Another FJ40 Rebuild - 1983 LX

[keith richardson]

Some "BEFORE" pics

 

[keith richardson]

So then we start the disassembly

A few days later - Time for a short update on the tear down progress.

 

[keith richardson]

UPDATE:-

Tub and body panels have been sandblasted, some of the body panels have been sprayed with a primer just to prevent the sandblasted surface from rusting as all the rust removal work starts as a matter of priority.

These are the doors that will be cut into half doors

The roof gutter is going on;-

And this one is just for THEO  ;D

The old one is on the top the new one the bottom

 

[keith richardson]

OK here are some pics
unfortunately the flourescant light and camera flash dont do the colour any justice.

Here is a sample of the detail they go to when fixing the rust.

This is the colour in "normal" light

This is the colour in flourescant light

And thiois is the colour in the sunlight

Speedo Cluster rebuild

Nice work JT  ;D ;D

Before:-    >   >   >

After:-   >   >   >

 

[keith richardson]

Sorry for the watermarks on camera lens - my nephew was fiddling with my camera

I will take some better pics when I get the body into the workshop next week

 

[keith richardson]

Been doing a bit a chassis stripping this week.

Only problem is the spring shackle pins are siezed in the bushes - it's time to break out the gas axe.

So work is plodding along steadily
Its nearly time to start sandblasting

UPDATE:-

All leaf springs removed from chassis, chassis now bare - ready for sandblasting.
These are the last of the "before" pics as it will never look like this again

The coast cancer is BAD ! ! !

These next two pics make me think I should be ordering two new rear brake drums  :'(

 

[keith richardson]

UPDATE

BTW - as you all know my daughter named Kermit (but not on this forum) and now my wife has come up with a name for the LX - After seeing the painted tub for the 1st time - she said AARRGGHH you painted it BLACK ! ! !  then I showed her how the metalflake shines out when its in the sun, so she now calls the LX

DARTH VADER​

This has been a long time coming, work has been progressing very slowly on the LX rebuild - but I'm not in any particular hurry.

I sent all the nuts, bolts, brackets, pipes and other miscellaneous items for yellow passivating. All nuts and bolts are being sorted into linbins for their respective size and strength rating

Axles - diffs steering knuckles and wheel bearings have all been completely replaced with new bearings and seals. ARB air lockers are being set up for both front and rear.

The chassis was sandblasted, some strengthening and rust repair welding was done, then rust bulleted and painted.
A bit dusty , , , ,

all the other under chassis bits and pieces have all been sand blasted, rust bulleted and painted

The front disk calipers in the process of being rebuilt

 

[keith richardson]

Well - at last here is a long overdue update

The current state of affairs - we have a rolling chassis

This is the bent push rod.

 

[keith richardson]

BTW these are the pics that the seller sent to me when I bought it in Sydney NSW

 

[fridayman]

Makes me wish I had the space for a project like this... Very nice!

 

[Ben]

nice work and nice truck.

 

[Dark Dude]

.....And they say the camera never lies! BTW: Most digital camera can do a custom white balance if you're taking pictures in mixed lighting. I did a very similar rebuild on the last of the 2 door Range Rover Classics 12 years ago. I envy you. This is going to be a great project when it's finally done. BTW: Where exactly are you on the planet earth?

John

 

[keith richardson]

Situated - Johannesburg - South Africa

 

[spackrackman]

Hi Keith, look what I now have,

A 1983 lx

{Admin - fixed your image link}

 

[keith richardson]

spackrackman

a 1983 LX

Hey - looks just like mine
That rego looks Aussie - is it ex Aus???

<<<<<<<<UPDATE>>>>>>>>>

Look what arrived recently from UK for Darth Vader a whole 36sq feet, can you believe that DYNAMAT isnt available in South Africa

And now for a few update pictures

Reinforced brake hoses.

Some painted bits n pieces

At long last we have completed the total rebuild of the 2F engine
All new bearings, new pistons and rings, skimmed head 60thou, skimmed block, skimmed flywheel, new fuel pump, new valve seats (for unleaded) etc etc
Everything is new

I also had the freewheel hubs powder coated

The cogbox is now just awaiting its final coat of silver and black paint, then it will be mated to engine and FINALLY dropped onto the chassis

 

[keith richardson]

The cogbox and transfer box has now been stripped and new bearings and seals are going in together with a new coat of paint.

The brake pipes, where possible have been routed into the chassis and where there is a possibility of abrading the pipe has been covered with a thick wall heat shrink

The stainless steel spring protected brake lines.

The shocks have been fitted - Rancho 9000XL adjustable

 

[Red Oktober]

Fantastic ...... can't wait to this beast unleashed

 

[jeepmadmike]

The best bit of a restoration now - the final assembly it's such a great feeling then it's all going back together, it makes all the cleaning painting welding and effort on bits no one see so worth while

 

[keith richardson]

At last..........

The final assembly process on the cogbox and transfer case
Items replaced, all bearings, all seals, gear lever bushes and 1st syncro.
I even changed the oil seal on the speedo drive  ???

Now its just bolting it to the motor and dropping it onto the chassis, then I can finally put the tub on.

 

[keith richardson]

Well I thought this day would never come - the motor and cogbox are finally in the chassis.

Now for the tub. . . .