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Reed 78 FJ40 Rebuild
Hey guys, back again with another project for a customer.
This is something I have been working on for a little while (turned out to be more work than we thought!!!) It is a 1978 Toyota FJ40 the plan is rebuild the body and tub,lift the suspension install a 383 small block and build a roll cage. When the body was brought to me it was in VERY poor condition. Rot everywhere you looked it was sandblasted underneath to remove the old nasty stuff before it was dropped off. It will receive new Quarter panels, new Rocker panels, floor panels as needed ,bracing and any other spots as needed. Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. This was taken after I had mocked up the new Quarter panel and started cutting things off. (sorry do not have a before shot)
Pic #2. The new Quarter panel. Pic #3. I changed gears here real quick so I could get the new Rockers installed so this is of the inner structure being rebuilt. Pic #4. After it was all redone and ready to fit the new rocker. Mark... |
Re: Reed 78 FJ40 Rebuild
I'll follow along Mark.
I really like the way you tackle things, I can learn so much from you! This Toyota is (was) a Jeep lookalike, right? |
Re: Reed 78 FJ40 Rebuild
Glad you are posting this new project, will be fun to see.
Dwight |
Re: Reed 78 FJ40 Rebuild
Kees, Yes they are very similar in the look of them (I feel they are better looking than the jeep)
Thank you my friend for checking this out it has been a fun project! We ALL can learn from one another! Mark... |
Re: Reed 78 FJ40 Rebuild
Thank's Dwight!
More to come.. Mark... |
Re: Reed 78 FJ40 Rebuild
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I want to apologize for the lack of BEFORE shot's !!
I thought I took several but I didn't so this is what I had.. Pic #1. The new rocker being fit. Pic #2. After I got it tacked in place. Pic #3. All welded and metal finished. Pic #4. The Drivers side. How I fit the new rockers, I first started with the passenger side panel (new) flipped it over and layed it over the top of the (old) drivers side and traced the shape and repeated for the passenger side. This gave me a perfect cut line on both sides. Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. The Drivers side all wrapped up.
Pic #2. This is a shot of the passenger side wheel tub "parts" as they were removed to be replaced. Pic #3. The tub after the pieces were removed. The reason it was done this way is do to things wanting to flex the rear section of the floor was rotted and if I were to remove the entire tub things would get out of hand. Besides the rest of the tub was decent shape. Pic #4. The new panel being fit. Mark... |
Re: Reed 78 FJ40 Rebuild
I just was going to ask why not replace the whole wheeltub, but you was a bit quicker then me ;) and answered it at #3 :lol:
Seems a lot more work thou? |
Re: Reed 78 FJ40 Rebuild
HaHa! yes after I looked over things, before I started to cut things out I noticed that the floor and the sides would move to much so I had to go this route. It is more work in some ways (I did check on new tubs they were $600 ea!! ) so the customer said to just fix the bad spots!
Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. Tacking it all in place.
I did spray rust encapsulator on the supports before I tacked this in. Pic #2. After all the welding and metal finish was done. Pic #3. In this shot I'm showing the new flange being made. The entire flange when done will have holes popped in it for spot welds for the quarter panel. Pic #4. After metal finish was done. (And you can see how bad the rear sill was rotted and needed to be replaced before the quarters go on) |
Re: Reed 78 FJ40 Rebuild
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Pic #1. Here I've started on the front section of the tub. There is a few different angles to make for this piece. also if you notice the floor section will need repair work as well.
Pic #2. Another shot of the floor section. This area has an under structure of the support that is flanged, the floor section that is flanged and the panel for the tub is also flanged. They will all be spot welded together like the factory. Pic #3. The new floor piece being fit. Pic #4. all welded and metal finished. Pic #5. The new panel for the tub ready to go in. Mark... |
Re: Reed 78 FJ40 Rebuild
Nice work Mark. Boy, this is sure one where you have to think about sequence of repairs...like you did with the tub. Good example for all of us to follow.
Wow, that is rusty. Are these vehicles pretty rare? |
Re: Reed 78 FJ40 Rebuild
Thank's again Doug!
It was one of those thing's where you sit,study and finally Do.. The odd thing is, they are not super rare but they have a HUGE following for these things and bring Stupid money for them Restored! A company by the name Icon does a ground up build and are getting $125,000.00 for them!! Fuel inj. Kevlar coating for the body etc. Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. The panel welded in.
Pic #2. The flange spot welded like factory. Pic #3. This is the old sill (under the rear doors) This will need to be replaced before I can move forward with the quarter panel. (it was on order as well as the side uprights that's why I started on the tub first) Pic #4. The rotted floor section removed. (if you notice the aluminum angle holding the sides together to keep from moving) Pic #5. This was the new floor panel installed. If you look close the passenger side upright is rotted and will be replaced as well (was on order as mentioned above) Mark... |
Re: Reed 78 FJ40 Rebuild
Boy, that's some repair work!
I'm glad you know what you are doing!! |
Re: Reed 78 FJ40 Rebuild
LMAO!! yeah,well I'm figuring things out as I go Kees!!
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Re: Reed 78 FJ40 Rebuild
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Pic #1. Sill being fit, checking for being square for the door opening etc.
Pic #2. All spot welded in place. Now ready to start with the quarter panel. Pic #3. The flange has been punched with holes for spot welding. Pic #4. Fitting the QTR. Pic #5. All tacked and spot welded. Mark... |
Re: Reed 78 FJ40 Rebuild
1st class metal working skills you have there. Great job on the restore of this Toyota!
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Re: Reed 78 FJ40 Rebuild
Thank you very much!
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Re: Reed 78 FJ40 Rebuild
Wow, extensive repair. Nice work. Is there a rolled edge along the bottom of the quarter and wheel opening?
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Re: Reed 78 FJ40 Rebuild
Yes! Just like factory they are really nice quality pieces.
Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. Here I'm showing the back section after it was welded to the sill, and ready for A Lot of welding..
Pic #2. After the welding,Grinding and metal finish was done. I textured the metal for the Armorthane coating that was going to be applied originally but the customer has since changed his mind and is going with the Kevlar coating instead. Pic #3.In this pic it shows the old QTR cut off (the black line shows the actual cut line and if you notice there is the old metal from flange still attached) Pic #4. This was taken to shoe the old brace that will need some repair! Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. The upright was replaced and the first panel replaced in the rear section tying the floor and upright together. (The reason I went this route is I did not want to cut to much off and have things get out of hand)
Pic #2. Support brace was repaired,drilled and new flange nuts installed (SAE Nuts) Then the new patch welded in. Pic #3. Her I am starting to make the new flange. Pic #4. In this shot I am using 1x1 tube clamped to the tub to keep it nice and straight while welding. And if you notice the remaining portion of the tub has been repaired. These spots (with holes) are for the future RollCage to be bolted to. |
Re: Reed 78 FJ40 Rebuild
Man!
You're building a complete new Toyota!! Really nice work Mark! |
Re: Reed 78 FJ40 Rebuild
Yes Sir! This turned out to be alot more work than we had thought it was going to be. When it showed up it had bed liner covering the floor and wheel tubs so you couldn't see all the rot..
Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. The drivers side front section of the floor needed the same repairs as the passenger side.
Pic #2. All repairs done in this section and flanges all done. Pic #3. Drivers tub side was then cut out for repairs. Parts of the floor would also have to be repaired. Pic #4. Small section of floor removed. Pic #5. New piece made and ready to be mocked up. Mark... |
Re: Reed 78 FJ40 Rebuild
Haha, you make it look like a minutes work here and so simple to do :lol::lol:
But we know better....don't we?? keep up this great work! |
Re: Reed 78 FJ40 Rebuild
Nice work Mark. This is almost a "How to build a body from scratch" tutorial. Very cool save!
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Re: Reed 78 FJ40 Rebuild
Thank's Kees and Doug!
You guys are right, this thing was a basket case when it showed up it's the worst body Iv'e Ever had to rebuild!! It has been a real learning experience for me. A ton of pre planning on what to do next if you cut one thing loose what will happen kinda thing. As for time we all know these thing's suck up time like Hoover Vacuum!! :lol: Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. Fitting the new panel for the tub. I also had the floor pieces tacked in place for fitting.
Pic #2. After getting it tacked in, and ready for final welding. Pic #3. Iv'e jumped forward to the quarter panel rather than just showing the same thing over again. (If you look close I had the doors set in place to make sure the side were square before welding) Pic #4. After welding and metal finish. Pic #5. Fitting the rear doors. (The extra holes are for the Large rear doors when the top is being used ) Mark... |
Re: Reed 78 FJ40 Rebuild
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Moving on....
Pic #1. Here are the floor plates for the roll cage that will be built. It is going to be a rockcrawler style of cage, very tough looking! Pic #2. This was the starting point, after I got it plum,level etc. it was time to get the rear hoop mocked up. Pic #3. Using the overhead hoist and Dad we were able to get it set at an angle we felt looked pretty good and tacked it in place. Pic #4. Both uprights tacked in.. Mark... |
Re: Reed 78 FJ40 Rebuild
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In these next shots Iv'e jumped a few steps to save some time.
Pic #1. All bars mocked up and tacked in. Pic #2. Front view shows how the center section is raised some. Pic #3. A better view from top. Pic #4. All welded. Pic #5. We ran into a problem when we tried to remove the cage it would not come out! (rear plates hung up on sides of tub) Come to find out, this was a weld in cage and stays put!! Sooo, I cut the rear tubes, sleeved,drilled and Viola!! all fixed. |
Re: Reed 78 FJ40 Rebuild
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Now since the roll cage was finished I then moved on to getting the body shot in rust encapsulator on the underside of body and out side.
Pic #1. The body after spraying. Pic #2. Shot of inside. Pic #3. In this pic it is showing the new LED turn signals. On these FJ's they came from the factory with these Gigantic blinkers that mount on top of the front fenders 6" x 4" so they went away and I put these custom ones in the grill housing. |
Re: Reed 78 FJ40 Rebuild
It looks like a body again! Nice work Mark. And a good choice on the custom blinkers.
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Re: Reed 78 FJ40 Rebuild
Looking great Mark!!
And I agree with Doug, the blinkers are way better than factory! |
Re: Reed 78 FJ40 Rebuild
YES they are, the stock one's resembled something off of a school bus!!
Thank's again guys.. Mark... |
Re: Reed 78 FJ40 Rebuild
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In this post I have got started on the chassis finally.
The rear section of the chassis has 2 cross braces that were rotted and the upper shackle perches were rotted badly as well so I first cut the heads of the rivets (all 24 of them ) followed by the air hammer to remove them. Then was able to install the new upper mounts and braces. Pic #1. After pieces were removed. Pic #2. New braces and perches installed. Pic #3. I went ahead and installed the rear disk conversion before I moved on to the springs. Pic #4. The new springs and shackles. (it will be a 4" lift on the leaf and 2" on shackles for a total of 6") Way too much in my opinion on a short wheelbase truck but it's not mine. ;) Mark... |
Re: Reed 78 FJ40 Rebuild
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Pic #1. In this shot it shows several things...
1. The tube coming through the cross member is for the snout of the new steering box (GM) it will be trimmed to fit and welded in. 2. The plate sitting on the floor is the new mounting plate that gets welded to the frame. 3. If you notice on the front shackle It's a snotted up mess and will need fixing! Pic #2.New plate after it was welded in and the shackle was repaired as well. Pic #3. Passenger side boxing plate and shackle was repaired. Pic #4. The new box in place. (GM style box or Saginaw from a tornado) Mark... |
Re: Reed 78 FJ40 Rebuild
Nice repairs on the frame Mark. Does the GM box give better ratio or more strength?
You know I'm really liking a GM part on this build. :) |
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