1982 FJ40 Restoration

[rover67]

There's a place in Denver that I think does galvanizing. I discovered it during extensive googling. I was planning to call them up actually just to double check. I worry about getting the galvanize into the threaded holes and warping of the frame itself mainly. I had a Rover that I had parts re done on and it was kind of a nightmare to tap the threads out but maybe it's an option here. I'm gonna check.

Do you have any experience and/or suggestions? Any is welcome as I am trying to "do it right" for sure.

 

[White Stripe]

Quite a few 40 guys have galvanized their frames. U may have to chase out some holes afterwards, but I can't see that taking long. I have never heard of galvanizing warping a frame. Only thin sheet metal.

 

[rover67]

Started work on the drivers side floorboard and frame mount. Went better than I thought it would.

 

[rover67]

Front axle was a gimmie I rebuilt that right before I quit driving it so all it took was some pressure washing.

 

[rover67]

Some clutch parts from Kurt. New Aisin master and slave. Didn't have issues before but figured I might as well hedge my bets since I'm doing the rest of the stuff. Flywheel machined with the appropriate 0.020" step. New Aisin friction disk, pilot and throw out bearings. I installed the pilot bearing before putting the motor on the stand.

 

[SteveH]

Great looking floorpan and welding work!

 

[nakman]

Looking good Marco, keep after it! And holler if you need a hand- can't wait for the '82 40 run!

 

[rover67]

I got the drivers side mount finally done last night, I dissassembled the windshield, welded up holes and cracks in my hood, and loaded the body parts in the 4Runner. Drew stopped by this morning before we went to work to help me flip the body so I could do the passenger side body mount and floor board and to help put the frame in my trailer. I had bugged Mike about using his bigger trailer but it looks like it's gonna fit in my small trailer.

I called Blast Tech today and left a message to warn them I'm coming Friday, I called them earlier in the month and talked to them they seemed super cool. I'll try back later. Feeling a bit nervous I won't get the last body mount done but I guess I do have two nights and now that is really all that's left.

 

[Rezarf]

Looks great Marco, and this is hardly a "refresh" at this point.

According to craigslist, "frame off restoration" means new shocks.

 

[AdamKFarmer]

Looking good Marco, keep after it! And holler if you need a hand- can't wait for the '82 40 run!

I like this idea!

 

[rover67]

Honestly I think rising sun has like 10% of all the 1982 FJ40's ever made.

Nak, Ken, Adam, Me, anybody else?

Ok maybe more like 1%

We should do a group photo when this one's done. Maybe Cruise Moab.

 

[rover67]

Drill guide to relocate the hood brackets and hold down for the windshield. I made it frame measurements from Adams '82 hood and double checking with my brackets. This and the stainless pads which I'll add later I discovered were the only differences in my hood and the late ones so boom later model hood sourced! Thank Toyota for using the same stuff for years!

 

[rover67]

Phew. Passenger side body mount done. Dare I say body work complete?

 

[AdamKFarmer]

Amazing work!

 

[subzali]

Likey likey.

 

[rover67]

Normal work has been involving lots of time in various MRI rooms with magnets up to 3 tesla so I've been more vigilant about proper eye protection lately. I've been digging Al's old dirt bike goggles for this type of work they are muuuch better than regular safety glasses for keeping fine metal particulate out of my eyes.

 

[Crash]

Looking good Marco. Really good thought on using old dirt bike riding goggles for keeping out the fine crap. I'll have to search my old gear bag, the one with the 1st gen Scott plastic riding boots, first gen Bell Moto helmet and a bunch of other late 70's and early 80's enduro stuff to find my Scott goggles with the bullet proof lens. Probably haven't been through it in 20 years. Scott used to have a display at all the Rocky Mtn. Enduro Circuit events where they would shoot a 22 cal. rifle directly at the lens and the bullet wouldn't penetrate it. The lens would scratch super easily but wouldn't break so they would be good for grinding purposes where a shield is a little unwieldy and/or you needed to keep metal shavings and dust out.
My 40 isn't an '82 but it does have the '83 tub. Would that count to make your photo of '82?

 

[rover67]

My 40 isn't an '82 but it does have the '83 tub. Would that count to make your photo of '82?

absofreakinlutely!

https://youtu.be/dOV5WXISM24

 

[Rezarf]

Go Marco Go! Lovin' the progress!

 

[DanS]

Very nice looking Marco!

Really good thought on using old dirt bike riding goggles for keeping out the fine crap.

Safety goggles, with straps are the only way to go.

Get good ones (roughly $25) and you will put them on and never take them off in the shop. They last me a half year or so each.

I kind of think I might have to buy a set of these:
https://www.amazon.com/Garrett-Wade...id=1485496421&sr=8-34&keywords=safety+goggles

But here's the type of things I'm talking about:
https://www.amazon.com/Pyramex-Safe...id=1485496852&sr=8-37&keywords=safety+goggles
https://www.amazon.com/Pyramex-High...coding=UTF8&psc=1&refRID=MX591TN59TG7EF6VHJW5
https://www.amazon.com/Pyramex-Safe...coding=UTF8&psc=1&refRID=MX591TN59TG7EF6VHJW5
https://www.amazon.com/Crossfire-91...id=1485497002&sr=8-61&keywords=safety+goggles
https://www.amazon.com/Uvex-S0620X-...id=1485497002&sr=8-64&keywords=safety+goggles

The good ones never fog on you, and aren't even a little uncomfortable. The only problem I have with them is that I can't find a set that works well while wearing my glasses--only my contacts. It's actually one of the biggest reasons I wear contacts so often, because it lets me wear the goggles in the shop, and when they are that comfy I am never tempted to do anything without them.

Dan