Started on the restoration of my FJ40 yesterday.

[JLPurcell]

Started the tear down of my 72 Land Cruiser yesterday, it is a pleasure to take a vehicle apart that is not rusted together at the nuts and bolts. So far sourcing parts looks to be much easier than it is for the Z. We will see as I get deeper into the project.

[siteunseen]

That's a fine damn site compared to the newer ones.

[ajmcforester]

Love it I bought a 2007, but I always wanted one of the older ones. I just never found one that wasn't all rusted up, or modified in a way that makes it hard to get it the way I wanted it. A lot of the times the front ends were changed out, the wheel well were overly cutout and/or they were more rust than steel.

I like how yours looks very simple and original like, and my favorite tire for my off-roading the BF Goodrich TA KOs

[JLPurcell]

I just got back in from the garage, in one full day I have: removed all of the front end up to the firewall, removed all of the interior, removed the back swing doors and swinging spare tire carrier, I have ran a tap in all of the threads to clean them out, removed the white portion of the top and drilled out all of the screws fastening down the aftermarket roof rack and rails. I will post some photos soon. I was originally looking for a Datsun Patrol and had the same issue with not being able to find a clean survivor to start with. While looking for a Patrol I found this FJ and it is completely rust free and all original. It came from Sonora county, CA and was a one owner vehicle until it was bought from the family for resale on ebay.

[JLPurcell]

Photos of the start of the project:

[ajmcforester]

It looks like you got a good one, your definitely lucky. The Patrols are so rare that it would be like restoring a 2000GT, you need to fabricate all most al the broken and missing parts. With the FJ40 you can buy almost everything new or used.

[JLPurcell]

The body is back and at the body shop. The body is rust free and that is priceless!

[djwarner]

After working on Rustprone Datsuns, this looks like a joy to work on. BTW Keith Martin mentioned in his latest blog about visiting Concours of America where a restored FJ sold for $68,750.

[JLPurcell]

Almost ready to close it up! Waiting for a few parts from powder coat and plating ;-)

[ajmcforester]

nice shell, not everyday do you find a body on anything that old in that shape and ever rarer on a 4x4 legendary vehicle.

[JLPurcell]

I am working to get the frame and drive-train caught up to the body so I have a place to sit the tub when the paint is complete!

[JLPurcell]

The frame is now ready for powder coat. I have mocked up, fabricated and installed all of the brackets etc... for the power steering upgrade. The front splash panel is modified for the new steering location. Goes to powder coat on Tuesday. I do have a few more small parts to blast prior to powder coat.

[ajmcforester]

I'd paint it is easier to fix when scratched

[JLPurcell]

I'd paint it is easier to fix when scratched

I have wrestled with this for the last few months and my hotrod buddies have convinced me to give powder coat a try.

[ajmcforester]

Did you look into powder coat primers, then paint. Their is several advantages to it first is the coating get everything, it does not absorb oils and moisture. It uses a rough texture to allow the paint to adhere, and they say you need to scuff the paint to the primer to repaint a spot. The primer is designed to be painted the surface will oxidize and discolor without paint. I was looking into it for the Z to get the hard to paint areas on the hood doors and whatever else would fit the oven.

[JLPurcell]

Did you look into powder coat primers, then paint. Their is several advantages to it first is the coating get everything, it does not absorb oils and moisture. It uses a rough texture to allow the paint to adhere, and they say you need to scuff the paint to the primer to repaint a spot. The primer is designed to be painted the surface will oxidize and discolor without paint. I was looking into it for the Z to get the hard to paint areas on the hood doors and whatever else would fit the oven.

No, to be honest I do not know that much about powder coat. I am dropping off the frames, pans etc... this morning. The company has a large automated oven that will do large parts, they come highly recommended.
I have a pressure sprayer which I used last night to clean all of the parts and frame with lacquer thinner then I wiped all of the parts down with the same. The company runs the parts through the oven first to burn off any oils etc... then powder coats them. I will post pics when complete.

[ajmcforester]

Don't get me wrong powder coating is great stuff it has revolutionized production and protective coatings. The problems is most powder coating do not take paint well and make it hard to do touch-up on. On a framed car it might be the a at to go, including the suspension. On a 4x4 the frame gets scratched going over things and needs to be painted to protect the metal the problem is the paint flecks off the powder coating. I see this problem when touching up my roof rack on my FJ Cruiser, and the frame rails. Not to say powder coating will not have advantages on a 4x4 it is stronger and will take more abuse, it bonds better to the metal so it is less likely to chip off. Not to mention how good it looks with no paint runs.

[JLPurcell]

While waiting for my frame to get back from powder coat I am going to try and reproduce the horn button. There are no NOS available and I have a good part to make a mold with. I have ordered the mold and casting material and will need to make a vacuum chamber.I will post more as the project moves along.
This is my starting point; my existing part is in good condition with the exception of the crazing of the plastic.

[hr369]

did you rebuild the engine yourself? thats an F series with the shims under the crank caps right?

i had a heluva time getting oil pressure in mine after i rebuilt it. this was my first engine i ever rebuilt.
i didn't replace the oil pump. probably should have. i probably should google low oil pressure after rebuild
fj40. its been bugging me for years what went wrong.

[ajmcforester]

While waiting for my frame to get back from powder coat I am going to try and reproduce the horn button. There are no NOS available and I have a good part to make a mold with. I have ordered the mold and casting material and will need to make a vacuum chamber.I will post more as the project moves along.
This is my starting point; my existing part is in good condition with the exception of the crazing of the plastic.

That will be fun to play with. I've wanted to borrow someone's good ash tray for the early 240Z and scan with a 3D scanner to reproduce one made with a abs 3D printer. If I do it I might just make it a cover that look like the ashtray door opens. That way I don't need to take the door off and risk braking it besides you can't use it for smoking if it was out of abs

[JLPurcell]

I have cast the first test part. The mold is great and the part is great with all of the fine detail. I will have to buff the reproductions out or buff one out and make a new mold due to some slight transfer of the crazing. The next step is to build a vacuum chamber that creates a minimum of 29" of vacuum.This will make the part crystal clear with no air bubbles.
This is the original and then the test cast.

[JLPurcell]

I just picked up the frame and parts from powder coat. I as giddy as a 16 year old seeing their first car! I will post photos soon.

[bacarl]

Great project. You have good taste in vehicles! The 240Z and FJ40 are a couple of my favorite classics, along with early 911s. Maybe one day I'll own one of each

Do you have a more detailed build thread going anywhere for the FJ40?

Looking forward to frame/body pics!

[JLPurcell]

Great project. You have good taste in vehicles! The 240Z and FJ40 are a couple of my favorite classics, along with early 911s. Maybe one day I'll own one of each

Do you have a more detailed build thread going anywhere for the FJ40?

Looking forward to frame/body pics!

New Member!!

This link is to the Land Cruiser Club it has more detail and will begin to have much more now that I have the frame back. Thanks for you kind comments and your interest. JLP

[olzed]

Nice job. I had a new one many years ago. Great truck.

[JLPurcell]

Here are a few photos of the frame back from powder coat. I just finished blasting and painting the rear differential and springs (soaked on the black gloss paint). Will start assembly tomorrow, back to a roller!

[Blue]

Looks to clean to get muddy ever again! Very nice!

[bacarl]

Man that looks great! They must have a hell of a big oven, good grief!

What's the grate thing in the sixth pic?

[JLPurcell]

Man that looks great! They must have a hell of a big oven, good grief!

What's the grate thing in the sixth pic?

That is the expanded steel rock guard that goes in front of the radiator. Same material as the JDM front grill for the 240Z.

[JLPurcell]

Good day today, had the day off and was able to get the springs and axles back under the frame today. All new bushings and new shackles and pins with grease zerts. Engine in by end of week???



As you can see in the pics I have not restored the tie rod yet. I did not want the front end flopping around. I will order the ends and new tie rod and pitman arm once the engine is in the frame down on the suspension.

[ajmcforester]

Frame will need scratch so you can call it an off road device, but besides that the frame looks great

[JLPurcell]

Adam, I did scratch one of the rear springs putting them back on. The front was much easier once I finished the learning curve on the rear. I will touch it up, and this is going to be a driver. I went to the storage facility this morning and started my Z it is running like shi*. Need to get it home to see what is going on. But I am not driving it enough. I hope to get the Z to ZCon next year. Memphis! The last time I went to drive the Z and noticed it was not running right the hood would not open!!! This morning I loosened the hood bolts behind the grill and releasing the tension allowed the hood to open. I ran it and left the hood unlatched and the put the cover back on it. Did I ever tell you that my son while attending college in Philadelphia dated a girl from Cherry Hill?