That is great: IT'S ALIVE!

Keep posting about this build. I really enjoy your work and your perspective.

Very impressive!

Where are you going to put the fan that cools down the intake after shut down to prevent vapor lock/hot start issues on the 3FE?

Also, what transmission and transfer case are you going with? Looks as if you are planning for part time transfer case seeing that you have lockers. If you want to go full time and are looking for parts, I have a trans and transfer case out of a 91 laying around. SmileWavy But they'd make that 3rd pedal useless!!


Cool project, love LC's

I'm not going to run a cooling fan but can add one later if it seems to be necessary. I know of at least a half dozen 3FE conversions in FJ40's that are out there and going strong. None of them added the fan so let's hope it doesn't become an issue for me.

The transmission/transfer case are stock 4 speed models and should be a nice upgrade from the 3 speed. I don't have any lockers just yet but hope to add some in the future![

A couple weeks ago I got new tires put on the truck and took it for a test drive.
I was pretty happy with the way it drove although traveling faster than 35mph was not fun without a windshield.

So it was good bye to this:

http://i371.photobucket.com/albums/o...pscca31b79.jpg

And back to this:

http://i371.photobucket.com/albums/o...ps488e6057.jpg

I also finished up a couple small side projects too. I had to cut out the botched V8 transmission tunnel and start over:

http://i371.photobucket.com/albums/o...ps20e70f4e.jpg

http://i371.photobucket.com/albums/o...psb0a8e9cd.jpg

http://i371.photobucket.com/albums/o...ps827b4c9f.jpg

I also got to work on my auxiliary fuel tank filler. I'm not installing a tank just yet, but I figured now is the time to install the filler for a future installation.

http://i371.photobucket.com/albums/o...ps50c723ab.jpg

Rough cut hole:
http://i371.photobucket.com/albums/o...ps77a94b54.jpg


http://i371.photobucket.com/albums/o...psf6adcec6.jpg


I also added a home made bracket to the bib to attach the emergency hood catch from a later 40.

http://i371.photobucket.com/albums/o...psb231ebad.jpg

I just know I'm likely to forget to latch the hood at some point and the thought of having my nicely painted hood fly up and self destruct makes me sick.

http://i371.photobucket.com/albums/o...psbe831a56.jpg

I also got my seat heaters installed and the seats reupholstered yesterday.

http://i371.photobucket.com/albums/o...psb60e3a99.jpg

I've been trying to finish up the last bits of wiring before getting into the body work and paint (which I dread). I got my new Tuffy console in the mail and as soon as I had the switches I wanted, I started cutting it up. ...this was a little scary.


First off, the Tuffy console with the radio compartment is not really a good fit between the FJ40 seats. I really have to squeeze it in there and I'm pretty sure the driver's seat won't slide easily now.

I decided to mount my aux switches and seat heaters to the front of the console as opposed to the dash. There was a lot of "measure three times, cut once" involved in this. I also added a 12v socket and a dual USB charger as well just for grins.

The cupholder will likely be mounted directly to the transmission tunnel, just aft of the shift lever.

Oh, speaking of shift lever... I also had to take my newly powdercoated lever and put an elbow mid way down the shaft to work with the Tuffy console. Bummer.

Anyway, here are some photos:

Scribed and ready to cut. Notice I positioned everything where it will cover or remove the existing cup holder holes. Also, I used a sheet metal punch to cut the holes for the chargers:
http://i371.photobucket.com/albums/o...psd6ad7b29.jpg

I used the modular carling switch brackets from Air On Board for the switches:
http://i371.photobucket.com/albums/o...ps26490ee4.jpg

The rear light switch will control the spare tire mounted flood light I'm planning to use. I'm adding two interior lights using red LED lights. This will preserve night vision and since it'll look a bit like a battle ship CIC, I figured "zombie Lights" wasn't too far off. I also used nut-serts to hold the charger faceplates, which I thought was a nice touch.

http://i371.photobucket.com/albums/o...psc8f331ad.jpg

Heater switches mounted up and all done!
http://i371.photobucket.com/albums/o...ps852d4158.jpg

I also got a couple patch panels fab'ed up to replace the rotted metal on the rear top sill/hard top joint.
This is the last of the rust repair on my 'cruiser.

http://i371.photobucket.com/albums/o...psec8b4740.jpg

Cut out:

http://i371.photobucket.com/albums/o...psb24149de.jpg

Construction paper template:

http://i371.photobucket.com/albums/o...pscd1fd8ad.jpg

Transferred to sheet metal and bent to match:

http://i371.photobucket.com/albums/o...ps2541e7dd.jpg

Welded in and blended to match... 'ish:

http://i371.photobucket.com/albums/o...ps452ac0d5.jpg

Now my focus is body work and paint prep.


Speaking of paint... I had a local paint shop and had them mix up three paint samples for me to choose from. The problem I had is that they could not find several of the PPG numbers I had for the Toyota paint codes (Nebula Green and Breathe Green).

So, the finalists are:

Fashion Green (left)

Olive Grey (center)

Light Olive (right)

http://i371.photobucket.com/albums/o...ps849ac29f.jpg

http://i371.photobucket.com/albums/o...ps40482576.jpg

http://i371.photobucket.com/albums/o...ps83bae1af.jpg

http://i371.photobucket.com/albums/o...ps05fd169e.jpg

I've all but eliminated Olive grey so the real choices are between the two lighter greens.

It's exciting to see paint laid down on a panel... then I realize how much work stands between me and actually spraying the body and I want to cry.

Also, I'm pretty proud of my home made body dolly I made out of 1.25" angle.

It has come in VERY handy.

http://i371.photobucket.com/albums/o...psd430d30c.jpg

http://i371.photobucket.com/albums/o...psd5de861f.jpg

So impressive. I am always in awe of talent like yours.

I like the darker green but, really, who cares...this thing is going to be yours, all that matters.

Excellent craftsmanship! What did you use to fabricate this piece?

My vote is for the light olive and then flat or satin black mirrors, bumpers and wheels.

http://forums.pelicanparts.com/uploa...1384120199.jpg


http://forums.pelicanparts.com/uploa...1384120220.jpg

All I can say is WOW! Great work!

Thanks guys!

The patch piece was just made from 16 ga. steel. I used the poster board as a template. Then, I used some machinists dye to color the steel and traced the poster board shape with a scribe. I have a little nibbler that I used to cut it out and used a bench vise to bend the ears to make the box shape.

Fantastic progress. I wouldn't worry about the little 3FE fan, I removed mine when I desmogged my FJ80 and it didn't make a difference. Great motor that really woke up when I removed all of the cobbled together emissions junk.

Got some more work done on the truck. I flipped the tub over (not an easy task by yourself) and began work on Project Sound Deadening.

I applied one layer of Dynamat Xtreme to the underside of the tub, then used brush-able seam sealer to seal all the edges. Then I got it scuffed with a scotchbrite pad and shot two heavy coats of primer over it. Next will be to spray a good coat of Rock-it Liner to the undersides to cover the Dynamat. Hopefully it makes a difference in engine heat/noise.

http://i371.photobucket.com/albums/o...psb5392343.jpg

http://i371.photobucket.com/albums/o...ps992a6c9c.jpg

http://i371.photobucket.com/albums/o...pse049627e.jpg

http://i371.photobucket.com/albums/o...pse6da240f.jpg

http://i371.photobucket.com/albums/o...ps5fbfa8bc.jpg

http://i371.photobucket.com/albums/o...ps25d2934f.jpg

http://i371.photobucket.com/albums/o...psc9eee7fb.jpg

http://i371.photobucket.com/albums/o...psae368fd2.jpg

Here is my 78, I doubt it will ever look as good as your does in primer!


http://forums.pelicanparts.com/uploa...1384271233.jpg

Update?

Here's a mega update for you, Don. :)


Soundproofing and rock-it lining the tub:

http://i371.photobucket.com/albums/o...ps43b35639.jpg

http://i371.photobucket.com/albums/o...psij1w9dup.jpg

http://i371.photobucket.com/albums/o...ps6fx0zf52.jpg

http://i371.photobucket.com/albums/o...ps8vljyf3s.jpg

http://i371.photobucket.com/albums/o...psgorseqq5.jpg

http://i371.photobucket.com/albums/o...psgh2quofp.jpg

Laying down 2K primer:
http://i371.photobucket.com/albums/o...ps2anqujhr.jpg

http://i371.photobucket.com/albums/o...psq08cjxe2.jpg

Rock-it lining interior:
http://i371.photobucket.com/albums/o...psdgrzjozm.jpg

Then, I jambed the tub and painted the cowl and dash:

http://i371.photobucket.com/albums/o...pswqlxlmyp.jpg

http://i371.photobucket.com/albums/o...ps7kjviaec.jpg

http://i371.photobucket.com/albums/o...psghf2kkx2.jpg

Working by myself requires a certain amount of creativity when it comes to getting things done. This, for example, is a lift (of my own design). I call it the Lift-o-matic 5000:
http://i371.photobucket.com/albums/o...psbyypjrvh.jpg

http://i371.photobucket.com/albums/o...pslfq4mj7n.jpg

http://i371.photobucket.com/albums/o...pshzlouacd.jpg

http://i371.photobucket.com/albums/o...ps3ksislql.jpg

http://i371.photobucket.com/albums/o...ps5udjmswf.jpg

http://i371.photobucket.com/albums/o...pspwtum5aq.jpg

http://i371.photobucket.com/albums/o...psqcbcyr5c.jpg

Then I set about installing my newly wrapped wire harness:

http://i371.photobucket.com/albums/o...psws4b6olf.jpg

...with all new connectors:

http://i371.photobucket.com/albums/o...psvdka4h7s.jpg

This is clearly not original. I integrated the FJ62 fuse panel to benefit from the modern spade fuses and to have more fuse positions. I also added a relay panel to handle the hi/lo beams as well as the switched ignition/ECU demands of the 3FE:

http://i371.photobucket.com/albums/o...psyvkrfa6t.jpg

http://i371.photobucket.com/albums/o...psdhmewv6s.jpg

http://i371.photobucket.com/albums/o...ps7iox9lud.jpg

More paint:
http://i371.photobucket.com/albums/o...psq98npgmp.jpg

More work on my home made tailgate (made from two welded together barn doors:
http://i371.photobucket.com/albums/o...ps6qichdln.jpg

http://i371.photobucket.com/albums/o...pssygr5xxo.jpg

http://i371.photobucket.com/albums/o...psfniywdif.jpg