1977 FJ40 Restoration

[DHC6twinotter]

WTH..you not only have a Piper Cub sitting in there but a bi also! Jealous.

x2

[Robinhood4x4]

That's just the place where we're working on the truck. The biplane is for sale. Anybody interested?

The nice thing is, since the airplanes are wooden, it's important to keep the area climate controlled so that means we can still work on the truck even if it's 115 out.

[Skywagon]

I figured I may as well chime in as it is my project... haha.

Yeah, the shop is my hangar and the Piper Cub is mine; my father and I restored it 18 years ago. The biplane is for sale (it was my father's who passed away) and that space will allow for another project, maybe another airplane restoration is in order next...

I do want to say that Steve is a great friend to help me with this project and we are both learning a lot along the way. I have rebuilt engines, transmissions, differentials, done bodywork, repained, etc over the years but never tackled a project as extensive as this one. Although it was his idea/influence that got us into this mess to start with... haha.

[04 Rocko Taco]

I know when I got to the "frame" protion of my body swap on my '84 Runner trail rig, I was almost overwhelmed with everything that needed doing.... but after a few deep breaths, and some lunch, I got back to it.
You guys are doing some good work, and I am greatly enjoying following this thread.

[Robinhood4x4]

Now that it's well over 110 deg out, we're a little more sluggish and taking things at a more relaxed pace, despite the swamp cooled hanger. The first order of business was to give the frame a nice power wash. Unfortunately, the heated water function wasn't working so it only got the loose stuff off and not the 1/4" layer of dirt and grease that covered everything.

[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080921s.jpg[/img]

Once things dried off we got to business by taking off the drive shafts and tranny/t-case.

[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080958s.jpg[/img]
[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080961s.jpg[/img]

After breaking out the sawsall for one stubborn motor mount, the engine lifted off effortlessly.

[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080990s.jpg[/img]
[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080991s.jpg[/img]

Overall, the day went pretty smooth and without too much fuss. Thanks to a probable leaky rear main seal, most of the bolts were well oiled and didn't put up much of a fight.


Got a question about the fly wheel though. Are these cracks normal or do they mean we'll need a new fly wheel?
[img width=800 height=533]http://www.robinhood4x4.com/UY/FJ40/teardown/P1080999s.jpg[/img]


So the next order of business will just be to clean everything. Our plan is to park the frame, engine, tranny over a big tarp (as it is now) and just start scraping and soaking the layers of grime that covers everything. Once that happens, the real fun starts! We'll get started on rebuilding the axles and suspension.

From there, things are kinda up in the air as Clayton decides on whether he wants power steering, AC, and injection.

[DHC6twinotter]

Injection? You guys swapping out the motor? 2FE "hybrid", 3FE, 1fzfe, or something else?

Anyways, you guys have a really great project going. I'm pretty jealous.

[Robinhood4x4]

The 2FE hybrid is a consideration, but more likely an off the shelf TBI kit, or a custom direct injection scheme. One of the advantages of working for a place with a bunch of motorhead engineers.

[corax]

Got a question about the fly wheel though. Are these cracks normal or do they mean we'll need a new fly wheel?

Those are probably just surface cracks, machining the flywheel will take 'em off

[04 Rocko Taco]

Got a question about the fly wheel though. Are these cracks normal or do they mean we'll need a new fly wheel?

Those are probably just surface cracks, machining the flywheel will take 'em off

Agreed. Although, make sure you check the thickness of the flywheel after it is machined. (the step difference between friction surface and non friction surface around the edges) I had a lot of trans issues with my G series trans due to a flywheel that was machined a few to many times.

[Bob98SR5]

any diesel engines under consideration? what i'd suggest is find a good source of wvo, make a filtering system w/ a centrifuge, build (or buy) a 2 tank wvo system, and then you got the ultimate off road machine with fuel costs being a relatively small issue.

looks like a fun project. wish i was there to advise you guys on the rust issue and help where needed.

call me if you have any questions, steve.