FJ45 Build/Restoration
07-27-2016, 07:03 PM
#22
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08-02-2016, 05:55 PM
#24
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08-02-2016, 07:01 PM
#25
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Latest update with the project has been the differentials. I sent them to Ken at gearinstalls.com. This guy does great work, specializing only in Toyota diffs. I had them both rebuilt using master install kits, marlin upgraded pinion seals, 3:70 gearing, and Aussie lockers front and back. I went with the 3:70 gearing for better HWY. manners (lower RPM), and maybe a little better fuel mileage. The Aussie lockers are great, I've had them in several Toyotas in the past. They're essentially unnoticeable on the street but obviously make a big difference in the trucks ability off-road.
Here they are removed:
And here they are freshly rebuilt from Ken.
And here's the rear diff installed. Notice how thick the rear leaf pack is! Many of these FJ45's in outside countries had true factory 1 ton ratings. Another interesting point is these non-domestic FJ's came with full floating rear axles, something I don't think we ever got here. From my understanding they have more than twice the load rating, and they did not use C-clip retainers like the U.S. FJ's (which were prone to c-clip failure). It's also much easier to service the rear bearings. They're set up just like the front wheel bearings and can be repacked (notice the extended hub past the brake drum). Just an interesting Toyota factoid for ya.
Also got the doors finished. I stripped both down to bare metal front and back, then painted them inside and out for a full color change. I was amazed to not find a single spec of rust on either of them,
Here they are painted. I bought over $500 worth weather stripping and some replacement linkage to get these doors properly rebuiltt. Wasn't expecting the seals to cost that much.
I picked up some new door panels, new handles, new window cranks, ect.... to finish them off.
I had to do some work to the cooling system as well. Replaced every hose, new belts, and a new heater valve went in.
I started on the interior as well. I gutted it (wasn't much to remove).
Ordered a new OEM gauge cluster to reassemble the interior with. Old one had a few faulty gauges.
Painted all the dash pieces to match each other, and new shift instruction decal for the glove box. Used flat clear coat to reduce glare.
Next I did a little work to the front end while I had it apart for the diff rebuild. I put in the upgraded marlin seals, new dust seals (all four corners), new a spindle nuts, new rock rings (thicker knuckle seal retainers than stock), also grabbed some magnetic drain plugs for the diffs from trail gear.
Decided to installed new wheel bearing in the front while I had the hubs off.
And here she is getting its first test run down at the river. Trucks running great, and the Aussie lockers make the FJ feel unstoppable.
Also got the rear end cleaned up with some new tail lights, new license plate mount, tow hook, etc...
Been lazy on the bed sides (drop sides). Here they are, just need to get them finish them up. I did get the tailgate done tho. The beds been a pain to get finished. The entire thing is galvanized, fully welded, and very thick steel. Whoever bought this bed in Australia must have paid a lot for it. Being that its galvanized every piece has to be acid washed to properly etch it before the epoxy primer goes on, making the process a little more time consuming.
Still have a lot of work to do, such a finishing the bed sides, some interior work, new stainless exhaust going on this week, etc... Will post another update soon.
I appreciate everyone's comments, and hope you've enjoyed the build process so far. Let me know what ya think now that's its nearing completion. Criticisms, complements, suggestions are all welcome ( I have thick skin, no worries).
Here they are removed:
And here they are freshly rebuilt from Ken.
And here's the rear diff installed. Notice how thick the rear leaf pack is! Many of these FJ45's in outside countries had true factory 1 ton ratings. Another interesting point is these non-domestic FJ's came with full floating rear axles, something I don't think we ever got here. From my understanding they have more than twice the load rating, and they did not use C-clip retainers like the U.S. FJ's (which were prone to c-clip failure). It's also much easier to service the rear bearings. They're set up just like the front wheel bearings and can be repacked (notice the extended hub past the brake drum). Just an interesting Toyota factoid for ya.
Also got the doors finished. I stripped both down to bare metal front and back, then painted them inside and out for a full color change. I was amazed to not find a single spec of rust on either of them,
Here they are painted. I bought over $500 worth weather stripping and some replacement linkage to get these doors properly rebuiltt. Wasn't expecting the seals to cost that much.
I picked up some new door panels, new handles, new window cranks, ect.... to finish them off.
I had to do some work to the cooling system as well. Replaced every hose, new belts, and a new heater valve went in.
I started on the interior as well. I gutted it (wasn't much to remove).
Ordered a new OEM gauge cluster to reassemble the interior with. Old one had a few faulty gauges.
Painted all the dash pieces to match each other, and new shift instruction decal for the glove box. Used flat clear coat to reduce glare.
Next I did a little work to the front end while I had it apart for the diff rebuild. I put in the upgraded marlin seals, new dust seals (all four corners), new a spindle nuts, new rock rings (thicker knuckle seal retainers than stock), also grabbed some magnetic drain plugs for the diffs from trail gear.
Decided to installed new wheel bearing in the front while I had the hubs off.
And here she is getting its first test run down at the river. Trucks running great, and the Aussie lockers make the FJ feel unstoppable.
Also got the rear end cleaned up with some new tail lights, new license plate mount, tow hook, etc...
Been lazy on the bed sides (drop sides). Here they are, just need to get them finish them up. I did get the tailgate done tho. The beds been a pain to get finished. The entire thing is galvanized, fully welded, and very thick steel. Whoever bought this bed in Australia must have paid a lot for it. Being that its galvanized every piece has to be acid washed to properly etch it before the epoxy primer goes on, making the process a little more time consuming.
Still have a lot of work to do, such a finishing the bed sides, some interior work, new stainless exhaust going on this week, etc... Will post another update soon.
I appreciate everyone's comments, and hope you've enjoyed the build process so far. Let me know what ya think now that's its nearing completion. Criticisms, complements, suggestions are all welcome ( I have thick skin, no worries).
Last edited by J.yota; 08-04-2016 at 07:47 PM.
08-04-2016, 07:54 PM
#27
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Thread Starter
Thanks, I appreciate the kind words! Wasn't sure how my color combo, flat clear, ect....would all come together in the end. I think it looks pretty good for the most part now that its almost finished,
08-04-2016, 08:18 PM
#28
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Thread Starter
Looking for any opinions here, much appreciate your thoughts before I spend a bunch of money doing this. I'm contemplating having a canopy frame made at a local fab shop for the FJ. There's an upholstery shop near me that says they'll build the canvas covering once I had the frame done. This whole project quoted out was just under $900. Not sure if the added "looks" and utility of it is worth my time and money.
Here's a few pics of finished ones I found to give you an idea of what it should look like. I would plan to match the canvas color to the trucks sand beige color.
I would also like the sides and rear to roll up similar to this one.
Does it look goofy, too busy, look good, etc... ? Let me know your thoughts, thanks!
Here's a few pics of finished ones I found to give you an idea of what it should look like. I would plan to match the canvas color to the trucks sand beige color.
I would also like the sides and rear to roll up similar to this one.
Does it look goofy, too busy, look good, etc... ? Let me know your thoughts, thanks!
Last edited by J.yota; 08-05-2016 at 05:57 PM.
08-16-2016, 06:08 PM
#30
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Thread Starter
Small update here, trucks almost finished. I did decide to have the canvas canopy built for the FJ, I think it'll finish it off nicely. The canopy should be done by the end of next week, at least that's what the upholstery shop said.
One of my recent projects included converting an water holding tank that was originally mounted under the bed into a useable tool storage compartment. Grabbed my cut off wheel and a few rivets and had it done quickly.
Here's the box remounted after coating it with Raptor Bed Liner. The bed liner is really good stuff, but at $130 a gallon its expensive.
I next finished off the bed sides, and bought some original emblems for the tailgate.
Here they are mounted, I think they give the flat bed a little more (finished) look.
Also got the interior finished.
New door panels
Moved onto sorting/detailing the engine bay.
The drop sides make this truck really useable and easy to load, I like this flat bed.
Took her down to the river for some poser shots
That's it for now, I'll try to get some pics up soon when I get the canopy done.
One of my recent projects included converting an water holding tank that was originally mounted under the bed into a useable tool storage compartment. Grabbed my cut off wheel and a few rivets and had it done quickly.
Here's the box remounted after coating it with Raptor Bed Liner. The bed liner is really good stuff, but at $130 a gallon its expensive.
I next finished off the bed sides, and bought some original emblems for the tailgate.
Here they are mounted, I think they give the flat bed a little more (finished) look.
Also got the interior finished.
New door panels
Moved onto sorting/detailing the engine bay.
The drop sides make this truck really useable and easy to load, I like this flat bed.
Took her down to the river for some poser shots
That's it for now, I'll try to get some pics up soon when I get the canopy done.
Last edited by J.yota; 08-16-2016 at 06:16 PM.
08-17-2016, 01:58 PM
#31
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Thread Starter
If anyone's interested, I'm going to put my FJ45 up for sale once I complete it. I recently bought a Land Rover Defender (Isuzu Turbo Diesel). I can't afford to keep this anymore, as the Rover needs a lot of money and time thrown at it. This Land Cruiser will be hard to replace once completed, hate to let it go but I can't keep em all. Haven't thought on the price much, but probably around 30K so I can at least get my money back (this would be valuing my time and labor at zero). If you're interested feel free to message me for more info etc..
Anyways, here's the new to me 1986 Rover Defender.
Anyways, here's the new to me 1986 Rover Defender.
Last edited by J.yota; 08-18-2016 at 06:58 AM.
09-11-2016, 07:10 PM
#33
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Thread Starter
Been working on the FJ a little more lately. Recently found an original rim, so I bought a new matching 33 BFG to mount up as my spare tire/wheel. Nice to have a full size matching wheel and tire under the bed.
Forgot to post pics of the front axle rebuild while I had it out for the front Diff rebuild/re-gear.
Also had the canopy completed. I was into this over 1200 for the fab work on frame, material, and labor. I'm really happy with the results. The upholstery shop did a perfect job on it, and they spent a lot of time making it water tight.
Had them build it with roll up sides to make loading things a little easier.
Took the wife out for a little wheeling until she was tired of being bounced all over.
I'm nearly finished with the FJ, and very pleased with it so far. Drives great, it'll do 60+ all day on the hwy. and still climb up a tree with the Aussi lockers front & Rear. Hope you guys have found some entertainment with this build, I certainly enjoy watching all the buildups here.
I will be putting the FJ up for sale this week, I'll be asking 46K. If anyone's interested feel free to PM me for more info. As fun as this truck is, I need to let it go to finance my Land Rover project.
Forgot to post pics of the front axle rebuild while I had it out for the front Diff rebuild/re-gear.
Also had the canopy completed. I was into this over 1200 for the fab work on frame, material, and labor. I'm really happy with the results. The upholstery shop did a perfect job on it, and they spent a lot of time making it water tight.
Had them build it with roll up sides to make loading things a little easier.
Took the wife out for a little wheeling until she was tired of being bounced all over.
I'm nearly finished with the FJ, and very pleased with it so far. Drives great, it'll do 60+ all day on the hwy. and still climb up a tree with the Aussi lockers front & Rear. Hope you guys have found some entertainment with this build, I certainly enjoy watching all the buildups here.
I will be putting the FJ up for sale this week, I'll be asking 46K. If anyone's interested feel free to PM me for more info. As fun as this truck is, I need to let it go to finance my Land Rover project.
Last edited by J.yota; 09-11-2016 at 07:44 PM.
09-15-2016, 05:52 PM
#35
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Thread Starter
Took the FJ out for an over night trip. Wanted to enjoy it a little before it sells. Set up camp with my sidekick, and had a great time hiking and shooting.
Also refinished the decking in the bed.
Weathers been great here in Oregon, might try to squeeze in one more camping trip this month.
Also refinished the decking in the bed.
Weathers been great here in Oregon, might try to squeeze in one more camping trip this month.
Last edited by J.yota; 09-15-2016 at 05:53 PM.
