FJ4overland

[JPaul]

This is making me really think about getting an FJ40 as a project.

 

[SuperBuickGuy]

it wouldn't be the first time that a project I was doing encouraged them to take on one of their own - and it's totally the reason I post, if I can do it anyone can.... it takes awhile but it's worth it in my opinion
steering


opened up the hole a bit and got the engine harness into the cabin


it's waterproof so I think this is where I'm going to put the fuse panel....


​

 

[SuperBuickGuy]

misc stuff
the water pump is leaking, and there's a sound like the timing chain is rubbing on the timing cover.... both require draining the system...


onto adjusting valves


and buttoned back up

funny, I couldn't figure out why the motor was turning over so hard.... I suppose it being in gear would do that...

this, is an awesome purchase.... perfect flares every time


now you see it


now you don't


and I still don't think I have enough volume going to the slave cylinder... the FJ40 cylinder is ~5/8, this one is 7/8, the recommendation is 3/4.... problem is I have 1 1/4" travel available on the slave and only using about 1/2 of that (5/8").... which is a volume issue. but more playing with it is going to occur. I have several master cylinders, so next will be a 1" bore.... and we'll see.

 

[SuperBuickGuy]

onward
gas pedal


chop, reweld


now on the opposite side


and other stuff, blacking out the badging and the marker frames


the markers aren't quite done yet, I need dual filament bulbs because I eliminated the side signal off the grill

time to start fitting the center console...
​

 

[SuperBuickGuy]

New water pump, painted.


installed,


and picture for posterity of the belt routing



and found the source of my scraping sound

bent up and away from the balancer

yeah, stupid stuff

got the right(ish) hose for the hydroboost

and stole the heat cover off the wrong one...

and my tube bender needs a new bolt - weird, this $5.00 bender broke bending 3/8" steel line.... pos right?


first fit, maybe now some might see the reason I wrapped the headers.... smart, no?


with a little extra bending, it fit

and covered...

also the steering screws were drilled and installed with loctite and jam nuts

and ran fluid through the system


in other news, two extra holes after painting... dammit


also installed my new chrome valve covers


which replaced the very bent ones... and they're chrome, and cheap, and heavier gauge then GM covers... mock if you must, but be certain if you mock you best be someone who has finished more projects then I have... :grin:

 

[JPaul]

I think there is nothing wrong with chrome on a muscly V8. Especially when it's on a classic vehicle.

 

[SuperBuickGuy]

time to modify the tank for efi


I really need to get my dies for my brake - I should be able to do 1/2" bends... but alas, no




edges trimmed


test 1


and drilled for the fittings


hopefully finished tomorrow

 

[3Hummers]

You getting anxious to finish this project and start driving it?

 

[SuperBuickGuy]

I know this sounds odd, but yes and no... I love building stuff, I hate being disappointed that it doesn't match the image in my head when it's done (which is why this is the 8th FJ40 I've owned)...

 

[SuperBuickGuy]

mostly finished with the pickup/tank













there it is.... whole system


once I got it in place, I had to bend the float over to clear... no biggie, it works


did I ever mention I never got the keys with this vehicle?


there it is, I still need to seal the access then pressure test the tank to be sure there's no holes...


I still don't know what I'm going to do about the holes but I do need to make inner fenders and this is step one

 

[SuperBuickGuy]

Today
run throttle cable




still need to find e-clip to hold it on....

clean up the sealing surface


and there it is with gasket... I still don't have the sealant, so I'll wait until I have that before making it tight then testing it for leaks

and I'll wait for another elbow to replace the one I just broke (dammit!)
fortunately, I could run one



lines run



nutserts inserted


hump installed


because I tied the bars together at the base, I had to move the vent


and moved


all lug nuts on.... I need to do an alignment, so that's kind of next


and get the front end installed... but here it is


​

 

[scoreh3]

Getting closer to us seeing the road test !

 

[SuperBuickGuy]

starting here


spacer for air cleaner... I hate it and I'll make it out of something more durable then plastic


heater is sort-of in


yeah, I know, I was going to use the firewall... get over it, or don't.... I don't care


and now my clean rig looks like an explosion of wiring...


ah well, must make a mess to make it finished.

 

[SuperBuickGuy]

Sandblasted this


didn't have enough sand for the surround... ugh

finished up the air line




and spent time wiring... nope, you can't tell at all


though I did learn that europeans use white for ground... which would have been helpful to know. Fortunately, despite a complete lack of instructions online, some helpful Russian posted a youtube video where you could see how he connected the wires.... yay Russians.

we won't talk about how much time I spent with those lights.

 

[SuperBuickGuy]

random work
stripped the windshield frame and the front panel


halogen light bad without vent in the back


hmmmm, maybe move forward (note the use of special blue welder's tape? I bought that off Pirate)


and I put a cover over the wires, and will have to redo one wire ... ugh


back to the frames


about 1/4 of the way there.... I've done the easy stuff now I have to sand the corners and make sure that no stripper ended up inside the frame


and the other two bits


and started by etching the inside of the tank....


not pictured, I finished the fuel lines so once I line the tank the fuel system will be done.

 

[SuperBuickGuy]

a bit of tank lining


pretty, no?


a bit more of wiring... stupid elephant


and the passenger side frame painted... hopefully Sunday I can get the passenger side done...


​

 

[SuperBuickGuy]

a bit of unexpected time to dink on the '40
line the bottom


seal the pickup and return


connect lines


get sidetracked by honeydo


missed it by this much


oh well, either I'll move the seat over a bit or grind the offending plastic...

start button installed


and then I wired for awhile.... I hate wiring
​

 

[SuperBuickGuy]

Starting here


a ways to go here


looking better here


and now here


there will be a switch, though it might not be this one


and in answer to a question - this is a rough idea of what the sliders will look like

​

 

[SuperBuickGuy]

Narrowing in on vroom vroom
wiring the battery box (what a pain, I should have made it bigger)


if you look, you'll see there is power to the dash and the two gauges hooked up work.... not sure the oil pressure is right - but it works


and plumbed the heater core so I could refill the coolant.


I wired a switch to the ignition and the fuel pump makes noise - which says the computer is working since that is what turns it on...

tomorrow I'll pick up gas and see if it will actually make some noise
​

 

[RamRod]

Good luck tomorrow!


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[SuperBuickGuy]

remember all that brake fluid? I figured I'd have the fire dept. here soon


clearing up a bit


best of all it drove to this spot
http://vid230.photobucket.com/albums/ee308/stoneshrink/fj40/P2170002_zpspfwzqcvx.mp4

 

[SuperBuickGuy]

I've now driven it and..... oh boy, shocker, it drives quite nicely (don't tell Pirate, to them it's the stupidest build ever, dumbest build ever, will never get done build - we wouldn't want to blow their little minds).... I've not yet aligned it other then ball-park-tape-measure. But up to 40 mph it drives straight, doesn't bounce steer at all - which, to me, is pretty remarkable on bias-ply tires.

we now know it's equal to my wifes JoKe


no sway bar, yet, but again it drives pretty nicely


as you can see, some more assembly is required - but now it's no longer a static ornament and my worry about whether or not I got the geometry right is gone




and just to remind.... August 13, 2014, this is what it looked like


​brakes work well too, goes through all the gears.... it's almost like I know what I'm doing

 

[cgalpha08]

That's pretty bad a $$

 

[RamRod]

Looking great Aaron!


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[Big2dabank]

Great job and awesome workmanship. I hope your having more fun than frustration, I know my patience and sanity would not let me tackle something like this.


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