1-24 This is a build of a mostly original paint rot free desert FJ40 I bought for myself and a customer wanted it so we are going to build it his way.H wantss AC added and generally as reliable and sharp as we can make it.

The bones of this FJ are exceptional with no rot unlike 99% of these you will see.

It already has a corvette 350 in it with an SM 465 big dog 4 speed transmission. It also has Auburn limited slip units and 4.10 gears in the differentials which go with the spring lift with greasable eyes and HD shackles. We also recentlyadded power steering to it.

We will be taking photos of the inside to show how solid it is and then having it Rhino lined for protection purposes.

The interior is already removed to have some custom interior work done.

With the interior out, I called in a pro to have the glass removed so we can get paint everywhere as these tend to rust under the rubber weatherstripping..

We also started teardown of the front so we can get the radiator and aux rear heater to the radiator shop for boiling.

We have the hood, fenders and fender accesories removed. This has been done with literally hundreds of photos as this build is scheduled after the CJ7 being done and it will be 2 months-ish before we would consider reassembly.

I'm still amazed at how clean the metal is and how cooperative the fasteners have been. I'm told the steps are ALWAYS rusted and as I see these FJs advertised I typically read the ads that say, "Good body except rust where THEY ALL rust". That's just not true. Look at this metal...

Start with more (better) at the beginning, finish earlier, cheaper with something worth more when you're finished. Before you buy that high priced "restored" whatever, ask for the 'before the shiny paint' photos. ;)

The upper part of the top has been removed so we can paint the top more fully and also replace the upper gasket as everything rubber will be dried out from the desert.

2-2

I am evaluating how far apart this rig needs to come as unecesary labor wastes the customers money and add to the delivery time.

This is a picture underneath the hinge on the door...

It's clean enough that the extra work to remove, manage while preping for paint, painting, buffing and re-assembling isn't warrented. If it needed done, we'd do it.

2/7

Top and rear doors off...

The most prone area to rust on these is the lower barn door. Ours had some pitting but nothing we couldn't grind out and have no holes...

As the CJ build comes to an end...the FJ project picks up...

3/15

Engine out and going to be replaced with a 290 hp GM crate motor

Transmission and t-case out and on their way for rebuild

The driveshafts are newer HD replacement units to match the rebuilt differentials.

We will be using POR15on the underside of this rig as it will be driven year round. 1st step is degreasing but there is NO flaky rust to contend with ;)

Lots of prep work for the body...

Chassis cleaned up and getting ready for POR 15

I was kind of hoping to see the next issue as the factory steel fuel tank (which sits under the passenger seat) had pinholes of rust after it was blasted. This means we can put in a new poly tank and all new lines with no remorse!

More body work and prep....

Spot welds and original steel flooring. These are important photos as once the paint goes on, the potential next owner won't know what is underneath unless you have these. A rig full of rust or bondo looks the same as a clean machine like this...excepting the SPOT WELDS!

New 290 HP GM crrate motor with a few goodies...

Beautiful original body just about ready for paint....

These and the pictures before are what you want when you restore a classic. Shiny paint pictures can hide a multitude of metal sins. It's the BEFORE pictures that let you know if the money your spending will be there years later....when the rust that wasn't there in the first place, doesn't come back. When the body filler that wasn't used, doesn't pop out...etc etc.

Belearyof shiny paint (sometimes).

Paint inside after considerable prep...

Underside and chassis coated with POR 15

New Poly fuel tank with sending unit for a lifetime of use without leakage issues...

Body in paint! More pictures coming...

New HP intake installed w polished valve covers...

Engine placed...

New clutch installed and waiting on transmission and t-case...

Final paint for many parts...

Master Cylinder and booster, removed, sanded and painted.

Front Steering knuckles rebuilt with new rotors and brakes...

Lots of dash work. We read where some shops don't paint the dash if it's in nice shape so we discussed it @ length. We decided it is the focal point of the driver and needs to be 'right'. Aiding in this decision is the fact that several of the climate cables will be eliminated due to the aftermarket HVAC unit so the extra dash holes were welded up. My appologies for the sun in the background but it was a nice day outside and it's always great to have fresh air in the shop!

Restored dash cluster.... Many shops replace the original gauges with what I would call generic looking aftermarket pieces that just don't fit the era of the vehicle...

Cluster installed with tachometer and more accurate water temperature gauges

Ac unit mocked up while waiting on the tilt column. Really liking the uniform dash knobs...H

Heater hoses and AC pressure lines in place of the giant stock heater box....

Safety first. I was taught longago "better to stop and steer than go forward". New brake rotors, premium brake pads, and new flexible Stainless Steel brake lines. We also have new Warn lockouts with hub conversion kit and repacked bearings.

The hardtop had enough surface and seam rust it got fully blasted and will be in paint this week. Blastingthis took more time but was the right decision.Desert heat is hard on all things rubber but is way easier to address than rust!If this rig isn't driven in the winters, it will last a VERY VERY long time.

Cool factory rear heater unit restored and ready for use...

Exhaust manifolds blasted and hi temp painted. We debated headers but this will be a daily driver and we like the way these fit and hate the bolt tightening maintenance of 'exhaust snakes' (headers)...

We wanted the new engine to have a modern flare so we purchased this aluminum serpentine belt kit. One size fits, well nothing but eventually it will be right but of course it looks awesome!

We also opted to send back the AC compressor to Vintage Air to get a smaller unit that will sit on the motor with better symetry. The one I ordered sat way to high andprotruded beyondthe valve covers. The people @ Vintage air are very helpful!

Hardtop in paint and looking good!

This tilt column is a bit of a sore subject as we paid what I felt was a premium price to find it doesn't fit the stock steering linkage. Through osmosis, we were to have known we had to do a Saginaw steering conversion to use this....ahem. If you read this and want to contact me about who not to buy from, shoot me an email. It seems bad form to publicly bash a supplier.

We have a plan to make this work properly with no help from the supplier but it will take some time that we shouldn't have to invest for such a pricey product.

We're on to our third coupler to try and make our advertised as "bolt in" tilt steering comumn work but are hopeful it will be the magic piece. All of the sourcing and returning takes lots of time but not cutting corners makes for these bumps in the road seem small when the final product is done.

All body panels in paint now.... Shown below is the front grill section and upper roof...

And the rest waiting on details to be wrapped up...

We're getting closer on the front pulleys. We had to order the cool new chrome power steering pump to match the rest of the brackets...

Below is the (2nd) new AC compressor in smaller form to fit ina more harmoniouslocation on the engine. The one supplied with the AC kit sat up way too high and hung over the valve cover.

AC underdash unit installed...

Simple things like the supplied bracket in my hand not working right required the fabrication of the oneon the right that is holding the unit on...

The serpentine pulleykit finally meticulously shimmed with all accessories attached and lined up. It looks even better in person ;)

Many parts received today including:

The Howell Fuel Injection kit. I like their stuff because they use GM partsinstead of proprietaryones that can't be foundjust anywhere. This makes the vehicle easier to debug inany shop and therefore better for the end user throughout the life of the vehicle.

This is a well proven GM Throttle body which is far superior to a problematic carb and more user friendly in any climate...or incline!

Already installed...

These were a little hard to locate as FJs didn't come with fender flares. We found new ones to replace the aftermarket ones that were on there and had become dry and brittle from the sun. Once the project becomes so nice, everything that isn't perfect or near perfect detracts from the overall appearance

New Accel brand High Engergy Ignition distributor installed...

Power steering lines attached. Even things like this are a chore as the power sterring box has metric threads and the pump has imperial threads so the high pressure line was custom made. Details....

Both differentials were rebuilt prior to our ownership but the rear axle seals had dried from heat and showed signs of leaking. This picture shows the new rear axle seals, new brake shoes and also the expensive and hard to source twin wheel cylinders. I've never seen a drum brake set-up like these...

The steering linkage had mostly been replaced by the previous owner but there was one worn joint which is now new!

This is our 2nd set of spark plug wire looms as the first weren't up to the caliber the FJ is coming to be... It may not look like much but it takes time to get these on straight, not crossed and out of harms wayfrom the exhaust...

We've had the transfer case for a long time now but hadn't installed it as the gap behind the transmission gave us a great place to stand while wiring and plumbing the AC etc. Way better than leaning over or laying on your back.

Steering column mocked up now that we finally found the right adaptor to make up for the dishonest sale of it being a "bolt in" item. Next step is to take it apart and paint the bare steel and re-install and custom wire it in.

This is the specially sourced joint we had all the trial and error with that the selling vendor said didn't exist...

A simple pulley cover on the power steering pump that makes it all look further finished. Details! :)

Body parts going on....

Notice the SS fasteners on the windshield frame to add contrast to the overall build....

A normal steering column color is black but we thought the silver trim in the dash, seats, and interior bracketry would be complimented with a matching column.

Initial routing of lines on the engine...

All new flat tappet engines should have a Zinc additive usedat firstto aid in breaking in the camshaft....

This is the premium oil choice by one of mysupporting shops, Parson's Auto in Pandora, Ohio

Transmission tunnel cover in place as well as the new poly fuel tank...and a mess of wiring to tidy up

Drive shafts installed.

Another front photo :)

Still fighting with the "bolt-in" tilt steering column. We had to make our own mounting plates and redrill the firewall so that it didn't hang below the dash

Fabricated steering column to dash bracket

Custom mount of column installed...

AC Vent modified andmocked up in a different than suggested location as it would have sat to low on the left...

Fuel tank mounted with sender in place

Passenger door hung and installedDriver's door...

Door striker blasted and painted

Wiring has been ongoing and here is one of the few pictures we have of this with the main ECM harness going through the A/C bulkhead. The ECM itself will be located under the glove box inside the cab.

It's ALIVE!!! New Parking lights illuminated. The old ones were sunfaded and not complimentary to a new vehicle.

Time for some cooling...

This is the blasted radiator support...

Painted and installed...

Cool (parden the pun) new aluminum radiator! The original copper one was fine but we wanted the underhood to be complimented throughout!

The largest electric cooling fan we could use...

Installed with new custom made bushings

And my favorite view from the front...

The engine is looking super sharp with all the goodies including the just installed wter neck with o-ring gasket to ensure long leak free sealing!I need a better picture of this AND we have some other options to try as we got a couple steering wheels and buttons to choose from but this looks prettygreat compared to the giantToyota school bus wheel it originally had ;)

The AC fittings were not exactly cooperative but finally all collected up and installed.

Heater control valve installed...

Roll bar installed. The factory color for this was always black but we have some special upholstery in mind so we're hoping the additional silver accents (same as factory dash color)will compliment everything.

Upper hard top installed and ready for glass

One of the most tedious and important jobs is the custom wiring of all the 1976 originalwiring to modern aftermarket parts.A custom manufactured Tilt Column, Air conditioning, and Fuel Injection are plenty but little things like the bright light switch used to be on the column and the aftermarket column doesn't have that feature. This means an era correct floor dimmer is to be installed with wiring as required....Lots of hours of soldering and heat shrink...

Lights on! It doesn't look like much but with the custom dimmer switch moved from the column to the floor, it is a victory.

Relays mounted for the fuel injection...

Also seperate fuse block as the stock fuses in this FJ are glass!

Fuel filler neck and new fuel hoses installed...

Could the rear heat unit be more complicated?

Rear heat transit hoses in the stock location across the front floor

And the required crosses...

New custom cut front glass and new seal. I have the best glass guy! We couldn't find a new one in the catalogs and the old one had sand etching in it and would have been a blemish in a beautiful machine

Hand tinted professional rear tinted glass installed with all new seals. Try tinting the rear 90 degree curved glass!? Not a job for amateurs...

The radiator / condensor required some custom fitting to get it squared in.

Grill and new emblem installed.

The floor vent reinstalled and taped closed while the new gaskets are given time to cure in place. It is key that this rig be sealed as tightly as it can be...

The customer requested the key for the fuel fill be removed for less hassel in fuel filling. It looks much smoother this way!

There has been lots of wiring going in and she finally runs!

New detail items because the rig is so nice that the monor things stand out if they aren't perfect.

We made a decision to make the shifter silver in compliment to the other accent items and contrast to the other typical black items....

The fuel tank being in the cab and the need for specail lines and the electric fuel pump have been a task but it is getting in order...

Super cool new 17" wheels and tires...

Installed...

Warn premium winch with built in air compressor and new NOS front bumper

One beautifuly finished FJ40!

HERE 

is a link to 80 MORE CURRENT PICTURES from 11/18/2016