last photo, it looks like you are already out of travel on the door side... Hopefully there is enough room on the tub side.

rover67
12-15-2016, 10:08 AM
Yeah that's what I'm hoping too. I got some measurements from Adam Farmer to check to make sure I welded the bottom of the door sil/tub on right also.

SteveH
12-15-2016, 10:38 AM
Unless the pix is misleading, it looks like your door hinges would greatly benefit from a round of new door bushings, which will (slightly) help square up the door in the opening.

CCoT or $pecter has them. Order 4 spare bushings and replace you hood hinge bushings, if needed, too.

rover67
12-15-2016, 11:17 AM
I was postponing that with the assumption that I could get it close but you're right, should just do it now. Just ordered some!

White Stripe
12-15-2016, 09:28 PM
There is a guy on mud that makes brass bushings fyi.

rover67
12-15-2016, 11:13 PM
No pics of the aligned door but taking the hinges loose from the body and redoing them did it! I feel confident everything's gonna line up now so I started tearing it down. I got into the wiring on the drivers side and noted some PO wizardry that will need to be addressed. I also tore down the drivers door. Look like new latches and locks might be a good idea... time to search for that.

The pictures aren't amazing but I'm posting to help myself stay motivated.

http://uploads.tapatalk-cdn.com/20161216/13ebde4052d70eb6fe79449c22a6ac0b.jpg

http://uploads.tapatalk-cdn.com/20161216/1baa161fb0644d140afaabe503f816f1.jpg

rover67
12-15-2016, 11:55 PM
There is a guy on mud that makes brass bushings fyi.

Sweet!!!! I'll check him out!

simps80
12-16-2016, 12:55 AM
rad!

keep that ship coming Marco!!
it is looking good!

rover67
12-17-2016, 03:20 PM
Any magic tricks for getting the little clips on the dash off without destroying it?

http://uploads.tapatalk-cdn.com/20161217/cac3b12052278b31c430cff55c8beecd.jpg

http://uploads.tapatalk-cdn.com/20161217/b9797ad167d7f6c2e909e8a94f4c12f6.jpghttp://uploads.tapatalk-cdn.com/20161217/47ceb28eac71d02656e1c26d45c62320.jpg

http://uploads.tapatalk-cdn.com/20161217/06a5e9995455c53faef6773e53c2f1b4.jpg

Also are these holes for aftermarket ac?

http://uploads.tapatalk-cdn.com/20161217/44a564ea73b74fd349b83824eebb75f8.jpg

rover67
12-17-2016, 03:21 PM
Gotta fix the hacked radio hole...

rover67
12-18-2016, 03:07 PM
Figured it out, windshield frame has to fold down!

Today I took the door apart on the right side and took the harness out of the right side... also some emissions stuff. I'm gonna need some of the little wire ties that hole the wires to the body... I hope i can still find those.

60wag
12-18-2016, 04:43 PM
Lookin good. Is the tub coming off the frame for paint or staying put?

rover67
12-18-2016, 07:40 PM
Comin' off. I need to do the front body mounts which will involve taking it off so might as well. Plus it needs to be painted all underneath also.

As a side not it looks like the wire ties/clips for the harness are still available so that's cool.

nakman
12-18-2016, 10:53 PM
Looking good Marco, stay after it! Just one big puzzle... let me know if you want the box lid.

Rezarf
12-19-2016, 12:14 PM
Looking good Marco, yeah once you dial in the hinges on the door frames and cowl the rest comes together easily. Looking good, you'll want bronze bushings too not brass. Brass is too sticky, bronze is the slick stuff. Kurt sells a set of nylon ones that were really good but the on/off/on/off of the seasons killed mine pretty quick. Once you go bronze you'll be all set. I am going to try a set of the bushings on my hood hinges as my old ones are toast causing a rattle and fitment issues.

Uncle Ben
12-19-2016, 12:36 PM
Looking good Marco, yeah once you dial in the hinges on the door frames and cowl the rest comes together easily. Looking good, you'll want bronze bushings too not brass. Brass is too sticky, bronze is the slick stuff. Kurt sells a set of nylon ones that were really good but the on/off/on/off of the seasons killed mine pretty quick. Once you go bronze you'll be all set. I am going to try a set of the bushings on my hood hinges as my old ones are toast causing a rattle and fitment issues.

I use drilled out 38 special brass and it works perfectly!

simps80
12-19-2016, 09:18 PM
I use drilled out 38 special brass and it works perfectly!

helps doors to not hold so loosely


vJtf7R_oVaw

Crash
12-19-2016, 09:21 PM
helps doors to not hold so loosely


vJtf7R_oVaw

Hot band. Truly personified the term "Wild Eyed Southern Boys".

rover67
12-20-2016, 02:36 PM
That was a great song, and excellent reference!


Got a little further last night. I'm welding all the little holes that po's have put in it. Harness is out. Coolant drained. Need to weld up the holes for the AC in the firewall tonight and start on top and glass removal. Fuse box needs some attention but it's not too bad.

http://uploads.tapatalk-cdn.com/20161220/86309859490d234a0f835d3cb79035f0.jpg

http://uploads.tapatalk-cdn.com/20161220/f9b88d1c9ffb7ca0227fdfad7f8d56ac.jpg

http://uploads.tapatalk-cdn.com/20161220/5c848e9b2dda82949355f73c6bf067a4.jpg

http://uploads.tapatalk-cdn.com/20161220/6da7686a2fb533dfe50c903322026727.jpg

http://uploads.tapatalk-cdn.com/20161220/0e81bc2ed59b41115ed152fc6b5f433f.jpg

Crash
12-20-2016, 04:08 PM
Glass pulling - best done on a warm day. Pulled my 40's windows on a 70+ degree day back in late October. I'd already pulled the top's windows and was working on the windshield glass when I hear a big 'POP'. Looked over at the glass already pulled and saw one of the curved top pieces that had been in a single piece now in about 2000 pieces all over the garage floor. It had come out smoothly and easily but somehow a half hour later it shattered all by itself. Glass is cool stuff!
Keep up the good work, Marco. Your pictures are inspirational and show that the effort to keep the old iron on the road/trail is worth it.
:cheers:

rover67
12-20-2016, 07:18 PM
Maybe I need to leave the heater on in the garage for a day or so and get it nice and warm. Great idea!

akingf5371
12-20-2016, 07:30 PM
Looks great Marco! I'm getting flashbacks! Don't show me up too much!

cbmontgo
12-20-2016, 09:05 PM
Looking great, Marco.

Lastresort576
12-21-2016, 12:18 AM
This is awesome. One hopefully I'll be able to buy and tear into a 40 myself.

rover67
01-10-2017, 07:54 PM
https://uploads.tapatalk-cdn.com/20170111/9b7ef5ba3de6cc4a85bf88cbd3e9269d.jpg

I keep finding holes to weld as I take it apart!!! lots of random welding.

I got the rear door dissembled and glass out. had to cut the gaskets. Ya'll think I can still find OEM after i am ready to take them apart? I was almost ready to buy all the OEM ones today then remembered i may have them in my parts pile. Issues.

Also, striking out on a good and top. Mike says I need a period correct hood so I'm on the hunt! Classic cruisers doesn't have one but they were super cool to talk to on the phone today. They also didn't have a top so I could in sunroof mine.

Maybe I should attempt to fill the hole? Anybody tried that?

https://uploads.tapatalk-cdn.com/20170111/d48894cee2e022553ad1b888d12d088a.jpg

Almost ready to take the rest of the glass out and finish disassembly. I keep throwing things in the pile to take to the CAD playing shop. Scared to see the bill after that's done. it'll be nice to have everything replated though.

rover67
01-10-2017, 07:56 PM
Whoa sideways... sorry folks!So yeah anybody got a late model hood and top laying around?! :)

White Stripe
01-10-2017, 09:10 PM
Whoa sideways... sorry folks!So yeah anybody got a late model hood and top laying around?! :)

Their is a boat shop somewhere around Denver known for great fiberglass repair. Likely they could fix that. I don't remember what it's called, but 10 minutes on Google should bring it up.

kurtnkegger
01-11-2017, 09:38 AM
My Wife met a client at her veterinary hospital, who owns Applewood Auto Body, his name is Don Knox...anyway he used to be a Corvette body guy, and said he would be glad to talk fiberglass tops with us.

rover67
01-11-2017, 11:44 AM
Awesome, thanks for the leads you guys. I put a request out on mud and will also see where that goes.

aprosise
01-11-2017, 11:51 AM
Last time I was at Classic Cruisers, Brandon literally had a 6 foot tall stacked pile of fiberglass roofs. Right next to his 6 foot pile of intakes and 6 foot tall stack of bezels :lmao: Probably early model, but you could probably snag one up that is damaged and cut a sunroof sized patch out of one and fiberglass it in. Fiberglass is pretty easy stuff to work with.

rover67
01-11-2017, 01:35 PM
I talked to him, he said he didn't have anything for me with respect to either the hood or top. He did say he had a top, but it was complete and he didnt want to split it.

Your idea of getting one to sacrifice a patch out of we didn't discuss tho, i'll drop him a line and ask about it, great idea.

rover67
01-14-2017, 06:41 PM
I'm striking out on a hood I may have to just make mine work by updating it. Also I think I'll patch the hole in the top.
I need to scramble to finish this thing before the world runs out of reasonably priced 40 parts lol.

Anyhow, I made some progress today after having been out of town for a week. I got the glass out and the top torn down. Also started un-effing the radio hole that had been hacked by a PO. I also keep finding holes drilled for various crap like wires and brackets from PO work that I'm welding up. I think I found 8 new ones today.

https://uploads.tapatalk-cdn.com/20170115/e8c156192db760ce30a38a24b1912045.jpg

https://uploads.tapatalk-cdn.com/20170115/b2db0088f242769871bda14ea0c31ad9.jpg

https://uploads.tapatalk-cdn.com/20170115/36963b778cf16031083366d3b9f01a18.jpg

nuclearlemon
01-14-2017, 07:15 PM
hoods must be hard to find...icon is advertising that they're buying any available

rover67
01-16-2017, 11:31 AM
Radio hole:

https://uploads.tapatalk-cdn.com/20170116/054b3a6e1f95c2d02ad081a9019aec6e.jpg

rover67
01-16-2017, 05:31 PM
Old aftermarket AC holes:


https://uploads.tapatalk-cdn.com/20170116/17dea1f3950cda620c106ba7f7ea5cdf.jpg

https://uploads.tapatalk-cdn.com/20170116/fe9b2b9e0dad4ed8c788874c16939232.jpg

rover67
01-16-2017, 05:33 PM
Body comes off to do the front mounts:

https://uploads.tapatalk-cdn.com/20170116/a327f5534c6bbd32d59727a2e118b0d1.jpg

https://uploads.tapatalk-cdn.com/20170116/b758148759ce884dca2d924f7bb9769c.jpg

https://uploads.tapatalk-cdn.com/20170116/8b75584183f54888944255449f41f774.jpg

https://uploads.tapatalk-cdn.com/20170116/516e551b4be6e6201d6b62b234377c99.jpg

https://uploads.tapatalk-cdn.com/20170116/8f75528c6393bc82b1c1545582b659a1.jpg

rover67
01-16-2017, 05:35 PM
I need to remember that the gas tank, heat shields, and vent lines go on before putting the painted body on:

https://uploads.tapatalk-cdn.com/20170116/fd7d7323a8d946e07136e35d62be15f1.jpg

rover67
01-16-2017, 05:36 PM
Exhaust and heat shields as well as wiring also:

https://uploads.tapatalk-cdn.com/20170116/37b7ff7546d8e519e7d16894d3ec8fbb.jpg

https://uploads.tapatalk-cdn.com/20170116/9419ac98b6ae3032f7407960b882150c.jpg

rover67
01-16-2017, 09:23 PM
Got all the exhaust pulled, all the little brackets, brake lines, and doodads. I found a pinched rear brake line that looked near failure. I Just have motor and axles for the frame to be ready for powder. More and more parts in the pile for the platers dang it's gonna hurt but I think it'll be a nice touch.

aprosise
01-17-2017, 07:35 AM
Looking great Marco. Wish I had the space to tackle my 40 projects but I may have to pass it on.

akingf5371
01-17-2017, 04:17 PM
Looking great! I think using a tractor is cheating, you have to call your friends over like I did and pay them in beer!

OilHammer
01-17-2017, 10:20 PM
Body comes off to do the front mounts:

https://uploads.tapatalk-cdn.com/20170116/8f75528c6393bc82b1c1545582b659a1.jpg

NICE!!!!
That's the point where I wind up pausing for a beer and then realizing, "OMG, what have I just done?!" Lol. Man, you are FLYING on this now.

rover67
01-17-2017, 11:25 PM
I think I reached that pint tonight... motor out and clutch out.


It had a horrendous rear main seal leak as well as a leaky oil pan gasket. Those had to be addressed. Have a new clutch to go in just need to call cruiser outfitters for associated gaskets and seals. I'm wondering if I need to take apart the tranny and t case to re seal them... both seemed leak free and in stellar working order... hmmm.


https://uploads.tapatalk-cdn.com/20170118/dd7357f66ed1abdfdd635e6ec208bf5e.jpg

https://uploads.tapatalk-cdn.com/20170118/1aff3aa1b2240f9d03c6250efa594e35.jpg

wesintl
01-18-2017, 03:27 PM
whats wrong with ye hood?

simps80
01-18-2017, 09:47 PM
thread is full of awesome, so cool Marco!

rover67
01-18-2017, 11:07 PM
Frame is naked and motor on stand. I ordered a bunch on stuff from our friend at Cruiser Outfitters to get the tranny and clutch done as well as the oil pan gasket and rear main.

https://uploads.tapatalk-cdn.com/20170119/c66e349d492a2f031f726accf7194c19.jpg

simps80
01-18-2017, 11:23 PM
50075

Lastresort576
01-19-2017, 01:42 AM
great updates!

rover67
01-19-2017, 09:21 AM
whats wrong with ye hood?

It's from a slightly older model, so it's missing the stainless pads where the rubber from the bib meets it, and it also looks like the bolt holes for the windshield brackets are slightly forward of there they need to be.

I think i'm gonna modify my hood to make it work since I measured everything and it looks like Toyota used the same base hood piece with holes moved and those plates added.

rover67
01-19-2017, 11:41 PM
Body mounts were either paper thin or rusted out on the frame. That's now fixed!! Frame is ready for blasting and powder!!

https://uploads.tapatalk-cdn.com/20170120/41dd2aaeae468ba4861071a269a99c2c.jpg

https://uploads.tapatalk-cdn.com/20170120/ca4f9b8f8765f65ec109211c7031da24.jpg

https://uploads.tapatalk-cdn.com/20170120/ec199c77aa131fe6515f3d5297ea9c6e.jpg

https://uploads.tapatalk-cdn.com/20170120/716fbe5d217d17570e9a2225cff32e15.jpg

rover67
01-20-2017, 09:53 AM
Dropped the flywheel off at NAPA today. I made it a point to emphasize that it needed a 0.020" step. Fingers crossed! I have a fresh Aisin Clutch kit ready to go in and the rest of the stuff should be here today to get the pan and rear main R&R'd.

Next up, finish front mounts on body and modify hood.

MDH33
01-20-2017, 11:11 AM
Really enjoying watching your progress Marco! Keep it up.

rover67
01-20-2017, 11:33 AM
Cool, I hope the posting frequency is not excessive. I got tapatalk and its easy to do some stuff and throw up a photo with my phone while i'm in the garage.

OilHammer
01-20-2017, 11:42 AM
It's motivational. :) Not excessive