76 FJ40 Wheeler Build

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
So, I've been having major problems with my fuel getting heat soaked, making my fuel pump really loud. It got bad enough that my fuel began to boil driving up from Colorado Springs to Woodland Park. I'm sure the higher EGTs from pulling uphill combined with the change in altitude did not help either. I'm going to also try to run a lower octane fuel for a bit to see if the lower ethanol content helps as well.

I wrapped my exhaust under the floor boards to see if I can keep the tank cooler.

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If this doesn't solve it, I will be building some aluminum air-gap heat shields for under the floor as well. That should solve this problem completely. I don't have a ton of time right now with finals and other projects, but that is on the list. I'm really glad my exhaust is super easy to pull and replace.

I also wrapped the header a bit where it comes close to my fuel line. I have some wrap that is susposed to go over the lines coming as well. I'm sure there is some heat transfer through the injectors, and I need to replace my gasket for the sniper because I have some pretty bad IAC whistle in 4th and 5th gear when I start to load up the engine, so I will probably add a spacer in there to try and keep the sniper cooler as well.

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I still need to give the cruiser a bath since it got pretty dirty at Cruise Moab, but it's been cold and snowy, so that will just have to wait.
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
So, big, not so great, update:

Last Sunday I decided to go run Chinaman Gulch with some of the Rising Sun 4x4 guys. I decided to drive the cruiser out and back to add some highway miles to break everything in. It was a ton of fun, I scared my mom a few times, and got to drive the cruiser which is always great.

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With no radiator shroud, and a lot of slow, uphill crawling, I was running really hot. I was able to keep it under control with a lot of water on the radiator and the heater constantly running, but on the final descent out, I started to really gain heat that I could not seem to get rid of. Once I got to 220, I stopped and shut off my engine. Looking back, not the smartest move shutting off my engine. Now, at Cruise Moab, I added a tap to my lower radiator hose to get my heater because I thought that I needed suction through the heater core, so I cut my lower hose and added it in. It needed pressure, so I just added some exhaust tube to rejoin the two pieces of radiator hose as a quick fix to keep me running for Cruise Moab. When I stopped and shut off my engine, opened the hood, and started spraying some water on the radiator my lower hose blew off. It covered my shoes really well and burned my left foot. I'm really happy I was wearing jeans. It burned my left foot enough that I got some blisters, but it's fine now. Now, the patch that I added had no flanges, and the pressure from the sudden heat buildup, and the shutdown of the engine probably overcame the clamping force of the hose clamps and slid the hose off.

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I wish my lower hose was the only problem that day. I'm guessing we easily added 3+ gallons of water to the rad and block, and I still had to add almost another 2 when we got back to the Gunsmoke. I knew that hose was eventually going to bite me in the ass, and it did. I have plans on trying to keep a bit cooler on the trail, but that will be happening once this is driving again.

Driving home went great until it didn't.

Due to my foot, my mom offered to drive, and I begrudgingly accepted. Brad (@Dirt Claude ) was kind and offered to follow us back to make sure nothing else happened, and I'm really glad he did. About 2/3 of the way home, right before Wilkerson Pass, we started smelling something burning occasionally. It kind of smelled like coolant, so I thought that there must have been some dripping of the block onto the exhaust and the wind had shifted, causing us to smell it. Pretty suddenly, Brad sped up and motioned for us to pull over, as we were really burning something. I hopped out, and all that I saw was a stream of oil pouring out of my exhaust flange. I thought for sure we had toasted the motor. It was really strange, as oil pressure was great as we pulled off, and there were no other signs of something failing majorly. I start looking around, and everything is covered in oil. It soaked my cab under the mats and everything from the bell housing down on the left side was covered. I start feeling all of my cases, and they all feel exceptionally warm. I pull the fill plugs to see if there is any oil left that I could reach. Nope. Somehow, my Trans/Toybox AND transfer case all managed to lose oil. I'm really glad Brad was behind us, as my mom would probably have not felt/heard the change in the cases as she was driving, and they probably would have gotten to the point of grenading.

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I'm completely hypothesizing here, as I have not had time to start the autopsy. Finals week and preparing to move is killing me. Now, the Trans/ Toybox is expected. They partially share Oil. The NV4500 should still have some oil left when I drain it. I have no idea what to expect from the Toybox. The Split case is very unexpected. Here is my theory. I've had very small amounts of oil slowly go missing from my split case. I had no idea where it was going, and assumed that there was a small amount going out of the flanges when they started spinning, as there was a small oil ring above the rear flange. I'm now betting that the seal between the Toybox / Split case failed at highway speed and that it was probably slowly leaking, causing me to lose the oil in there. I have no idea why that seal may have gone bad, as they should have been rebuilt by a VERY reputable builder (@orangefj45, Valley Hybrids). I've heard that the toyboxes absolutely hate being overfilled with oil. When they get overfilled, they puke oil out of the shifter. So, I'm assuming that the toybox got overfilled, got angry, and puked oil everywhere. What that doesn't explain is why so much oil came out. I easily watched half a quart flow off the exhaust, I probably have another 1/2 quart in the cab, and I have no idea how much I lost on the road / everywhere else on the car. I wouldn't expect that an overly fully toybox could purge that much oil that quickly out of a shifter hole. Even if the boot came off, I'm not sure how easily that much oil could get out of a quarter-sized hole. Who knows how much came out, my panicked state of mind was probably not thinking that clearly. I'll have to measure when I drain everything. I'm sure that it is either the Toybox or NV that had a majority of the problem, as it was all the super expensive synthetic gear oil that the NV requires that was draining everywhere and was coating the cab.

The really strange thing is that there were no symptoms at all leading up to the failure. There were no strange noises, whining, clunks, vibrations. Nothing. I could see that much oil coming out if cases started to separate, but I would assume that there would be several holes in whatever case started to separate. All the cases were torqued and loctited as well, so I'm pretty sure they aren't coming apart. All the drain/fill plugs were tight and accounted for, so I'm doubting one fell out and replaced itself. Even if a gasket fell out, which is pretty much impossible, I doubt that that much oil would come out that quickly. Anyways, I'm not 100% sure what fully happened, especially since there were no symptoms before the problem. I'd love some other theories or ideas to what failed if you have them.

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Anyways, Brad, being the great guy that he is, helped me limp to a turnoff, and then drove us home to grab the truck and trailer, and was even kind enough to go back and help me load. 11/10 I would break down with Brad again. Also, major thanks to everyone that donated water and everything else to help get me off the trail.

So, the cruiser drives, and it drove on and off the trailer and through several gears getting off the highway just fine, so I don't think that there is any major damage in any of the cases. Once I get up to Proffitts, I'll probably drop everything and inspect just to be safe, which I'm REALLY not looking forward to, but at a minimum, there is probably going to be a new seal going into the Split Case, and I'm probably going to be isolating the Toybox from the NV, as it really doesn't need to share the oil. It's a 1:1 straight through to the Transfer, and only really builds heat in Low, which is really only used for short periods on obstacles.

Anyways, it was a mostly fun day with some disappointment mixed in, but it could have gone a lot worse.

-DJ
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
A few little updates of things.

I saw this guy in town.

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We tried stuffing 2 cruisers on a trailer. It barely fits. You need at least 21' of deck to get two on.

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I also replaced my air filters with something a bit stubbier, so they clear the master cylinder. Some more updates to the engine will be happening soon.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Got the hard top on today for transport.

I'm really happy with the look. I think it will look even better with the hard doors, sliders, tube fenders, roof rack, rear tire carrier, and paint.

🤣

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Still a lot to do, and some fixes to be had. I'm thinking I am going to move my wheel wells up before final paint.
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
I've been at my new job for about a week now, and have finally found some time to keep working on the cruiser. I added a 1-inch spacer to my sniper to hopefully help with fuel overheating and a few fouling issues I have been having. I got some new AN fuel lines run and wrapped to move it from the exhaust and added a 180-degree thermostat. I'm hoping to get a shroud and some electric pusher fan mounts made and installed within the next few weeks to help with cooling issues.

I've been looking and designing things that I want to get done this summer, and one of them is a super low profile, prerunner-ish, roof rack.

I knocked the CAD out today, and this is what I came up with. Let me know what you think, as I'm always looking for changes to make it look better.

Front

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ISO

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Sides

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I added some TEQ logos to add some flare and differentiation from other racks.

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Top

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Anyways, I'm planning on getting some front fenders, sliders, and rear tire carrier built this summer and finishing the paint and body of the cruiser.
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Boy, it's been a while....

A lot of things have happened in the past several months, and I kinda forgot to update this thread. I've started school again, so I'm back to having more free time, so here are some updates.

Door sheet metal done. The doors took a while to clean up and patch, but they turned out ok.

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Since the toybox decided to puke oil all over my cab, I decided that I was going to raptor line the floor pan since I was tired of worrying about my paint. Best decision I ever made.

We mixed up some paint here and tinted the liner to match. It came out to be very close.

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The tint is a really close match in the sun, but is missing a little blue in the shade.

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To try and insulate my tank even further, I deided to add a rubber pad to the floorboard above the tank. I'm hoping it helps.

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The hump turned out very nice. It matches this time, unlike the old paint I had on it before.

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Reassembled.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
I got my rear box lined as well since everybody ends up walking on it.

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Inverter installed.

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New severe duty fan clutch and high flow 6 blade fan installed. It really sucks.

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Beginning of the fan shroud.

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Some terrible TIG welds. It's my second time ever really doing aluminum, and I've only used a TIG like 5 times before, so I'm assuming I just need more practice.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Ugly tig welds....

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As a note, this combination of shroud, clutch, and fan has completely solved all my overheating issues.

I've been crimping up some new A/C lines. I just need 1 more fitting and I can get it charged today.

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Our head fabricator, Alex, complaining that my rear seats are too small, and the cage is too close to his head.

For reference, he is ~6'5". I'm not planning on taking anyone taller than 5'8" in the back. Too much bonk possibility on the cage.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Rear wheel well move.

Taped out.

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Moved up 2", and backwards 2".

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Looking much better.

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Driver Side moved.

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The guys here convinced me to boatside the 40 to make more room for the sliders, and I'm really glad I did. It really opened up some extra space to add in sliders, and it allows for me to keep the same breakover angle.

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It took a lot of whomping on the body to get it straight enough for mud, but there is a max of about a 1/16" on the body. I'm currently using 3M Platinum Plus body filler.

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Side done.

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Doors and top sides primed.

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Body fully blocked and ready for primer.

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Body primed.

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Hood primed.

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About 5 hours of blocking later, and the body is ready for final paint.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Finally, paint! The paint is PPG Delfleet, so I couldn't get a code for the Audi Nardo Gray, but the chip I used is basically indistinguishable from the Nardo Gray.

The Delfleet is an extremely durable paint, ment for fleet and semi applications, so it is much more scratch and chip resistant than most paints. It's somewhere around 60% solids, and it's a PITA to shoot without some practice. I'm glad I convinced our head painter to paint it for me. :)

The body came out pretty dang straight, so I am happy. For the amount that I rushed this, it went well.

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Natural light really brings out the blue in this color.

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Finally back out in the sun.

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I stuffed some OEM badges on.

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More paint.

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Doors on and hardtop sides on.

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Hood and aprons.

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Amby doors on.

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Back in the sun.

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Rear Aux lights finally mounted.

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Glass back in, and back to factory running lights.

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New CB antenna mount.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
More paint, Cygnus White, this time.

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Windshield, top, and bezel installed.

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My Bowfin Cruisers roof rack that I won last year. I'm not sure I love it on this 40, but the design is great, and it's growing on me.

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Alex was really kind and folded up some sliders for me. They are 3/16" plate, gusseted.

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Truman, being the center of attention, as usual.

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Mounting these was a massive PITA due to my exhaust, but I was able to get 3 non-bent cross members welded to the frame. Two are 1.5" x .120 wall DOM, and the other is a slightly notched, vertical standing 1/2" x 2" solid flat bar.

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Tube fenders.

I got some pieces bent, but the lengths and angles were just a tad bit funky, so I had to shorten and notch it some.

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These have tube clamps on both ends so everything is fully removable.

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One side skinned.

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I really like the way these look, but they are a bit heepish.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Sliders and tube fenders painted.

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The first use of the roof rack, to transport luggage to SAS 5.

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At SAS.

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A few of my favorites from SAS this year.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
I went to the Gunnison Car Show with work.

A few pictures from the show. I was next to Kitty, and it made my cruiser look really small. We had a really great lineup, with several 40's, two 60's, a 100 series, a minitruck, and a Toyota Epic 22 Boat, aka the 'Toybota'

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I ended up driving Kitty back with my sister's BF. He had a blast. It gets all the looks.

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Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado

Notyourmomslx450

Cruise Moab Committee
Cruise Moab Committee
Joined
Aug 4, 2014
Messages
3,236
Location
Westminster
Outstanding! The 40 looks great!
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado

brettf

Lifted
Joined
Feb 13, 2017
Messages
110
Location
Golden
Super impressed with the work you've done. Great looking 40 and it looks like it performs awesome too. This thread has been great to follow, keep the updates coming as you can!
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
Super impressed with the work you've done. Great looking 40 and it looks like it performs awesome too. This thread has been great to follow, keep the updates coming as you can!

Thanks! There are a few minor adjustments to the font links that I need to get done to help it climb a bit better, and possibly a suckdown winch, but it does pretty good.
 
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