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1969 FJ40 hot mess to minty fresh or..spring green fresh?

simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
I joined facebook to document this.
but I've tired of facebook. So i'll be transferring all this over to here for future reference.

A bit of background:
a buddy decided he wanted to do a group project to rescue an fj40 and preserve it.
Well...
yea.
2 years later it's almost done. This will be going up for sale when its done, which is unfortunate because the only thing I have more invested than money in this deal is time...but I can't keep 4.

the cool part is, this was a very original 1969 fj40 that was used in a shop class, but neglected for a while. I am proud of the results, and this will make a VERY NICELY preserved fj40 for someone to be able to use for its intended purpose.

So here it is on day 1.
treeroot and John drove to wyoming to buy this thing in March of 2016..around May of 2016 is when it wound up in my physical possession to house the rebuild or maybe June...Anyway its been a long process, and like I said the results are cool. I'll never do this again though.

One of the things I like about this early 69 is some of the early character items I like, for instance the front turn signals, the steps with the trim rings and vinyl, the door hardware that is better in my opinion than the later stuff. The metal is nice and thick, three on the tree etc.

a keen eye will spot the sweet sheet pop riveted in around the sill

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note the rad trucker poofy finyl door panels and sweet blue upholstery (and also the pretty nice fj40 oem floor mat for a later year, but rare and hard to get a hold of one that is servicable, so a nice addition)

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
brakes

first order was to get the car to stop, the brakes didn't work at all to begin with. The brake overhaul included rebuilding and honing, de-rusting, and painting all 8 wheel cylinders, one new brake line was required, new brake master.

After brakes, the clutch was inoperable. This required new clutch master and clutch slave cylinders.

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
carb

After brakes and clutch, the Land Cruiser was closer to running, driving, stopping, shifting...
Up next was a carb rebuild on the Aisin carb...Mike D did this.
If you break off the fuel outlet fitting from the pump, some years are straight some are 90, but both are 13mmx1.5 by 1/8 BSPT...kind of a rare fitting...

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
body work

doesn't look horrible with the stainless panel riveted in there by the P.O., but we knwo what's in there!!!
also you can see the non-oem truck-lite driver side light that was used, and the bracket hacked up to use it, since it is larger diameter than o.e.m. light.
sweet trucker vinyl again.

after the carb, clutch, and brake work, it was a driver.
the owner (our buddy) got collectors plates. this was probably april of 2016 around

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
preliminary electrical

I went through some iterations troubleshooting the electrical. found all the shorts,
soldered them up, got the gauges working etc. soaked the fuse block in vinegar to clean it up, put in new fuses etc. pulled a big a** pile of P.O. wiring out of the harness that was scotch locked.
eventually I went through another phase of this, more recently and replaced all of the oem sections that were compromised by scotch locks etc with new parts from coolerman.

but after the initial work, I got the horn working with an aftermarket relay, the gauges, then came the lights.
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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
lights work

the rear truck lite tail lights didn't function and were ugly, and I planned on replacing with OEM anyway, the P.O. had hacked up the tail light brackets. eventually all these lights would be replaced, but I wanted to get all the lights working.

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
body work 1

started small on the body work to get some experience with this particular welder and metal..

took off the 3 legged trucker mirrors, welded the holes closed.
then plugged this giant hole on the cowl

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
rear sill begin

started the rear sill work by stripping the pop riveted cover off, then cleaning up the rear xmember, removing all broken bolts, then tapping holes etc.
in anticipation of what lied ahead, made a new 240v extension chord, not pertinent to the build, but I like the pictures.

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
next was cleaning up the metal back to good metal cutting out all the rust.
got new body mounts for the new sill.

The new sill was made by awl_teq in Canada from ih8mud. his stuff is so pure. very nice pieces he makes. you have to wait a while, but the product is worth it.

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
once the rear sill was located and squared, holes for latches and hinges square to body location etc, bolted it in with new mounts to start locating remainder of patch work that needs done on rear skins.

by now, the welding new was yielding good results as long as I cut the bad metal way back into good, I could get it to do what I wanted

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
sill cont

then Mike D showed up and showed me up on panel shaping by hand and welded in this right side sweetness this crap is more art than science with hand tools, and vises. if I were to do this again, a good press brake, sheer, and other tools would be a must have just for time savings.

rear sill for the most part done.
Next step was to locate hinges for barn doors, weld in scab plate on back of rear quarters (months later lol) and mount up the hinges.
But before that, finish rosette welds on rear sill cover and final clean up on skin panel welds. put the new tail lights back on and took it for a drive. It is way more solid now with the rear repaired.

about a week later I final welded the rosettes etc

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subzali

Hard Core 4+
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Aug 22, 2005
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10,320
Location
Denver CO
x2 :bowdown:
 

SteveH

Hard Core 4+
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Aug 10, 2006
Messages
2,917
Location
Colo Springs
Great documentation of the repairs. Nice work!
 

kurtnkegger

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Jan 24, 2011
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1,508
Location
Denver Burbs
This site has been without 40 porn for WAY too long!! Thanks for posting Mike! Loving the work
 

simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
trying to keep the timeline in order some...this is about late July 2016

John helped unscrew the original battery set up.

they had this messy dual battery tray in there, half-ash bolted to the original
so we undid all that, then found an extra 80 series hold down, cut it down and welded it to proper size... painted it all,
turned out good

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View attachment 54536

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
door

then I fixed this busted door limiter.
it had succumbed to enough wyoming wind at some point to rip the metal out of the door.
so I patched the door, made an new limiter, welded it together.
it's fine. also late july 2016

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simps80

Rising Sun Member
Joined
Jan 22, 2009
Messages
2,715
Location
Arvada, CO
rocker

tried my hand at this rocker patching.
eventually this all got redone again as a whole, but it was good practice for hand fitting the metal
it's funny to look back at the early work which was later re-done to see the progression of the thought process, etc.


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