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LJ78 Build Thread

Ben Feb 6, 2017

  1. StarCruiser

    StarCruiser Well-Known Member Guru I am in uk

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    Oh boy Ben! I thought I was bad taking up the whole of our spare bedroom with camping stuff. That's made me feel a whole lot better, except it is our only spare bedroom!

    I wouldn't like to be in your shoes if Bec ever reads that last statement…:animals-dogrun:
     
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  2. AndyCook

    AndyCook Well-Known Member I am in scotland

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  3. doyle61

    doyle61 Member I am in ireland

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    Yep Ben you have a keeper there lad:thumbup:. Great work on that exhaust..........don't suppose you could pop over to Ireland when your going to the UK next time and build one for me:think::shifty::icon-biggrin:
     
  4. doyle61

    doyle61 Member I am in ireland

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    Yep Ben you have a keeper there lad:thumbup:. Great work on that exhaust..........don't suppose you could pop over to Ireland when your going to the UK next time and build one for me:think::shifty::icon-biggrin:
     
  5. Ben

    Ben Well-Known Member Guru I am in australia

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    :lol:

    Thanks guys. :thumbup:

    I went away motorbike riding and camping last weekend. :icon-cool:

    And while I was sorting my camping gear out before I left, I came across some of the camping bits I've been buying up over the last 6 months, these are all bits that will live in one of the drawers in the back of the 78.

    My aim is that everything will have a place and there wont be any wasted space in the drawers, so I've been buying products that pack up nice and tight.

    IMG_0397_zpsabapvmxv.jpg

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    These are the 2 means of cooking I will carry, a fold up BBQ plate for cooking over an open fire, in the green canvas bag and a gas stove for when fires arnt allowed.

    IMG_0401_zpsouobad5s.jpg

    I'm still in the planning stages of the drawers and storage area but I've got a good idea of how I'm going to build it all. :icon-biggrin:

    The camping and motorbike riding trip was eawesome! :dance:

    But I wished I'd had the 78, fully setup with fridge, solar power, camp lighting, water tank etc. :shifty:

    IMG_0410_zpsxbxjfknh.jpg

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    The bike riding was lots of fun and there was lots of jumping! :icon-twisted:

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    So much so that I've decided I cant sell my bike, so I'm really hoping for a nice tax return next month off the government. :pray:

    Work is progressing well on the 78 and I got some pics a few days ago from the panel shop.

    They had finished all the bodywork and had got it in the spray booth ready for primer! :dance:

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    Theres a chance I might even get it back before the weekend! :icon-biggrin:

    I've been busy sorting out more of the parts for it.

    I needed to clean all the surface rust off the bits for the rear number plate light.

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    The sides off the battery trays.

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    And the super rare solid axle 1KZ-T engine sump.

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    Gave them a good clean up with a wire wheel in the grinder.

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    Then gave them a coat of my favorite, acid based rust convertor.

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    I left them to soak overnight, then after giving them all a light sand and a wipe over with thinners they got a few coats of acid etch primer.

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    Followed by some coats of black enamel.

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    I finished welding the middle section of exhaust.

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    I found all the bits I need to convert to manual free wheeling hubs, so I can ditch the unreliable electric hubs.

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    I've had to source one more hub though as one of the spare ones I'd got has got sheared off studs in it. :doh:

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    I needed to restore the rear number plate light that had been sprayed rattle can black followed by a layer of the blue primer.

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    An hour of wet n dry sanding later most of the paint was off.

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    I then masked off the area of black that I didnt want painting.

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    And gave it a few coats of grey primer.

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    Followed by some silver enamel.

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    Stupidly I didnt let it dry for long enough and when I tried painting the black in around the letters, I lent on it and left marks in the soft paint. :doh:

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    So I sanded it back down, re-masked it and gave it another few coats of silver.

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    I've been cleaning more blue primer off more parts ready to bolt back on.

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    And I made a start sorting the electric mirrors out.

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    Both of the glass mirrors fitted when I bought the 78 were the wrong ones, not only the wrong shape but they were flat instead of convex. :doh:

    The mirrors themselves were also covered in matt black rattle can paint. :thumbdown:

    I ordered one replacement piece of glass from Amayama for the drivers side and alrady had a passenger side mirror spare, that I could use the glass out of.

    IMG_0490_zpsv0puu6qr.jpg

    Managed to remove the glass from the spare mirror without damaging it. Its not in perfect condition but will do for now.

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    My spare mirror on the right shows what these mirrors should look like.

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    The matt black paint cleans off easily enough as theres no primer underneath it and it hasnt really stuck very well to the chrome.

    The bases on the other had are a real mess and needed repainting.

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    I gave them a good sand down and ended up getting them nice and smooth with some 800 grit wet n dry paper.

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    They were hung up and given a few coats of acid etch primer.

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    Followed by a few coats of satin black enamel. :icon-cool:
     
  6. StarCruiser

    StarCruiser Well-Known Member Guru I am in uk

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    Good progress Ben. Tedious bits to do. Shame about the paint getting spoiled leaning on it. That's the sort of thing I would do. :doh:
     
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  7. clivehorridge

    clivehorridge Well-Known Member Supporter Guru I am in romania

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    IME, all jobs have a ratio, 95% done in 10% of the time and the other 5% takes the remaining 90% of the time...

    Keep at it, you'll get there.... :thumbup:
     
  8. doyle61

    doyle61 Member I am in ireland

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    Good progress there Ben. It's them small jobs that when added up take a huge amount of time. When the body is away and you do these jobs then is where you and up gaining time on the project
     
  9. Gary820

    Gary820 Well-Known Member I am in great_britain

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    It's going to look great when built back up.

    I found I've got space in my drawers since sorting and organising tools and camping gear, We carry more then we need too.
     
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  10. Ben

    Ben Well-Known Member Guru I am in australia

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    Thanks guys. :thumbup:

    The black paint was dry on the mirror bases this morning.

    So I gave the mirrors a clean up.

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    Not perfect as they are a little scratched, but a lot better than they were.

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    While I was at it I decided to clean the grill up as well.

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    Not very clear in the photo but I've cleaned the right hand side bottom and the bottom left is still tarnished and dull.

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    Cleaned and shiny.

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    Dull and tarnished.

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    I picked up a grill the other day when I was out picking, that I thought would be perfect for this project, but on closer inspection its a bit damaged, so its become a piece of wall art for now, below my rusty, roached out 40 series grill. :icon-cool:

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    But I did manage to salvage the Turbo badge off it which was missing from the one I cleaned.

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    All the square headlight, diesel 70's got a Turbo badge on the grill so I'm glad I've found one for it. :icon-biggrin:

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    Last night I got a few texts from my spray painter.

    He thinks I'm crazy for requesting pics of it in primer, but he sent me some across anyway! :shifty:

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    Last night he gave it its coats of base coat! :dance:

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    This morning it was getting given its clear coats, then its getting cut and polished and tomorrow evening I might get to pick it up! :character-beavisbu:
     
    Gary820, doyle61, StarCruiser and 2 others like this.
  11. StarCruiser

    StarCruiser Well-Known Member Guru I am in uk

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    Lookin' good Ben. Bet you're itching to get it back. :)
     
  12. clivehorridge

    clivehorridge Well-Known Member Supporter Guru I am in romania

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    So nice to see that blue :puke-front: disappear. I guess it will haunt you in other areas of the truck you cant reach, but the new colour looks fantastic! :thumbup:
     
  13. Ben

    Ben Well-Known Member Guru I am in australia

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    Thanks guys. :thumbup:

    I'm normally awake at 4am everyday (not by choice, just wake up and cant get back to sleep :angry-screaming:)

    Well today I was awake at 3am! :sleeping-sleep:

    I feel like a kid on Christmas eve! :shifty:

    Going straight from work this afternoon to see it for the first time and get it loaded on a tilt tray and taken home! :dance:

    Anyway...........

    I was in the garage at 3:30am this morning, as you do and decided to put the mirrors back together.

    Tried pushing the spare mirror back onto the ball mount and cracked the bloody glass! :doh:

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    So I will have to order a new one. :shifty:

    Fitted the new piece of glass to the drivers side.

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    I had a delivery yesterday, a brand new genuine windscreen seal! :dance:

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    I'm just hoping it fits. :pray:

    As I read online that hard top LJ70's have the same windscreen and seal as Troopy's and 79 series utes. :ugeek:

    I gave the garage a good tidy up and its now all ready for the 78! :icon-biggrin:

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    If all goes to plan, in 4 hours I will be picking the nice shiny 78 up from the panel shop! :dance:
     
  14. pyemaster

    pyemaster Active Member

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    Looking forward to the pics dude!

    Owen
     
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  15. Victor

    Victor Member

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    Im gonna treat myself to some broken studs this weekend Ben! During washing after the last offroading i kind of noticed all bolts holding the manual hub on the passenger side was gone :whistle:
     
  16. StarCruiser

    StarCruiser Well-Known Member Guru I am in uk

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    Shame about that mirror Ben. I'm a bit concerned you might be turning into me, cos that's three things I would have done!

    We're waiting …:whistle:

    Love the colour BTW, well, the base coat anyway. :)
     
  17. Phantom

    Phantom New Member I am in malta

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    Great work there Ben. Excellently documented and easy to follow :)

    The truck already looks lightyears away from the time you got it!

    Keep up the updates and the good work!
     
  18. Paddler Ed

    Paddler Ed Well-Known Member I am in australia

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    Hey Ben,

    How have you run power to the back of the vehilces? I'm working on a system at the moment and need some inspiration...
     
  19. Ben

    Ben Well-Known Member Guru I am in australia

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    Thanks guys. :thumbup:

    After working on it for 27 hours this weekend I'm just about to write a 280 pic update! :sleeping-sleep:

    Ed.......I havent started my wiring yet but theres 2 main ways to run power to the back.

    1. Under the carpet, inside the vehicle.
    2. Underneath the car, running the cables inside the chassis rails, especially good for thick cables for duel battery setups/invertors/rear winches etc as their too big to fit under the carpet and they need to be nicely protected. :ugeek:
     
    Paddler Ed and StarCruiser like this.
  20. Ben

    Ben Well-Known Member Guru I am in australia

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    Update time. :dance:

    So heres some pics that I didnt get until after I'd picked the 78 up from the panel shop, as the guy didnt want to spoil the surprise for me. But they need to go first to keep everything in order. :icon-cool:

    So heres the 78 in the spray booth.

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    I got to the panel shop as planned, Friday afternoon and finally got to see the 78 in paint! :happy-wavemulticol:

    We loaded some of the panels and a door in the back of my Astra that I was driving, loaded the bonnet and one of the front guard into the back of the 78 and pushed it outside.

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    I couldnt fit everything in with out risk of damaging some of it, so I arranged to pick up this guard.

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    This door and the radiator support panel the next morning.

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    The tilt truck soon arrived and the guy got the 78 loaded.

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    I followed him home and for the first time in over 3 weeks it started raining. :doh:

    Luckily not heavily as the 78 had no glass in it.

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    The panel shop is only 15 minutes from my house so we were soon home and unloading the 78 :banana-angel:

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    The driver helped me push it into the garage.

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    It was by this point only 3:30pm, but I had to get to a bank appointment and then we were going out for dinner with my in-laws, so no time to play cars for me! :doh:

    The next morning I was up again at 3am and by 3:30am I was in the garage. :shifty:

    IMG_0560_zpsz84pfvsm.jpg

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    Now.......

    Time to assess the job the panel shop have done. :think:

    They havent done a bad job, its pretty bloody good really. I'd say I'm 90% happy with what they've done.

    But they did let themselves down with a few little bits. :thumbdown:

    Firstly they didnt bother to clean off the old adhesive on the front passenger door, where weather shields were once fitted.

    For this there is no excuse, it would have taken 30 seconds with a razer blade to scrape that shit off. :angry-screaming:

    IMG_0563_zpsupbc5rb2.jpg

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    It looks f****** terrible! :icon-evil:

    I spoke to the guy about it and hes just like "Oh your weather shields will cover that when they go back on"

    Well thats not the point, its not right and its one of the areas he is going to have to put right for me when it goes back in a month or 2! :eusa-naughty:

    Moving on to the other issues.............

    When I dropped it off I told the guy who was there at the panel shop a few things I wanted/needed doing on the 78.

    I actually walked him round the car and showed him a few areas and things I wanted doing and he some how managed to forget all of them and certainly didnt tell his boss or the other guys, supposedly. :angry-screaming:

    I wanted them to seam seal the passenger rear door where I had scraped out the old seam sealer to do the rust repair.

    So they painted it and didnt bother seam sealing it first. :doh:

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    The other area I wanted seam sealing was inside the passenger rear arch where I had done the rust repair, as there is a tiny gap.

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    And the other thing the guy forgot was the one thing on the whole car I wanted him to mask and save for me, the Araco sticker on the drivers door.

    The bastards removed it. :angry-banghead:

    IMG_0572_zpsd2yosdab.jpg

    But apart from those issues, it looks great and I'm very happy with the colour and how its come up. :clap:

    I will buy some seam sealer and do the seam sealing myself before it goes back to them to paint and I will order a replacement Araco sticker as I want to keep the car looking as original as possible. :icon-ugeek:

    So...................

    Saturday morning and I unloaded all the panels and door out of the Astra and where else to put them than the Queen suite, our last remaining, usable spare room that my wife had been busy filling with baby stuff in preparation for our first born. :shifty:

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    To be fair I didnt have much choice as the rest of our house is all tiled apart from the lounge which has laminate flooring and I didnt want to put the freshly painted panels down on anything that might chip the paint. :)

    With the Astra empty I finally made a start putting it back together! :dance:

    Doors first.

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    Dug out all the door parts.

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    Fitted the little rubber door stops first.

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    Followed by the striker plates that needed a clean up with some steel wool first.

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    Front door seals next and it was so nice fitting brand new ones! :icon-cool:

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    Thankfully I labelled everything really well, especially the seals as theres a lot of them.

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    Passenger side Rear went in next.

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    Followed by the drivers side rear.

    I found the drivers and passenger side rear door seals, but they needed a clean, like everything else they were covered in paint. :doh:

    IMG_0610_zpsexmmndti.jpg

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    I decided to come back to those and do something else.

    I fitted the mirrors.

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    Fuel cap and lock.

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    And spotted they had painted over my Diesel sticker. :thumbdown:

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    Rear lights next.

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    Interior light, door switches next.

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    Fitted the front 2.

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    But the other 2 needed cleaning as they were covered in paint. :thumbdown:

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    So I decided to give a few things a good scrub with some hot soapy water.

    One of the major benefits of having a partner who sleeps like a normal person is that they invariably arnt around when you want to do things you know they wouldnt approve of. :shifty:

    Like cleaning car parts in the kitchen sink. :lol:

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    All of the plastic trims off the handles needed the blue primer and matt black paint beneath that layer, cleaning off before I could fit any handles.

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    They were awkward and slow to clean but it had to be done.

    Once clean.

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    They could be pushed into position on the handles.

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    And the handle bolted in position (along with the lock above it)

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    Starting to look good with the clean and shiny chrome mirrors and handles. :icon-cool:

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    It was by this point 7am and Lexi and I went off to collect the rest of the panels and door from the panel shop. :character-grommit:

    All carefully wrapped up to protect that nice shiny new paintwork.

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    They all went into the queen suite with the others.

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    And all the blankets, duvet/duna covers and bed sheets, that I'd carefully smuggled out of the house the previous morning while the Mrs was asleep, could be folded up and put away. :shifty:

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    I woke the Mrs up and got her to come and give me a hand to fit the rear rear doors.

    All with nice shiny new bolts.

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    *At this point I was blissfully unaware of the horrors that lay ahead with the rear door. :icon-rolleyes:

    I mean I knew there was a slight bit of paint damage from when I picked it up and it was stuck to their panel stand, but a tiny bit of paint damage like that can be put right when they fix the other bits. :)

    IMG_0660_zps0dzop3fq.jpg

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    IMG_0662_zpsvrs3bcep.jpg

    No, what I soon discovered was that even though they look identical and most people would think they are the same, the rear doors on the 3 door 70/71 are in fact very different to the doors on the 5 door 78/79. :wtf:

    The 78/79 slopes forwards 40mm further than on the shorty. :icon-surprised:

    Meaning if you fit a door off an LJ70 onto a 78 you end up with a dirty big gap like this! :puke-front:

    IMG_0664_zpsl3ekbaqi.jpg

    IMG_0665_zpsturdepig.jpg

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    IMG_0668_zpsv9542upj.jpg

    The reason I didnt use the original door is because its got a huge dent where someone has reversed into something and pushed the spare wheel into the door.

    IMG_0672_zpse8g5caiy.jpg

    IMG_0673_zpstf5pvn90.jpg

    At this point I decided to distract myself with other work on the 78 and try not to think about my monumental cock up! :shifty:

    So back to the exhaust.................

    And another of my cock ups. :icon-redface:

    I didnt have a proper look at the EGT probe or the boss it needed to fit it into my down pipe. I googled VDO EGT size and got a thread dimension of 1/8th so found and ordered a stainless steel boss that size off ebay.

    Only when I came to use it I found it was completely the wrong size. :thumbdown:

    IMG_0669_zpsjbekhrkp.jpg

    When the probe originally came it had a threaded steel boss that I welded into my exhaust, then that double threaded adapter screwed into that and finally the probe screwed onto that. :ugeek:

    IMG_0670_zps56iib2kd.jpg

    So while I tried in vain to find a suitable stainless steel bung locally I had some good fortune while I was looking around in Supercheap Auto.

    I discovered exactly what thread the EGT probe is. :ugeek:

    IMG_0651_zpsolfp0fvh.jpg

    And in a huge stroke of luck, the second bolt shop I tried had some stainless steel M12 1.25 bolts in stock. :dance:

    It was complete chance he had them and he only had 4. He said he would never normally stock stainless steel bolts that size as they are too expensive so nobody wants them. :D

    IMG_0671_zpsfrcki2f1.jpg

    Now I thought about going to work and using the lathe to make a perfect boss, but decided that would waste too much time and I should just crack on and do it at home.

    The first step was to cut it to length.

    IMG_0674_zpsjgjaih9y.jpg

    Luckily for me the bolts were continuse thread meaning I could actually keep the head on, which will be good if the probe ever becomes seized as it wont damage the exhaust pipe if I can get a spanner on the boss to grip it. :think:

    Cut it to length.

    IMG_0675_zpsnzhtijvp.jpg

    Marked across all the corners to give me the center.

    IMG_0676_zpson8eaych.jpg

    IMG_0677_zpstj27nq9l.jpg

    Then after center punching it it was into the vice on the drill press for the pilot hole to be drilled through.

    IMG_0678_zpsq7bjnvv8.jpg

    IMG_0679_zpseoft29ul.jpg

    Followed by a 6.5mm bit.

    IMG_0680_zpsyfv5hcoy.jpg

    I gave both sides of the hole a quick clean up with a countersink bit and then it was finished. :icon-cool:

    IMG_0681_zpsfxp1g9gf.jpg

    IMG_0682_zpsrxyhbysc.jpg

    IMG_0683_zpswycxplf4.jpg

    Drilled a hole in the down pipe with a step drill.

    IMG_0684_zpsux2ps46a.jpg

    IMG_0685_zpsyv9jwezh.jpg

    Used an M6 bolt to clamp it in position.

    IMG_0686_zps7qmhl3aj.jpg

    IMG_0688_zps7tkkwspk.jpg


    And TIG'd it in position. :icon-twisted:

    IMG_0689_zpsuingmvby.jpg

    IMG_0690_zpsz7u7u3n5.jpg

    IMG_0691_zpsleu6qgyc.jpg

    IMG_0692_zpstoybvn0m.jpg

    Fitted the EGT probe.

    IMG_0693_zpscdlyqebz.jpg

    IMG_0694_zpszkipavyr.jpg

    I could then finally get the exhaust fitted, which would mean I could then fit the entire front end of panels.

    IMG_0695_zpszlzqsqc5.jpg

    IMG_0696_zpsnzh5j7m8.jpg

    Radiator support and inner arches went on next! :character-beavisbu:

    IMG_0700_zpsfuynijii.jpg

    Next I assembled my latest tool/toy.

    IMG_0701_zpsm1k1q4zt.jpg

    Definitely the best $30 I've spent in a long time, dont know how I managed without one for so long, they are incredibly handy. :clap:

    IMG_0702_zpsox04ypao.jpg

    So now I had some where safe and soft to lay the passenger side front guard while I fitted some bits to it. :icon-cool:

    IMG_0703_zpss5vosndy.jpg

    These clips had to go on next, these are the M8 nuts that the inner arch bolts to.

    IMG_0704_zpsa7byd8f0.jpg

    IMG_0705_zpsmsb7nymd.jpg

    First guard on. :dance:

    IMG_0706_zps9wd0gxdi.jpg

    Drivers side next,.

    IMG_0707_zpsoaozhw0o.jpg

    I needed to fit the new aerial next.

    IMG_0708_zpshjqel0zm.jpg

    So the end un-screws like this.

    IMG_0709_zpshe54i9sw.jpg

    That then gets pushed through the hole in the guard.

    IMG_0710_zps92mpsmrn.jpg

    And bolted on with a bracket at the bottom.

    IMG_0711_zpsqimotbkb.jpg

    IMG_0712_zpsrzsgtfdr.jpg

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    I taped the new cable to the old one to pull it through the bulkhead.

    IMG_0714_zpsshjwza70.jpg

    Fed the cable through and got the drivers guard on.

    IMG_0715_zpsevftqzhn.jpg

    IMG_0716_zpsnb6ty8k4.jpg

    Radiator went on next.

    IMG_0717_zpsoqczsszt.jpg

    IMG_0718_zpso4fdwpds.jpg

    Followed by the little top panel.

    IMG_0719_zpsvticzuhc.jpg

    IMG_0720_zpskpdh9trn.jpg

    The bonnet catch and the support bracket for the bottom panel.

    IMG_0721_zpshdxqtthv.jpg

    Fitted the scuttle panel next.

    IMG_0722_zpsz2caq9l1.jpg

    Found and fitted all the bits back into the radiator support panel next.

    IMG_0723_zpsrvaejbvy.jpg

    And fitted the bottom panel complete with those sexy new clear lights. :icon-cool:

    IMG_0725_zpsyvswdocx.jpg

    IMG_0726_zpsznd5uvyi.jpg

    IMG_0727_zpslbzfrtd1.jpg

    IMG_0728_zpsw5bdvdqw.jpg

    IMG_0729_zpsvr6wmppw.jpg

    Fitted that iconic badge on the passenger guard next.

    IMG_0731_zpshgfrcze1.jpg

    I think its a real shame that Toyota stopped these badges with the 70, the 40, 60 and 70 all got them, then they stopped! :thumbdown:

    IMG_0730_zpsw6fqngxv.jpg

    And that was day one of the reassembly. :sleeping-sleep:

    I was pretty exhausted by this point (3pm) but if I hadnt wanted to spend time with my Mrs I think I'd have kept going until midnight as I was loving seeing the truck come back to life with every part bolted back on. :shifty:

    *Edit, had to split the update due to a 200 pic limit per post. :crazy:
     
    Last edited: Jun 12, 2017
    Duvs and Pat like this.
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