The installation has begun

Ethan's first oil change.

And back on...

Minor motor mount modification due to the original owner welding something to it...

Ohh Ahhh! We are painting this a racing red brake drum. Primer must go.

Fluted, larger brake drum for the front brakes. They are actually 3" wide up front. Compared to the rear of 2.25".

Old and new to be modified to match.

Now this is more like it.

Greasing the zerk fittings

MMMmmmm good. Old mixes with new grease.

It looks like Christmas in September.

Heather and Allie greasing the joints. LOOK! They painted the garage as well.

Opps! Nut dropped a nut! Admire the speed.

Fuel pump preparation by Ethan

Drive line assembly

Who's going to test drive Ethan's work?

Before the steering damper shock installation

And After installation of damper shock


And now Erin's turn to turn the wrench...

We have begun to install the components, level the fluids, and make sure we use all the nuts, bolts, and screws.

Body Work

Lower Dutch doors ready for balsting and primer.



Minor rust eliminated.

Jason from CRM Fabrications.

One of two minor cut-out spots on the whole body.

The other spot.

Major work to ensure the tub and top didn't rust again.

Not only are we on an exercise program getting a buddy ready for the Army, we are working on the FJ40 body. All rust has been eliminated. What minor cancer we found was cut out and new metal welded in its place. Jason at CRM Fabrications matched the turns in the top and bent metal back to the original. See the work.

Also, the '77 FJ40 has ambulence doors. This is inconvenient when you remove the top. We added the standard tailgate doors with new reinforced bolt holes. Looks original.

Blast All

Jaime is a big man to do this big job. Good work, Jaime.

While shopping around for a bead-blast company, I found one right here in Gainesville. Anthony actually came to the house to estimate the work. He picked the FJ up Friday and by Friday afternoon had it Bead-blasted. He has great attention to detail and looking at the product during the process, he isn't missing a spot.

Frame painted and parts go on

Transfer case, clean as a whistle...
Engine, transmmission and transfer case waiting for lubrication.
Rhino rubber on the frame, new shock, and read brake
New, clean brake shoes, springs and cylinders.
Crisp and clean transfer case gearing. Looks great after 33 years of use!!

The process is now reversed. The frame painting has been completed and the parts are going back on...

Next steps: turn the drums, remove the badges, windows, and gasketing for bead blasting the body (prior to painting), installation of the A/C and preparation for the wiring harness.

Final Parts come off and Erin Paints!!!

Transfer case is off and ready to re-gasket (although there were no leaks...)

ERIN is over there on the left!! James is looking at the transfer case prior to removal.

Frame paint and then the ruberized liner material for added protection.

Yep...Erin ran this part of the job....

And yes, I missed a spot, per my bride...

Frame cleaning and painting

BEFORE
AFTER!!
Mighty Mouse steals the paint gun...
Still going. He ends up a light shade of Grey at the end of the night...

Paint instructor. Notice he has a better mask than the student in the Maroon shirt.

Ethan and I learned to paint. Note to self: Wear a better mask! Mr. James teaches the "crew" how to airbrush the color black.

And then we paint

The blog is harder to keep up then the actual work. Since the last Blog, we have built a 100' walkway to the lake, had a reunion, and finally got back to the FJ40. The following are over the last few weeks and the end of Summer 2010. We are on the downhill slide. Painting and putting on parts. How about the BLUE ENGINE!!