Bezel Boys Cruisers - got bezel?

Classic Bezels 1951-1984 => Build Threads => Topic started by: Theo Marx on July 11, 2009, 08:48:06 PM

Title: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 08:48:06 PM
After all the bashing from the others I finally gave up driving her and started stripping her...  :'(


(http://lh5.google.com/coleenmarx/R_FERDeTL4I/AAAAAAAAAGw/x9JAOlOARMQ/P1010444.JPG.jpg?imgmax=512)



(http://lh4.google.com/coleenmarx/R_FEdzeTL5I/AAAAAAAAAG4/YrDNkRxcess/P1010448.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_FEujeTL6I/AAAAAAAAAHE/BSk8B9S4sHA/P1010450.JPG.jpg?imgmax=512)


PO seemed to have a thing for ammo boxes  ::)


(http://lh3.google.com/coleenmarx/R_FE7jeTL7I/AAAAAAAAAHM/fFxirUfx67g/P1010456.JPG.jpg?imgmax=512)


The OEM BB brackets needed some attention


(http://lh4.google.com/coleenmarx/R_FBTzeTLtI/AAAAAAAAAFo/IRsEWlwptqo/P1010705.JPG.jpg?imgmax=512)

With the "mask" removed


(http://lh4.google.com/coleenmarx/R_FBhzeTLuI/AAAAAAAAAFw/6OWzMG4Ny9w/P1010715.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_FBMjeTLrI/AAAAAAAAAFc/zuHSDXdp0Ns/P1010718.JPG.jpg?imgmax=512)

After some whirewheeling and some good stuff they were good as new.


(http://lh5.google.com/coleenmarx/R_FA9DeTLpI/AAAAAAAAAFQ/05FBSCAio4w/P1010721.JPG.jpg?imgmax=512)


Then on to the roof removal. First the snorkel and rear doors.


(http://lh4.google.com/coleenmarx/R_FCOzeTLwI/AAAAAAAAAF8/qqPfHQ5Tscg/P1010495%281%29.JPG.jpg?imgmax=512)



(http://lh5.google.com/coleenmarx/R_E93DeTLiI/AAAAAAAAAEY/_DuRkXiJPSQ/P1010746.JPG.jpg?imgmax=512)



(http://lh4.google.com/coleenmarx/R_E_9zeTLnI/AAAAAAAAAFA/VGGusC0Qui4/P1010755.JPG.jpg?imgmax=512)



Some door rails



(http://lh4.google.com/coleenmarx/R_E-XzeTLlI/AAAAAAAAAEs/o_WqVWz9JqU/P1010778.JPG.jpg?imgmax=512)



And then it was off with the help of the hired labour..



(http://lh4.google.com/coleenmarx/R_E-mzeTLmI/AAAAAAAAAE4/xivT3kiMnNA/P1010795.JPG.jpg?imgmax=512)



Then the front doors



(http://lh5.google.com/coleenmarx/R_E6SDeTLbI/AAAAAAAAADk/S6nHT4KRsWE/P1010838.JPG.jpg?imgmax=512)



Leaving only the Hard-top side panels and rear door rail



(http://lh6.google.com/coleenmarx/R_E8FTeTLdI/AAAAAAAAAD0/WC7jQNItgfU/P1010842.JPG.jpg?imgmax=512)



Small hiccups



(http://lh6.google.com/coleenmarx/R_E36TeTLYI/AAAAAAAAADQ/fTp9CTsYMk0/P1010812.JPG.jpg?imgmax=512)



 aside the panels came off...



(http://lh5.google.com/coleenmarx/R_E8ZDeTLeI/AAAAAAAAAD8/JG9jM2VY1hQ/P1010854.JPG.jpg?imgmax=512)



 and before long she was topless 8)



(http://lh4.google.com/coleenmarx/R_E80zeTLfI/AAAAAAAAAEE/QoQbQqL-aQo/P1010855.JPG.jpg?imgmax=512)



The inevitable discovery :I did not like the PO's attempt at a "Tuffy Box"



(http://lh6.google.com/coleenmarx/R_E2YTeTLPI/AAAAAAAAABw/-WQAVf92J_g/P1010860.JPG.jpg?imgmax=512)



(http://lh6.google.com/coleenmarx/R_E2hTeTLQI/AAAAAAAAAB8/Vr6vIYgHJNQ/P1010861.JPG.jpg?imgmax=512)



Box removed and what did I find hidden beneath ?



(http://lh4.google.com/coleenmarx/R_E2szeTLRI/AAAAAAAAACE/0HlJeBwfVWA/P1010862.JPG.jpg?imgmax=512)



Could it possibly be the missing key to my Longranger long range tank ?



(http://lh3.google.com/coleenmarx/R_E3CjeTLUI/AAAAAAAAACc/Zm_SbCdaQ9M/P1010866.JPG.jpg?imgmax=512)



After a quick clean-up



(http://lh5.google.com/coleenmarx/R_E3FDeTLVI/AAAAAAAAACk/2hqejMfhF0k/P1010867.JPG.jpg?imgmax=512)



(http://lh3.google.com/coleenmarx/R_E3IjeTLWI/AAAAAAAAACs/obh135CCJkQ/P1010868.JPG.jpg?imgmax=512)



Perfect fit !  


 ..  and then I found



(http://lh3.google.com/coleenmarx/R_E26jeTLSI/AAAAAAAAACM/igpZa3TbkKo/P1010863.JPG.jpg?imgmax=512)



 the reason why JT hides a stash of chips in his 40   ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:24:03 PM
In spite of  :pig: ninja turtle and his tjommies last night, I managed to get a little bit done on my truck today..


(http://lh6.google.com/coleenmarx/R_kleTeTMYI/AAAAAAAAAYo/VO_zwLZVl7A/P1010978.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_kl8zeTMZI/AAAAAAAAAYw/txVZbgvkgn8/P1020006.JPG.jpg?imgmax=512)


(http://lh5.google.com/coleenmarx/R_km-DeTMbI/AAAAAAAAAZA/YLMUApHi7y8/P1020032.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_koHjeTMdI/AAAAAAAAAZQ/_iVIPkk_6lM/P1020029.JPG.jpg?imgmax=512)


(http://lh5.google.com/coleenmarx/R_kmWDeTMaI/AAAAAAAAAY4/ffADQIPyzy8/P1020043.JPG.jpg?imgmax=512)


(http://lh6.google.com/coleenmarx/R_kn3TeTMcI/AAAAAAAAAZI/PHsS5SRY3OA/P1020007.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_kpwzeTMhI/AAAAAAAAAZ0/0bharq-rhB8/P1010991.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_kqCjeTMiI/AAAAAAAAAZ8/ZUSJ_upyNOY/P1010986.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_kqVzeTMjI/AAAAAAAAAaE/DRlgKaGBhtg/P1010995.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_ko8zeTMgI/AAAAAAAAAZk/aofYZ3xUuUQ/P1020047.JPG.jpg?imgmax=512)


(http://lh6.google.com/coleenmarx/R_kq-TeTMkI/AAAAAAAAAaM/7dUxkhGfbH0/P1020069.JPG.jpg?imgmax=512)


(http://lh6.google.com/coleenmarx/R_krPTeTMlI/AAAAAAAAAaU/o5g40NvSK-Q/P1020071.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_klEzeTMXI/AAAAAAAAAYg/mD1SKfUpkI0/P1020005.JPG.jpg?imgmax=512)


(http://lh6.google.com/coleenmarx/R_kimTeTMUI/AAAAAAAAAYI/8cCm0Ddr0c0/P1020050.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_kkdjeTMVI/AAAAAAAAAYQ/9EE3XCuPQL0/P1020100.JPG.jpg?imgmax=512)


(http://lh3.google.com/coleenmarx/R_kktjeTMWI/AAAAAAAAAYY/sIMtbb5V8aU/P1020097.JPG.jpg?imgmax=512)


(http://lh4.google.com/coleenmarx/R_ks-zeTMpI/AAAAAAAAAa0/pz6J_6HjjUk/P1020099.JPG.jpg?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:27:23 PM
For JT   ;)

(http://lh5.ggpht.com/coleenmarx/R_0sIPKnpFI/AAAAAAAAAf0/-k7qi00KXTc/P1020176.JPG?imgmax=512)



(http://lh5.ggpht.com/coleenmarx/R_0qNPKnpBI/AAAAAAAAAfU/USQo8PK71I0/P1020183.JPG?imgmax=512)



(http://lh6.ggpht.com/coleenmarx/R_0qnfKnpCI/AAAAAAAAAfc/abFU36uarPk/P1020185.JPG?imgmax=512)



(http://lh4.ggpht.com/coleenmarx/R_0pA_Kno-I/AAAAAAAAAek/fyAd0rdqtlU/P1020194.JPG?imgmax=512)



(http://lh3.ggpht.com/coleenmarx/R_0p2vKnpAI/AAAAAAAAAfM/uz0C5eLZsNg/P1020207.JPG?imgmax=512)



(http://lh5.ggpht.com/coleenmarx/R_0rwPKnpEI/AAAAAAAAAfs/j0oyr_dk_3g/P1020208.JPG?imgmax=512)



(http://lh4.ggpht.com/coleenmarx/R_0rN_KnpDI/AAAAAAAAAfk/rgJJ_3aIiew/P1020211.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:29:36 PM
Update from last night's efforts..


(http://lh3.ggpht.com/coleenmarx/R_5qwfKnpKI/AAAAAAAAAhk/suWOLl8x_hE/P1020222.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/R_5x7vKnpMI/AAAAAAAAAh4/mLnqRj603X0/P1020233.JPG?imgmax=512)


(http://lh6.ggpht.com/coleenmarx/R_5w3PKnpLI/AAAAAAAAAhs/G_5pdOsLlKw/P1020226.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/R_5qPvKnpJI/AAAAAAAAAhc/5qHUXw6cPg0/P1020258.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/R_5yRvKnpNI/AAAAAAAAAiA/Be79FJVtEmA/P1020242.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/R_50VfKnpOI/AAAAAAAAAiI/ygzR_jmMWW0/P1020243.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/R_51ffKnpPI/AAAAAAAAAiQ/jKwGyHPRG9s/P1020264.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:33:11 PM
Removed the front fenders but first had to remove all the attachments that go with it.   :o

(http://lh3.ggpht.com/coleenmarx/SAH_ze3YC2I/AAAAAAAAAjo/oi7oItL2R5g/P1020266.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SAIAHe3YC3I/AAAAAAAAAjw/LX2RSOMJzjc/P1020287.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SAIAVe3YC4I/AAAAAAAAAj4/RLTikKTm4Ck/P1020282.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/SAIAuO3YC5I/AAAAAAAAAkA/_I2TdUWjvbE/P1020310.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAIBGu3YC6I/AAAAAAAAAkI/WsORYJGjhMI/P1020315.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAIBZu3YC7I/AAAAAAAAAkQ/2Rh79IEavYo/P1020317.JPG?imgmax=512)


(http://lh6.ggpht.com/coleenmarx/SAICF-3YC8I/AAAAAAAAAkc/bim1afgMGB4/P1020333.JPG?imgmax=512)


The OEM battery holder is really robust and heavy   :o


(http://lh5.ggpht.com/coleenmarx/SAICnu3YC9I/AAAAAAAAAkk/NHuNOKq38qA/P1020355.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SAIC9e3YC-I/AAAAAAAAAks/L0VX5IjCN7E/P1020357.JPG?imgmax=512)


(http://lh6.ggpht.com/coleenmarx/SAIDR-3YC_I/AAAAAAAAAk0/bKBykasvOOc/P1020365.JPG?imgmax=512)


And then onto the wipers and motor housing etc


(http://lh6.ggpht.com/coleenmarx/SAJLU-3YDDI/AAAAAAAAAmE/gLDaCOuFfsY/P1020383.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAJLmu3YDEI/AAAAAAAAAmM/CDLlp3XnlYs/P1020385.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAJL2u3YDFI/AAAAAAAAAmU/CgqfATyZu8Q/P1020394.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/SAJMJO3YDGI/AAAAAAAAAmc/ZWeNgBU-OXg/P1020399.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAJMYu3YDHI/AAAAAAAAAmk/mlq3PWsf3Vk/P1020400.JPG?imgmax=512)


The result is that she now looks a tad broken...


(http://lh4.ggpht.com/coleenmarx/SAJI1e3YDBI/AAAAAAAAAl0/_DQxMErcVpc/P1020412.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/SAJK-O3YDCI/AAAAAAAAAl8/yLB1U9rBekE/P1020410.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:38:28 PM
Got a little bit done tonight.


(http://lh6.ggpht.com/coleenmarx/SAO5Zu3YDII/AAAAAAAAAnc/6lCo4TYmkDY/P1020423.JPG?imgmax=512)



(http://lh6.ggpht.com/coleenmarx/SAO5tu3YDJI/AAAAAAAAAnk/GVAavoYS43A/P1020476.JPG?imgmax=512)



Without a SST from TOY I was unable to remove the steering wheel from the splined shaft.No amount of Q20 and wiggeling seemed to work.If I can't borrow the required tool somewhere I will have to make another plan.


(http://lh5.ggpht.com/coleenmarx/SAO6Ue3YDKI/AAAAAAAAAns/MynFcYIBLGs/P1020441.JPG?imgmax=512)



(http://lh6.ggpht.com/coleenmarx/SAO6uu3YDLI/AAAAAAAAAn0/zGlPQkqB9_M/P1020487.JPG?imgmax=512)



(http://lh3.ggpht.com/coleenmarx/SAO7F-3YDMI/AAAAAAAAAoA/EVHMnQQ5zvE/P1020493.JPG?imgmax=512)



(http://lh6.ggpht.com/coleenmarx/SAO77u3YDNI/AAAAAAAAAoI/fBU2Lzj6M9E/P1020495.JPG?imgmax=512)



(http://lh4.ggpht.com/coleenmarx/SAO8jO3YDOI/AAAAAAAAAoQ/ZlDuofE6oJ0/P1020504.JPG?imgmax=512)



(http://lh6.ggpht.com/coleenmarx/SAO81u3YDPI/AAAAAAAAAoY/HD8ake6Kqa8/P1020507.JPG?imgmax=512)



With that out of the way I can reach the mounting points and plumbing for most of the other stuff


(http://lh6.ggpht.com/coleenmarx/SAO9Ou3YDQI/AAAAAAAAAog/KilGgsG0xfY/P1020525.JPG?imgmax=512)


And then another discovery   :o

(http://lh5.ggpht.com/coleenmarx/SAO9qe3YDRI/AAAAAAAAAoo/SSzbwWzSl6w/P1020518.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/SAO-G-3YDSI/AAAAAAAAAow/eY9DOOj6bdM/P1020519.JPG?imgmax=512)


It sure looks 25 yrs old.  ;)


(http://lh3.ggpht.com/coleenmarx/SAO-Y-3YDTI/AAAAAAAAAo4/peHaC29lNGY/P1020521.JPG?imgmax=512)

 ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:41:37 PM
Got a few things done tonight.

Removed the Heater valve(Hot Air) cable that was keeping the centre switch cluster from being removed, and threaded it through the firewall to the inside.


(http://lh3.ggpht.com/coleenmarx/SAUIHe3YDbI/AAAAAAAAArY/F0Kcfde3LQ8/P1020546.JPG?imgmax=512)


Then the cluster and the wiring


(http://lh3.ggpht.com/coleenmarx/SAUGse3YDXI/AAAAAAAAAq4/jARYxxTgGuE/P1020553.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAUHB-3YDYI/AAAAAAAAArA/QFUFINziypQ/P1020555.JPG?imgmax=512)


(http://lh3.ggpht.com/coleenmarx/SAUHse3YDaI/AAAAAAAAArQ/6Bfp6jyrBjU/P1020557.JPG?imgmax=512)


(http://lh6.ggpht.com/coleenmarx/SAUHcO3YDZI/AAAAAAAAArI/SPqLAKeBblw/P1020578.JPG?imgmax=512)


Was forced to cut the wiper motor wiring   :-X


(http://lh4.ggpht.com/coleenmarx/SAUJFu3YDdI/AAAAAAAAAro/RngwaEvSv1g/P1020560.JPG?imgmax=512)



Still trying to figure out the best and safest way to remove the metal heater pipes that go through the firewall to the heater  ???


(http://lh5.ggpht.com/coleenmarx/SAUEs-3YDVI/AAAAAAAAAqo/V5WnHKhk9Is/P1020571.JPG?imgmax=512)



(http://lh4.ggpht.com/coleenmarx/SAUFyu3YDWI/AAAAAAAAAqw/kMmSBvUl2z8/P1020577.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 11, 2009, 09:45:50 PM
Made some more progress tonight   :D


In order to remove the heater unit I had to remove the water pipes, comong from the engine running through the fire wall.They were in a very tight spot and so I started a little further up to free-up the pipes a bit as the old hoses are very sticky.


(http://lh6.ggpht.com/coleenmarx/SAZe9-3YDeI/AAAAAAAAAsk/oKxI1N-QG28/P1020580.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAZfXu3YDfI/AAAAAAAAAss/7W2LyIGkABk/P1020586.JPG?imgmax=512)


Them pipes running into and out of the heater


(http://lh4.ggpht.com/coleenmarx/SAZfxe3YDgI/AAAAAAAAAs0/4g-vnyCi3x8/P1020594.JPG?imgmax=512)


and through a tight grommet in the fire wall


(http://lh6.ggpht.com/coleenmarx/SAZgH-3YDhI/AAAAAAAAAs8/Ow9tf1YRDKc/P1020609.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SAZgle3YDiI/AAAAAAAAAtE/Q1DrQ91qNYI/P1020616.JPG?imgmax=512)


but after removing the grommet and sliding it over both pipes, they came out easy in spite of their odd bends etc


(http://lh3.ggpht.com/coleenmarx/SAZg5O3YDjI/AAAAAAAAAtM/Nvl7uBs22Os/P1020622.JPG?imgmax=512)


Then I just had to disconnect the 2 demister vents and unbolt the heater itself.


(http://lh6.ggpht.com/coleenmarx/SAZhM-3YDkI/AAAAAAAAAtU/9Ac1A_-IxZk/P1020631.JPG?imgmax=512)


The tool that I borrowed for the steering wheel was useless and so I resorted to a few bangs, using both hands and sure enough, after the 2nd bang she popped off.


(http://lh4.ggpht.com/coleenmarx/SAZh4e3YDlI/AAAAAAAAAtc/At7DPb1RmvA/P1020612.JPG?imgmax=512)


(http://lh5.ggpht.com/coleenmarx/SAZh9u3YDmI/AAAAAAAAAtk/LA0Yy6n2Gjk/P1020614.JPG?imgmax=512)


then I removed the padded dash..


(http://lh4.ggpht.com/coleenmarx/SAUI2u3YDcI/AAAAAAAAArg/3RG5cX59vFM/P1020567.JPG?imgmax=512)


.. and found this underneath


(http://lh4.ggpht.com/coleenmarx/SAZiYe3YDnI/AAAAAAAAAts/uwrk8CJXAaQ/P1020636.JPG?imgmax=512)



 8O Any ideas what it is? I just labelled the wires and continued onto the speedo cluster. With most of the other gauges and switches etc done it came out with little fight..



(http://lh5.ggpht.com/coleenmarx/SAZjKu3YDoI/AAAAAAAAAt0/5eJBr1yx0xU/P1020645.JPG?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SAZjSe3YDpI/AAAAAAAAAt8/zJUwohQwgUI/P1020653.JPG?imgmax=512)


So now she is a little naked..


(http://lh3.ggpht.com/coleenmarx/SAZkxO3YDqI/AAAAAAAAAuc/Uq-IUHmkfF0/P1020644.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 11:49:05 AM
Got a little bit done last night.In order to remove the steering column I had to remove a load of other stuff

(http://lh3.ggpht.com/coleenmarx/SAj-au3YDtI/AAAAAAAAAxI/xMC4ywgIP6Q/P1020707.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAj-ie3YDuI/AAAAAAAAAxQ/l7icO_pW2Z0/P1020710.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAj-zO3YDxI/AAAAAAAAAxo/1ZzTDjX-mWI/P1020734.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SAj-8-3YDzI/AAAAAAAAAx4/GXH9wAcypOA/P1020744.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAj-nO3YDvI/AAAAAAAAAxY/Y-n7JoaznCA/P1020723.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SAj-s-3YDwI/AAAAAAAAAxg/_O5I2pBfxlQ/P1020732.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAj_EO3YD0I/AAAAAAAAAyA/W9vvrL-7ht8/P1020749.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SAj_Lu3YD1I/AAAAAAAAAyI/16KcTELpj40/P1020772.JPG?imgmax=512)

During this time I got g@tvol of all the aftermarket goodies' crappy wiring ...

(http://lh3.ggpht.com/coleenmarx/SAkBCe3YD2I/AAAAAAAAAyQ/6ysyvaFmdMg/P1020781.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SAkBLe3YD3I/AAAAAAAAAyY/kxJV6A-4vUA/P1020783.JPG?imgmax=512)

... and now she looks better.

(http://lh3.ggpht.com/coleenmarx/SAkD-e3YD-I/AAAAAAAAAzU/Ygpr4vjuxXk/P1020796.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SAkEFu3YD_I/AAAAAAAAAzc/VvuJT9hc1c4/P1020797.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAkD3O3YD9I/AAAAAAAAAzM/J3KMYKXSp4o/P1020782.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 11:50:51 AM
Made some good(for me as it is iro wiring) progress today. :D
Starting at the pax foot area as I had done the driverside previously

(http://lh6.ggpht.com/coleenmarx/SAuILWplsGI/AAAAAAAAA3Q/3D8tLNSvahM/P1020842.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuIPWplsHI/AAAAAAAAA3Y/KrhSujYENfs/P1020855.JPG?imgmax=512)

All coded, tagged and bagged..

(http://lh3.ggpht.com/coleenmarx/SAuIWmplsII/AAAAAAAAA3k/hxNY9VXDcGY/P1020868.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuIdWplsJI/AAAAAAAAA3s/sYxuxfFbhbE/P1020879.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuIhWplsKI/AAAAAAAAA30/tMGEeEa7DTs/P1020898.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuInWplsLI/AAAAAAAAA38/wC_IarxSDU0/P1020909.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAuIvGplsMI/AAAAAAAAA4E/jVO5TWf4Gc8/P1020915.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAuI1GplsNI/AAAAAAAAA4M/4xwAIYZ5V5Y/P1020927.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuI6WplsOI/AAAAAAAAA4U/ZFc-LFJcUqE/P1020944.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuJCWplsPI/AAAAAAAAA4c/MkqNcNmEKRI/P1020954.JPG?imgmax=512)

The tail of the snake as all the extentions had been removed..

(http://lh3.ggpht.com/coleenmarx/SAuJJmplsQI/AAAAAAAAA4k/vAJRjjjBq70/P1020967.JPG?imgmax=512)

Pulling the head through..

(http://lh4.ggpht.com/coleenmarx/SAuJS2plsRI/AAAAAAAAA4s/GOSa931NawY/P1020971.JPG?imgmax=512)

The entire snake !

(http://lh4.ggpht.com/coleenmarx/SAuJb2plsSI/AAAAAAAAA40/VsDNx0aynWk/P1020975.JPG?imgmax=512)

That still left the OEM Heat & Sound shield

(http://lh5.ggpht.com/coleenmarx/SAuJiGplsTI/AAAAAAAAA48/AESlVFOU3Hk/P1020982.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAuJqWplsUI/AAAAAAAAA5E/vn2yESe9VuA/P1020989.JPG?imgmax=512)

Leaving her almost bare inside !

(http://lh6.ggpht.com/coleenmarx/SAuJxWplsVI/AAAAAAAAA5M/5F6tHHizdEE/P1020991.JPG?imgmax=512)

Next will be the rest of the loom on the outside
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 11:53:38 AM
Having yanked a 3rd of the snake yesterday, tonight I moved on to the next 3rd which is in and around the intake side of things ...

(http://lh4.ggpht.com/coleenmarx/SAzmWmplsWI/AAAAAAAAA6E/QwTdiDrBxKY/P1020335.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAzno2plsXI/AAAAAAAAA6Q/Nl04NF9XTyM/P1020992.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SAznv2plsYI/AAAAAAAAA6Y/WpStQb-jpgo/P1030006.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SAznzWplsZI/AAAAAAAAA6g/Xve70mLHdHc/P1030019.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SAzn5mplsaI/AAAAAAAAA6o/wdDVgDoYURE/P1030033.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SAzoAGplsbI/AAAAAAAAA6w/wwzEn1uJhLY/P1030044.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SAzoGWplscI/AAAAAAAAA64/O6xQn_YfhK0/P1030054.JPG?imgmax=512)

Almost loose..

(http://lh5.ggpht.com/coleenmarx/SAzoP2plsdI/AAAAAAAAA7A/r4pvTFBgijw/P1030056.JPG?imgmax=512)

The entire snake

(http://lh3.ggpht.com/coleenmarx/SAzoZWplseI/AAAAAAAAA7I/a3o1TncNh9M/P1030068.JPG?imgmax=512)

And now she looks like...

(http://lh4.ggpht.com/coleenmarx/SAzogmplsfI/AAAAAAAAA7Q/ifPmaJCoQSg/P1030071.JPG?imgmax=512)

I also solved the mistery of the loose grey wire ....

(http://lh3.ggpht.com/coleenmarx/SAzqiWplsgI/AAAAAAAAA7Y/aWSZaLRiwts/P1030027.JPG?imgmax=512)

See the naked but oily pin? It still had the empty plug attached when I found it
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 11:57:56 AM
Visually I didn't get much done last night. Need some more tools first  :(

(http://lh5.ggpht.com/coleenmarx/SBDvh6AV4vI/AAAAAAAAA9A/TKZPaftWN3Q/P1030192.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SBDwqaAV4wI/AAAAAAAAA9I/jQOodRL5tSc/P1030098.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SBDwwqAV4xI/AAAAAAAAA9U/AeseVJ13qMQ/P1030099.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SBDw46AV4yI/AAAAAAAAA9c/LegrqD7_jJ4/P1030197.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SBDxCqAV4zI/AAAAAAAAA9k/eAyPbZxc_8M/P1030198.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 11:59:01 AM
Some progress....

Starting with LRT

(http://lh3.ggpht.com/coleenmarx/SBYUn6AV41I/AAAAAAAAA-8/JWe9GvqCkyU/P1030155.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SBYVN6AV42I/AAAAAAAAA_E/bYAdzmWOX2o/P1030252.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SBYVWKAV43I/AAAAAAAAA_M/2PHOnROHizg/P1030254.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SBYVfaAV44I/AAAAAAAAA_U/Nh0qYOMnP_Q/P1030256.JPG?imgmax=512)

Which left the towbar...

(http://lh4.ggpht.com/coleenmarx/SBYWgKAV47I/AAAAAAAAA_s/jW2NLpc58NU/P1030223.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SBYWoqAV48I/AAAAAAAAA_0/tNgp1oOo9AY/P1030257.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SBYWzKAV49I/AAAAAAAAA_8/_K-fhhdrusI/P1030270.JPG?imgmax=512)

.... and then the last of the wiring and rear lights

(http://lh4.ggpht.com/coleenmarx/SBYWUKAV45I/AAAAAAAAA_c/DTddr9_GV3g/P1030219.JPG?imgmax=512)

 ... even paper was used  :roll:

(http://lh6.ggpht.com/coleenmarx/SBYWYqAV46I/AAAAAAAAA_k/rh_z8mmHKYI/P1030220.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SBYW6aAV4-I/AAAAAAAABAE/k-e2TJkiY8Y/P1030272.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SBYYBqAV4_I/AAAAAAAABAQ/DR3z0qkZ0TM/P1030264.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SBYYJaAV5AI/AAAAAAAABAY/961z12hV3ME/P1030267.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SBYYWqAV5CI/AAAAAAAABAo/-2PtpABLP20/P1030281.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SBYYgKAV5DI/AAAAAAAABAw/kSQwj-SKDrY/P1030286.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SBYYpaAV5EI/AAAAAAAABA4/8mVBvLAS1AE/P1030296.JPG?imgmax=512)

The complete rear-end of the snake..

(http://lh4.ggpht.com/coleenmarx/SBYYRKAV5BI/AAAAAAAABAg/lqnrYp9t0vo/P1030269.JPG?imgmax=512)

With all the wiring eventually done I could move to other areas

(http://lh3.ggpht.com/coleenmarx/SBYY-6AV5FI/AAAAAAAABBA/RNDyhMZXqlE/P1030347.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SBYZHqAV5GI/AAAAAAAABBI/fHLH-V7Z5sA/P1030352.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SBYZQ6AV5HI/AAAAAAAABBQ/Zl2XIUKbgmY/P1030353.JPG?imgmax=512)

Even managed to finally remove that pesky single bolt on the windscreen hinge that had been a problem  :D

(http://lh6.ggpht.com/coleenmarx/SBYZ-qAV5II/AAAAAAAABBY/SkLkgOhAcXo/P1030299.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:26:13 PM
Update pics:

(http://lh6.ggpht.com/coleenmarx/SCiVlCbpQdI/AAAAAAAABHQ/VGiyIFFd2ds/P1030234.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SCiV3CbpQfI/AAAAAAAABHg/Y6m_JP7SoqU/P1030498.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCiXlibpQjI/AAAAAAAABIA/UKEDwcyVfLM/P1030416.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SCiYKSbpQnI/AAAAAAAABIk/yZnb7xaeRVg/P1030455.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCia8ibpQzI/AAAAAAAABKI/WdREh85nNUM/P1030335.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCibGibpQ0I/AAAAAAAABKQ/G_tQeN3u5bo/P1030342.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SCibQCbpQ1I/AAAAAAAABKY/ysf_2pXzB2c/P1030344.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCik_ibpRGI/AAAAAAAABM8/C5PgGd99A_4/P1030413.JPG?imgmax=512)

Hidden beneath all the bondo... :(

(http://lh5.ggpht.com/coleenmarx/SCib9ybpQ2I/AAAAAAAABKg/xd-yibWJYO8/P1030500.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SCicGSbpQ3I/AAAAAAAABKo/Tvv8wF_F1xk/P1030505.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SCicQSbpQ4I/AAAAAAAABKw/PRVa1vbRSj0/P1030514.JPG?imgmax=512)

Time to remove the heat & sound matting to see what it might hide..

(http://lh6.ggpht.com/coleenmarx/SCidmCbpQ6I/AAAAAAAABLA/BrtOPSsjmc8/P1030533.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SCid4CbpQ8I/AAAAAAAABLQ/LPvcaKp9_ew/P1030537.JPG?imgmax=512)

Only this spot in the back  :D

(http://lh6.ggpht.com/coleenmarx/SCidvCbpQ7I/AAAAAAAABLI/Z9zKjhTJb9c/P1030536.JPG?imgmax=512)

The front floor being a mix of good and bad


(http://lh4.ggpht.com/coleenmarx/SCieCibpQ9I/AAAAAAAABLc/l4RJu0Mce-o/P1030541.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SCieMSbpQ-I/AAAAAAAABLk/tB1SjoRBhmc/P1030546.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCieUibpQ_I/AAAAAAAABLs/HdPu0bZEzRs/P1030549.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SCieeCbpRAI/AAAAAAAABL0/OYquRWCw3E4/P1030555.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SCienybpRBI/AAAAAAAABL8/t7oNwDFe2BM/P1030556.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SCifFCbpREI/AAAAAAAABMU/1U-QBvcIdps/P1030569.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SCifOibpRFI/AAAAAAAABMc/qZjnj2FjHNg/P1030570.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:27:37 PM
The total amount of sound and heat matting removed

(http://lh5.ggpht.com/coleenmarx/SDHRtibpRHI/AAAAAAAABN0/MbDeXRD49As/P1030585.JPG?imgmax=512)

Then after countless hours to remove the sticky residue she now looks like this.

(http://lh3.ggpht.com/coleenmarx/SDHSACbpRJI/AAAAAAAABOI/mL8e5UVlY14/P1030600.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SDHSJybpRKI/AAAAAAAABOQ/yxh86our1io/P1030601.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SDHR2CbpRII/AAAAAAAABOA/1xNqDgn3WNc/P1030599.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SDHSUCbpRLI/AAAAAAAABOY/GNxyalwZkTQ/P1030602.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:30:52 PM
Quote from: Jonathan Tee
Can still see those pedals..

Where ?

(http://lh6.ggpht.com/coleenmarx/SDXIf-GBk6I/AAAAAAAABQc/M6DrW1S1KBg/P1030684.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SDXIpOGBk7I/AAAAAAAABQk/6hq3ibXy4Tc/P1030685.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SDXIy-GBk8I/AAAAAAAABQs/21cKykO2s_I/P1030687.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SDXI8eGBk9I/AAAAAAAABQ0/_BSM5OiZpNk/P1030688.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SDXJGOGBk-I/AAAAAAAABQ8/vA9MsXZE8Cs/P1030691.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SDXJPeGBk_I/AAAAAAAABRE/EXZ1n0KdJJU/P1030692.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:32:08 PM
Update: In preparation for removing the tub(after most of the patchwork is finished) I had to remove the last bit of plumbing that was attached to the tub..

(http://lh6.ggpht.com/coleenmarx/SEF8CjIiKlI/AAAAAAAABWk/uCBM9AP32hw/Vacuum%20hoses%20removal%20001.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEF8aTIiKmI/AAAAAAAABWs/NxuOhf3XiWc/Vacuum%20hoses%20removal%20004.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEF8uDIiKnI/AAAAAAAABW0/yYeylhMnfyo/Vacuum%20hoses%20removal%20027.jpg?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEF9YzIiKoI/AAAAAAAABW8/Tp0v-LMBZOs/P1030868.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEF9qjIiKpI/AAAAAAAABXE/kPe30C8-1Q8/P1030877.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEF99DIiKqI/AAAAAAAABXM/aH1VxrI66rs/P1030882.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEF-QzIiKrI/AAAAAAAABXU/8Dc3crlMvM4/P1030819.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEF-izIiKsI/AAAAAAAABXc/wFG2dCtOT6o/P1030863.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEF-0DIiKtI/AAAAAAAABXk/xgiu3H61ppw/P1030887.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEF_GDIiKuI/AAAAAAAABXs/TVxh4t5HaK0/P1030899.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEF_XzIiKvI/AAAAAAAABX0/uL_A30pbNTM/P1030903.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEF_pzIiKwI/AAAAAAAABX8/NiPQbETh8M4/P1030918.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEF_7jIiKxI/AAAAAAAABYI/fOyysGg6NIQ/P1030921.JPG?imgmax=512)

As soon as the last major patchwork is done, I will remove the tub from the chassis :D 

Then I also stripped the Ambi doors

(http://lh3.ggpht.com/coleenmarx/SEGANzIiKyI/AAAAAAAABYQ/GxDAFTkCdy4/Rear%20Door%28Driver%27s%20side%29%20100.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGAfjIiKzI/AAAAAAAABYY/QO_ZD6bJfqs/Rear%20Door%28Driver%27s%20side%29%20089.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGAxjIiK0I/AAAAAAAABYg/G7paKSG4aZ8/Rear%20Door%28Driver%27s%20side%29%20049.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGBDDIiK1I/AAAAAAAABYo/Vx7o6neAruo/Rear%20Door%28Driver%27s%20side%29%20001.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGBVTIiK2I/AAAAAAAABYw/PfH8skfGLrw/Rear%20Door%28Pax%20side%29%20006.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGBmjIiK3I/AAAAAAAABY4/vKQBLwzyIXs/Rear%20Door%28Pax%20side%29%20011.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGB4jIiK4I/AAAAAAAABZA/PNZCZXPfpag/Rear%20Door%28Pax%20side%29%20039.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGCJTIiK5I/AAAAAAAABZI/VxpeGOOml0M/Rear%20Door%28Pax%20side%29%20057.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGCbjIiK6I/AAAAAAAABZQ/MJIhsj6f5jM/Rear%20Door%28Pax%20side%29%20065.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGDaTIiK7I/AAAAAAAABZY/Xj_q4TKRutg/Rear%20Door%28Pax%20side%29%20077.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGD-TIiK9I/AAAAAAAABZs/0wIKH16mK6k/Rear%20Door%28Pax%20side%29%20104.jpg?imgmax=512)

Next up the front doors
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:36:12 PM
Quote from: Francois Bosch
Theo take that alarm clock out of the workshop, people might think you sleep with your 40 rather than in your own bed :twisted:


Lately it has been feeling like it....

(http://lh5.ggpht.com/coleenmarx/SDo3HeGBlAI/AAAAAAAABR8/xkdrs2c5fs0/Panel%20Beater%20Day%201%20002.jpg?imgmax=512)

Old floor and seem cut out

(http://lh5.ggpht.com/coleenmarx/SEGERTIiK-I/AAAAAAAABZ0/1bFh0lmAtgg/Panel%20Beater%20Day%201%20003.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGEkTIiK_I/AAAAAAAABZ8/j1o48Ezve7c/Panel%20Beater%20Day%201%20004.jpg?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGE2zIiLAI/AAAAAAAABaE/obzZPasoIEY/Panel%20Beater%20Day%201%20007.jpg?imgmax=512)

New floor piece shaped and fitted all the way into the sill.

(http://lh4.ggpht.com/coleenmarx/SEGFKDIiLBI/AAAAAAAABaM/pZ_ePa_7yCk/Panel%20Beater%20Day%201%20008.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGFdDIiLCI/AAAAAAAABaU/oK2HY0qEZpo/Panel%20Beater%20Day%201%20010.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGFvjIiLDI/AAAAAAAABac/uOGnr0gbNX8/Panel%20Beater%20Day%201%20011.jpg?imgmax=512)

new lip fitted above the floor piece

(http://lh5.ggpht.com/coleenmarx/SEGGCTIiLEI/AAAAAAAABak/ehMKHSHIZTc/Panel%20Beater%20Day%201%20013.jpg?imgmax=512)

and drilling the new spotwelds ala OEM

(http://lh5.ggpht.com/coleenmarx/SEGGoTIiLGI/AAAAAAAABa0/qlIH9fMDTPA/Panel%20Beater%20Day%201%20014.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGGVjIiLFI/AAAAAAAABas/zVRPRgJEfCA/Panel%20Beater%20Day%201%20015.jpg?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGG7zIiLHI/AAAAAAAABa8/FlOSOalY8EY/Panel%20Beater%20Day%201%20026.jpg?imgmax=512)

From the bottom
 
(http://lh3.ggpht.com/coleenmarx/SEGHNzIiLII/AAAAAAAABbI/dx01wTV4G98/Panel%20Beater%20Day%201%20028.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGHhDIiLJI/AAAAAAAABbQ/_kMoRH8kF8A/Panel%20Beater%20Day%201%20035.jpg?imgmax=512)


(http://lh4.ggpht.com/coleenmarx/SEGH0DIiLKI/AAAAAAAABbY/6GlgyoodEYE/Panel%20Beater%20Day%201%20037.jpg?imgmax=512)

Rough grinded, etched cleaned & temporarily painted with NS4 untill the Rustbullet Silver Label arrives...

(http://lh4.ggpht.com/coleenmarx/SDo4tOGBlLI/AAAAAAAABTY/twRxfa-pgJI/Panel%20Beater%20Day%202%20003.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGIGTIiLLI/AAAAAAAABbg/MleXJUQaGkI/Panel%20Beater%20Day%201%20039.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGIZTIiLMI/AAAAAAAABbo/ZNECLrps6PY/Panel%20Beater%20Day%201%20042.jpg?imgmax=512)

Once again the whole seam is opened and a new lip made to replace the old. NO SHORT-CUTS !

(http://lh5.ggpht.com/coleenmarx/SEGIsTIiLNI/AAAAAAAABbw/QsJ5yPi_LwM/Panel%20Beater%20Day%201%20045.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGI_DIiLOI/AAAAAAAABb4/-3bjv3dAgKw/Panel%20Beater%20Day%201%20046.jpg?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGJRDIiLPI/AAAAAAAABcA/Mdxhy019F3M/Panel%20Beater%20Day%201%20049.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SDo61eGBlZI/AAAAAAAABVM/rFhbZcQqDmk/Panel%20Beater%20Day%202%20039.jpg?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGJ1zIiLRI/AAAAAAAABcQ/TEj7uqu-ob8/Panel%20Beater%20Day%202%20012.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGKbjIiLTI/AAAAAAAABck/f9EUu-2ddXw/Panel%20Beater%20Day%202%20021.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SDo5nuGBlRI/AAAAAAAABUM/0UOYBoGeRjw/Panel%20Beater%20Day%202%20025.jpg?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGLBjIiLVI/AAAAAAAABc0/jXG7Bp5sEnk/Panel%20Beater%20Day%202%20037.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGLUTIiLWI/AAAAAAAABc8/OZCZ66ku83c/Panel%20Beater%20Day%202%20036.jpg?imgmax=512)

New lip to replace the old which was covered with Rust Bullet on the inside before being welded in, just like all the other closed areas..

(http://lh4.ggpht.com/coleenmarx/SEGMeDIiLaI/AAAAAAAABdc/jc-swoa_f5E/Patchwork%20003.jpg?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGL6TIiLYI/AAAAAAAABdM/H_TcPZ2Urvw/Patchwork%20001.jpg?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGMMzIiLZI/AAAAAAAABdU/NFxiMDX8cTg/Patchwork%20002.jpg?imgmax=512)

Seams that are too good to be cut out are drilled open and painted with Rust Bullet on the inside before being closed up and spotwelded again.

(http://lh4.ggpht.com/coleenmarx/SEGNDDIiLcI/AAAAAAAABds/XHNRacO6AxQ/P1040160.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGO-zIiLjI/AAAAAAAABeo/Hu4dt1dyr5M/P1040192.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGPZTIiLkI/AAAAAAAABew/Hxskrrbo8zs/P1040193.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SEGPtjIiLlI/AAAAAAAABe4/XUriRpXUGpU/P1040194.JPG?imgmax=512)

Rear ambi door

(http://lh3.ggpht.com/coleenmarx/SEGNnzIiLeI/AAAAAAAABeA/ClVa-nABc8M/P1040176.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SEGN5zIiLfI/AAAAAAAABeI/E5AxQ0flkoM/P1040180.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGOLTIiLgI/AAAAAAAABeQ/fIuUttcyzBw/P1040182.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGRDDIiLpI/AAAAAAAABfY/pg6aOwS-gEE/P1040212.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SEGOZTIiLhI/AAAAAAAABeY/v7gHMpTuB7M/P1040185.JPG?imgmax=512)

Driver's door: New bottom piece already Rust Bulleted and welded in.

(http://lh3.ggpht.com/coleenmarx/SEGOszIiLiI/AAAAAAAABeg/Vm4WVJ3LXpY/P1040188.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGQCDIiLmI/AAAAAAAABfA/6bOLwG4NeTM/P1040200.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SEGQbDIiLnI/AAAAAAAABfI/HzSnZQs0aQs/P1040203.JPG?imgmax=512)

Hardtop

(http://lh6.ggpht.com/coleenmarx/SEGQvjIiLoI/AAAAAAAABfQ/ogdwkd-sSYw/P1040207.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:42:36 PM
Another update  :P

(http://lh3.ggpht.com/coleenmarx/SFagrH4IyZI/AAAAAAAABig/Xx3AOk2OHfc/P1040550.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SFag1A4XYZI/AAAAAAAABio/hyZc8EU13KQ/P1040558.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SFahNKA0c-I/AAAAAAAABiw/6YauPDJz6kI/P1040564.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SFaheAWfyAI/AAAAAAAABi4/t0Z5YpO0Lo4/P1040570.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SFaiBOoqtxI/AAAAAAAABjA/SSWiLT3GfAg/P1040573.JPG?imgmax=512)

Self etching metal cleaner prior to the temporary NS4

(http://lh6.ggpht.com/coleenmarx/SFaiJ_yYpzI/AAAAAAAABjI/8qQIF4um8xU/P1040580.JPG?imgmax=512)

New lips on inside...

(http://lh6.ggpht.com/coleenmarx/SFaidq2pdwI/AAAAAAAABjY/u8cOO3aLY24/P1040593.JPG?imgmax=512)

From the other side

(http://lh4.ggpht.com/coleenmarx/SFaiTeS0u4I/AAAAAAAABjQ/xEPO0f4xIOg/P1040592.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SFailulgnzI/AAAAAAAABjg/QuUbQXdK3_o/P1040598.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SFaivuhAu1I/AAAAAAAABjo/PDyIS6w7vhI/P1040605.JPG?imgmax=512)

Also stripped the WS which is in perfect condition - probably from all the Tectyle ?

(http://lh3.ggpht.com/coleenmarx/SFajI0rhNRI/AAAAAAAABj0/4ds0wfKO2mk/P1040512.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SFajRxo5sDI/AAAAAAAABj8/JsKr5CdzB9o/P1040532.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SFajcEWr1jI/AAAAAAAABkE/NNdlgmxc4R8/P1040539.JPG?imgmax=512)

Only got 1 or 2 spots on the 2 hardtop panels to go and then all the patchwork will be done !
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:44:00 PM
Time for an update: Over the weekend we finished the last of the patchwork on the hardtop panels

(http://lh6.ggpht.com/coleenmarx/SF54yWueBRI/AAAAAAAABnI/loId7PATVJo/P1040609.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SF55Gnd3SDI/AAAAAAAABnQ/YXm2uGkoDE4/P1040612.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SF55blkpt1I/AAAAAAAABnY/QUCISH8Cw3s/P1040614.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SF55teku75I/AAAAAAAABng/WxWs5N3SxcM/P1040615.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SF56UVBvbrI/AAAAAAAABnw/o0Gu43NYKpI/P1040618.JPG?imgmax=512)

 Getting ready to test-fit all the doors etc before fine grinding, dressing etc can begin...

(http://lh4.ggpht.com/coleenmarx/SF56pCrFetI/AAAAAAAABn8/ZiX-jBdQbjc/P1040636.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:45:07 PM
Then last night we moved onto the Bib. Like the others' my bib's bottom was also shot(a definate weak point in the 40 series). I thought about just buying a replacement bib but after feeling somewhat confident from our recent fabrication we decided to give it a go ourselves.

(http://lh5.ggpht.com/coleenmarx/SF_4SVeQP7I/AAAAAAAABo0/17Ly-I0VyRw/P1040641.JPG?imgmax=512)

Both the inner and outside pieces needed to be replaced..

(http://lh3.ggpht.com/coleenmarx/SF_4vojFeEI/AAAAAAAABo8/htOGUqE6Cew/P1040643.JPG?imgmax=512)

We cut,  bent and shaped the new outside piece after lots and lots of calculations...

(http://lh5.ggpht.com/coleenmarx/SF_5bk97nBI/AAAAAAAABpE/WuSDt9TLY3M/P1040647.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SF_542nptjI/AAAAAAAABpM/_9xv9-Ps5BI/P1040649.JPG?imgmax=512)

and after tacking, welded it in place.

(http://lh4.ggpht.com/coleenmarx/SF_542nptjI/AAAAAAAABpM/_9xv9-Ps5BI/P1040649.JPG?imgmax=512)

All grinded down..

(http://lh4.ggpht.com/coleenmarx/SF_9GK-8tLI/AAAAAAAABpc/LfssQ6VbYpM/P1040653.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SF_9lwNDq1I/AAAAAAAABpk/iRr8BWH0yoM/P1040655.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SF_-xzV_08I/AAAAAAAABps/ToM0W1krRfE/P1040656.JPG?imgmax=512)

Although the inner piece has been shaped we did not weld it in as I needed to Rust Bullet the areas that would not be exposed to normal paint, once welded up and we wanted to test-fit the new bottom with the fenders etc first(in case we need to make alterations) before final welding and drilling etc
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:46:48 PM
So it was time to see if the "new" bib would fit properly.In order to do so I had to refit both fenders and side panels.

(http://lh5.ggpht.com/coleenmarx/SGFNJqwJR4I/AAAAAAAABq8/hsg2xAP6ugU/P1040657.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SGFN-y8BqcI/AAAAAAAABrE/NuVDT_5Vshk/P1040658.JPG?imgmax=512)

The culprit..

(http://lh6.ggpht.com/coleenmarx/SGFOvExkFwI/AAAAAAAABrQ/tvUf9PK1dto/P1040660.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SGFPDOtHXNI/AAAAAAAABrY/X_ktsYUXQw8/P1040666.JPG?imgmax=512)

Is this a perfect fit or what ? Even the angles of the swivel hinge was good !

(http://lh6.ggpht.com/coleenmarx/SGFPZMY0lMI/AAAAAAAABrg/N7DgWgjQEVw/P1040667.JPG?imgmax=512)

That meant we could weld in the inner part that acts as reinforcement

(http://lh3.ggpht.com/coleenmarx/SGFVVfbMt3I/AAAAAAAABsQ/Mz3m7tgnoO8/P1040669.JPG?imgmax=512)

With our spirits up, we decided to check on how some of the other parts that we had butchered, lines up..

(http://lh3.ggpht.com/coleenmarx/SGFPtcNgkjI/AAAAAAAABro/GkRpqVCoifc/P1040664.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SGFQDO2JaWI/AAAAAAAABrw/Pi5MXewEFZQ/P1040665.JPG?imgmax=512)

So far everything is perfect ! Tomorrow night we will try and do the same with the ambi doors.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:48:08 PM
After finally finishing the last of the welding(on the outside) and the test fitting it was time to remove the tub and face whatever she was hiding underneath, so today the tub finally came off !

(http://lh5.ggpht.com/coleenmarx/SGaxXwDDKCI/AAAAAAAABtI/b7eiXp7045A/P1040729.JPG?imgmax=512)

From the beginning I was praying/hoping that rustwise, she would be better underneath than on the outside and ontop as it seemed that the PO had sprayed her with some rubberising underneath. Most thought I was nuts and looked sceptical....

(http://lh3.ggpht.com/coleenmarx/SGayGshGbnI/AAAAAAAABtY/w6Nyr0gtGTA/P1040713.JPG?imgmax=512)

What a pleasant surprise it was to find that what looked like rust is actually very fine dust...

(http://lh6.ggpht.com/coleenmarx/SGayccVaSnI/AAAAAAAABtg/d8_szHQnKZc/P1040698.JPG?imgmax=512)

Bar a small spot at the left tub mount the sill is very good.

(http://lh6.ggpht.com/coleenmarx/SGaxznuxC7I/AAAAAAAABtQ/oYMcGZm9AIM/P1040720.JPG?imgmax=512)

It even still had the OEM stickers covering the factory holes

(http://lh5.ggpht.com/coleenmarx/SGazXIj-pWI/AAAAAAAABt8/kMnDq-H3dG0/P1040701.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SGazD3WGldI/AAAAAAAABt0/06VZ3Un8jAk/P1040705.JPG?imgmax=512)

If it wasn't for the rain preventing me form painting the Rust Bullet on the few patches we need to weld, we could have finished all the outstanding welding. :(  When some of the helpers found other entertainment we took it as a sign and called it a day early...

(http://lh6.ggpht.com/coleenmarx/SGaywd12ysI/AAAAAAAABto/qosYON2B9JQ/P1040689.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 13, 2009, 12:49:38 PM
Time for an update: In prep for engine and box removal we removed the tierods , shocks and last of the brake hardlines. The help arrived early enough for the rugby and cladded in traditional war-dress nogal, we lost and then I got my own revenge by putting him to work!  :twisted:

(http://lh5.ggpht.com/coleenmarx/SHUmhLsfnhI/AAAAAAAABu0/dDTXb9NRxRA/P1040808.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SHUm2I9ooqI/AAAAAAAABu8/ExpFagBrdQM/P1040806.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SHUnN36HeII/AAAAAAAABvE/CYlvvEtWf-U/P1040810.JPG?imgmax=512)

Thanks mate ! :thumright:

Then today I got a huge pressie !!  :P

(http://lh3.ggpht.com/coleenmarx/SHUonFhR7aI/AAAAAAAABvc/Et7Z_rv0gSs/P1040851.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SHUo9ik7TmI/AAAAAAAABvk/wWcG8Z_iuZw/P1040852.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SHUn-pjULGI/AAAAAAAABvM/WP-seVluXYw/P1040857.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SHUoT1mCBmI/AAAAAAAABvU/9BRkMDTZuoI/P1040854.JPG?imgmax=512)

These were custom made for an 80 series but we have already worked out how to fit them in the 40. Watch this space...  8-)

Thanks JB ! You are the best !   :salut:

Now I just need to find the 2 outside seatbelts etc
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 02:29:29 PM
Got a little done ..

(http://lh5.ggpht.com/coleenmarx/SHuoaKJ151I/AAAAAAAABy4/k27zTrhqxcY/P1040890.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SHurWSFGu1I/AAAAAAAAB0E/Ppm32T-VCUQ/P1040928.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SHuqspy2ZCI/AAAAAAAABz0/bHHY_B_QglY/P1040951.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SHurCTbgr4I/AAAAAAAABz8/ALgD0L01o8Q/P1040953.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SHuot6Cm0XI/AAAAAAAABzA/Np5gUHLG7lc/P1040919.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SHupYNYPpiI/AAAAAAAABzQ/Pey4JQmHEeQ/P1040945.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SHupCxAP62I/AAAAAAAABzI/j8hAauuSjJU/P1040943.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SHups1cbGLI/AAAAAAAABzY/oxgKidRi-nI/P1040946.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SHuqBisjcJI/AAAAAAAABzg/GOih4ELPpIg/P1040956.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SHuqWm2WSKI/AAAAAAAABzo/d7M-smjsz2s/P1040958.JPG?imgmax=512)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 02:31:42 PM
In preparation for pulling the motor and boxes I have been stripping some more stuff ...  :)

(http://lh5.ggpht.com/coleenmarx/SJdR3jRPEoI/AAAAAAAAB4Q/rsAn3FcMlhs/P1040955.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SJdPskYbzGI/AAAAAAAAB3U/vv1X0abzrlw/P1040982.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SJdQBRv3cmI/AAAAAAAAB3c/oQrUMiEn_5Y/P1040995.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SJdQVZbW4fI/AAAAAAAAB3k/q4-jbgaX7Pg/P1050005.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SJdQoz3_NzI/AAAAAAAAB3s/IpypUGreZZM/P1050013.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SJdQ798iqjI/AAAAAAAAB30/vFqK207CuUk/P1050021.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SJdPDbn_SJI/AAAAAAAAB3E/sWRvUTrxugE/P1050046.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SJdOZ7M-NKI/AAAAAAAAB20/-J0-l0zLnzM/P1050044.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SJdRPlQBCvI/AAAAAAAAB4A/2WaOXA4Xd7k/P1050042.JPG?imgmax=512)

The intake side I may just leave "intact", as far as possible

(http://lh3.ggpht.com/coleenmarx/SJdRkbj6XFI/AAAAAAAAB4I/cwQUon3DiAk/P1050049.JPG?imgmax=512)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 02:34:23 PM
Due to the location of the P/S pump my engine only had 1 engine hoist bracket and therefore I had to fabricate 2 longer ones from some big angle iron

(http://lh5.ggpht.com/coleenmarx/SLMBfoxDP-I/AAAAAAAAB9k/qkoyt8r2uis/P1050162.JPG?imgmax=512)

With them installed and a borrowed hoist from JB it was smooth sailing 8-)

(http://lh3.ggpht.com/coleenmarx/SLQ5C8LLrAI/AAAAAAAACAk/O3cdVNbYM1I/P1050165.JPG?imgmax=512)

inspite of the size and weight of the combo

(http://lh5.ggpht.com/coleenmarx/SLQ45NlIzRI/AAAAAAAACAc/O1ZemLdDQhk/P1050163.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SLMBKYwLODI/AAAAAAAAB9c/czgkS5mjYAk/P1050176.JPG?imgmax=512)

(http://lh5.ggpht.com/coleenmarx/SLMCDB65RRI/AAAAAAAAB9s/M7ubOu1wWU4/P1050170.JPG?imgmax=512)

(http://lh6.ggpht.com/coleenmarx/SLMCYzvPbfI/AAAAAAAAB90/FpbP9dLHpNM/P1050169.JPG?imgmax=512)

With our spirits up and our curiosity getting the better of us we decided to pull the rear shafts in order to see what the 3rd member's condition was like in our notso expert opinions. :hillbilly:

(http://lh3.ggpht.com/coleenmarx/SLMGpP-LhpI/AAAAAAAAB-w/w3zzwFbX0bs/P1050172.JPG?imgmax=512)

(http://lh3.ggpht.com/coleenmarx/SLMGzuw15II/AAAAAAAAB-4/8RXghhKItHE/P1050173.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SLMG99sxxFI/AAAAAAAAB_A/_f7P2oBBa7c/P1050174.JPG?imgmax=512)

(http://lh4.ggpht.com/coleenmarx/SLMHIOpA1FI/AAAAAAAAB_M/o56W2Z43dk0/P1050175.JPG?imgmax=512)

There is some definate backlash that JB will have to set but the rest seems very good actually 8-)  Oh did I mention that when I dropped the G/box and T/Case at  JB, he declared the clutch and pressure plate as brand new  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:14:33 PM
Some visuals of JB's work: The 40's have a known ailment in that the seal on the output shaft is known to start leaking.The oil from the Tcase then starts to leak into the Gbox and you end up with an empty Tcase and an overfilled Gbox(and a mouth full of gear oil when you unsuspectingly check the Gbox oil level  :oops: ). This problem is so common that in Aus and Us they even have the socalled "lazy man's cure" for it if you want to avoid pulling the boxes.

My gearbox and tc was pretty wet from the leak and so I dropped my boxes at JB. When I drained them I found some metal filings and therefore feared the worst.The news was better than I could ever have hoped for... 8-)

(http://lh3.ggpht.com/coleenmarx/SOPMoM5DurI/AAAAAAAACH0/hn2clbiFp2k/s512/P300908_11.07.JPG)

(http://lh3.ggpht.com/coleenmarx/SOPMswSwjiI/AAAAAAAACH8/1zspXIWP8pw/s512/P300908_11.07%5B01%5D.JPG)

In order to replace the offending seal you have to remove the rear nut on the output shaft seen here.This nut had to be removed with the aid of some heat- a sign that this box and tc has never worked hard before.

(http://lh3.ggpht.com/coleenmarx/SOPMw37Qa_I/AAAAAAAACIE/2ul6egJq0WI/s512/P300908_11.08.JPG)

(http://lh3.ggpht.com/coleenmarx/SOPM1toV2wI/AAAAAAAACIM/Szlph2Jxu_4/s512/P300908_11.09.JPG)

The offending seal: Clearly not well fitted if you look at the folded  "lip" ....

(http://lh3.ggpht.com/coleenmarx/SOPM5i9Fv_I/AAAAAAAACIU/yTo4wKvFTe0/s512/P011008_08.32.JPG)

(http://lh4.ggpht.com/coleenmarx/SOPNSpjKo8I/AAAAAAAACIs/rCv5LhXwcaE/s512/P011008_08.33%5B01%5D.JPG)

Usually the rear nut comes loose from hard work /wear and then the gear will damage the output shaft, leaving it looking like this

(http://lh5.ggpht.com/coleenmarx/SOPNNxAisUI/AAAAAAAACIk/rFwf2TQWFUk/s512/P011008_08.33.JPG)

Fortunately mine still looks like this

(http://lh3.ggpht.com/coleenmarx/SOPM92I8aUI/AAAAAAAACIc/siyI-eCwZqo/s512/P011008_08.32%5B01%5D.JPG)

Thanks again JB
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:17:29 PM
Here you go JT

(http://lh6.ggpht.com/coleenmarx/SOYJSM_XDcI/AAAAAAAACJo/9PftQ5V-Jn0/s512/P1050414.JPG)

  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:22:59 PM
Finished tapping all the required threads that were filled with galv  :D

(http://lh5.ggpht.com/coleenmarx/SPTRYmp6c3I/AAAAAAAACnA/0W1ahDScbBg/s720/P1050492.JPG)

(http://lh4.ggpht.com/coleenmarx/SPTRsgcFaRI/AAAAAAAACnQ/Pr2NjXqhn8M/s720/P1050486.JPG)

(http://lh5.ggpht.com/coleenmarx/SPTR2zoZQUI/AAAAAAAACnY/C5dzOYC4VgY/s720/P1050488.JPG)

(http://lh6.ggpht.com/coleenmarx/SPTRirdPT3I/AAAAAAAACnI/gP07Y96W1iU/s720/P1050489.JPG)

Now it is on to prep and paint, as I don't like the Heep look  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:27:15 PM
I started the prepwork on the bottom and sides of the frame tonight but I am not entirely happy with the results.I brushed the etch cleaner/primer on and sprayed it off with warm water after leaving it on for 1 hour. Tomorrow I will redo it but I will wash it on and off, using a sponge instead. In fairnes the directions did say that 2 or 3 applications may be needed for newly galved steel, so we will see...  :roll:

 Etch Cleaner/primer on

(http://lh6.ggpht.com/coleenmarx/SPZLCB0r0TI/AAAAAAAACow/d0wwcP2y6Fo/s720/P1050495.JPG)

(http://lh3.ggpht.com/coleenmarx/SPZK39rtETI/AAAAAAAACoo/7KMFw-hhwa4/s720/P1050498.JPG)


Etch Cleaner/primer "rinsed" off but some fatty areas clearly visible.(Could be all the cutting fluid I used when tapping ?)

(http://lh5.ggpht.com/coleenmarx/SPZKQAO6t4I/AAAAAAAACog/Gn6hxTKXUko/s720/P1050499.JPG)

(http://lh4.ggpht.com/coleenmarx/SPZKEVgETnI/AAAAAAAACoY/ELmvx0EomaE/s720/P1050500.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:34:28 PM
Time for an update: I "washed" the frame for a second time with Galv Etch but this time using some coarse steelwool. The result was much more to my liking...

(http://lh5.ggpht.com/coleenmarx/SP4YFuo0MjI/AAAAAAAACsk/FILjh0H5cag/s720/P1050505.JPG)

(http://lh6.ggpht.com/coleenmarx/SP4YPoeReQI/AAAAAAAACss/gocPxnfIfZs/s720/P1050506.JPG)

(http://lh3.ggpht.com/coleenmarx/SP4YaP0wRrI/AAAAAAAACs0/nPcxZ5BaHt8/s720/P1050507.JPG)

This meant I could paint with the Direct to Galv Hammerite immediately.However at the last minute I decided to go with a primer first, just for that bit of extra protection  :wink: I used Hammerite's Special Metals Primer which I was very impressed with as it spreads nicely and dries without leaving any brushmarks and becomes very hard. The only drawback is the fact that brushing takes a huge amount of time and it is difficult if not impossible to get in everywhere  8O

Ready for topcoat(s?)

(http://lh3.ggpht.com/coleenmarx/SP4YkM28emI/AAAAAAAACs8/xKqY_s_ej1U/s720/P1050572.JPG)

(http://lh6.ggpht.com/coleenmarx/SP4XgTheliI/AAAAAAAACsU/Q3HCZK9LHyM/s720/P1050573.JPG)

(http://lh6.ggpht.com/coleenmarx/SP4XtqVt_FI/AAAAAAAACsc/zSFpG_E8wyM/s720/P1050574.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:36:56 PM
While the primer coat went on relatively easy and quickly, the top coat was a complete different story.....

(http://lh3.ggpht.com/_p7bewmqq6YI/SRCh2f0VJQI/AAAAAAAACu8/59hf1jRp4xE/s720/P1050619.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SRCiEML4hKI/AAAAAAAACvE/gHFd0TEN0f8/s720/P1050623.JPG)

But eventually tonight she was done !

(http://lh3.ggpht.com/_p7bewmqq6YI/SRCiOopAGCI/AAAAAAAACvM/lWVbROMprQY/s720/P1050631.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SRCiZyckRJI/AAAAAAAACvY/GqDR0HQ2CpY/s720/P1050632.JPG)

 :cheers:

Now on to the small bits of the chassis etc ....

(http://lh3.ggpht.com/_p7bewmqq6YI/SRCheWuxomI/AAAAAAAACu0/w09xuQyHjYw/s720/P1050610.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:43:09 PM
Time for an update: With the bad weather we have had for the last 2 days I have not been able to paint the topcoats on the bumpstops and Gbox mount, so I moved on to the leaf springs to keep myself busy.   The only problem was that the bottom blade of the driverside pack was broken.

(http://lh5.ggpht.com/_p7bewmqq6YI/SRsyGlHzg5I/AAAAAAAACwg/HKtHNRv_U3Q/s720/P1050647.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SRsyQ41ak-I/AAAAAAAACwo/DwF-vOgXVdM/s720/P1050651.JPG)

 Fortunately I had come into posession of an old set of 60 ser springs recently(thanx Rob  :D ), that I was able to raid for a blade that could be butchered.

(http://lh5.ggpht.com/_p7bewmqq6YI/SRsyg-iK_sI/AAAAAAAACww/-wc5RZQZPic/s720/P1050656.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SRsyrc2Te-I/AAAAAAAACw4/ULD-3nqkapU/s720/P1050657.JPG)

Then it was just a simple matter of measuring and cutting it to the exact lenth as the camber et al was exactly the same. I could even use one of the centering pins as the OEM one's nut was shot. These springs are in any event just a temporary fit untill I get my new leafs  8-)
All cut and test-fitted

(http://lh3.ggpht.com/_p7bewmqq6YI/SRszG8OENWI/AAAAAAAACxA/LzYK-sio8R4/s720/P1050658.JPG)

Then tonight I whirewheeled all 4 spring packs and reassembled them ready to be painted as soon as the weather clears

All done and shiny, ready for paint
(http://lh4.ggpht.com/_p7bewmqq6YI/SRszYEUIseI/AAAAAAAACxI/nqmRXsAi9co/s720/P1050662.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SRszoe2ygEI/AAAAAAAACxQ/j-_vrrY5u1k/s720/P1050665.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2009, 03:46:31 PM
Got my completely rebuilt axles back from JB   :cheers:  Once again the news was very good, so it seems that this cruiser was never used for any hard work 8-)

(http://lh3.ggpht.com/_p7bewmqq6YI/SSm0l-rOLgI/AAAAAAAAC0M/SATlDCGmc6M/s720/P1050702.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SSm0RFDtrmI/AAAAAAAACz8/Yx3ifhkZtkY/s720/P1050724.JPG)

Lots of whirewheeling later ...

(http://lh4.ggpht.com/_p7bewmqq6YI/SSmzinXsIXI/AAAAAAAACzc/8BT4wuAjlJs/s720/P1050731.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SSmz7tBE6FI/AAAAAAAACzs/ZpK2J4a-rZM/s720/P1050733.JPG)

And then the same old routine of etch clean, prime and paint...

(http://lh6.ggpht.com/_p7bewmqq6YI/SSm0GKeci1I/AAAAAAAACz0/REocn7C_sMM/s720/P1050738.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:13:36 PM
After the prime and topcoat the axles came out pretty good

(http://lh6.ggpht.com/_p7bewmqq6YI/STRKsNylJ6I/AAAAAAAAC2k/N-fTxEg7os0/s720/P1050747.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/STROCq8Z0KI/AAAAAAAAC5c/5WkZUTVG29A/s720/P1050790.JPG)

Which meant it was eventually time to start assembly of the chassis..

(http://lh6.ggpht.com/_p7bewmqq6YI/STRMGsaLf0I/AAAAAAAAC3Q/S_gf4CPV058/s720/P1050759.JPG)

(Note to self: Do not let Swambo order custom bushes from a guy who asks:"Madam, what colour would you like those bushes ?", ever again !) 8O

(http://lh3.ggpht.com/_p7bewmqq6YI/STRMOeFF-KI/AAAAAAAAC3Y/nBkQk8ig2ws/s720/P1050760.JPG)

New greasable Ironman springpins

(http://lh4.ggpht.com/_p7bewmqq6YI/STRMY3IQcjI/AAAAAAAAC3o/_cG9zmVRO3k/s720/P1050762.JPG)

At least the front ones are yellow

(http://lh3.ggpht.com/_p7bewmqq6YI/STRNZzLTwLI/AAAAAAAAC4w/qdDViBPlWb4/s640/P1050773.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/STRNhmZz07I/AAAAAAAAC44/ge8pddJ1e1A/s720/P1050781.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/STRNpzhEWFI/AAAAAAAAC5E/Xok99_w8Y3U/s720/P1050782.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/STRNyAR--CI/AAAAAAAAC5M/eTmYwz5bZyE/s720/P1050784.JPG)

And suddenly we had a rolling chassis again  :cheers:

(http://lh3.ggpht.com/_p7bewmqq6YI/STROwqrcAlI/AAAAAAAAC6M/SXjWOjZerdo/s720/P1050799.JPG)

But then as preventative "maintenance" I had decided to replace my rear main oil seal and pilot bearing. Jb boroowed me his fancy pilotbearing puller which actually made it feel like cheating- no mes no fuss, 10 seconds and it was out !  8O Thanks JB  :D

The old non leaking seal and bearing. Also note the brand new welch plug(just like all the others) - one more telltale sign that motor was in fact rebuilt 8000kms ago

(http://lh5.ggpht.com/_p7bewmqq6YI/STRW6ztlfNI/AAAAAAAAC7M/sB8mZqEZtHk/s720/P1050801.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/STRW7kv3bQI/AAAAAAAAC7c/DlstNBseQIY/s720/P1050804.JPG)

New seal installed- the exact same one as found in the KZTe motor

(http://lh3.ggpht.com/_p7bewmqq6YI/STRW7exFKGI/AAAAAAAAC7U/2PR7Wgnai3E/s720/P1050803.JPG)

Bearing in and flywheel torqued

(http://lh3.ggpht.com/_p7bewmqq6YI/STRW79nbtFI/AAAAAAAAC7k/7fWpqzQnjmM/s640/P1050809.JPG)

Clutch and pressure plate installed. Do you recognise that old shaft serving as an alignment tool, Keith ?  :hillbilly:

(http://lh3.ggpht.com/_p7bewmqq6YI/STRW7_QDk_I/AAAAAAAAC7s/qLUlxI5b1rk/s720/P1050814.JPG)

I had previously restored the bellhousing

(http://lh3.ggpht.com/_p7bewmqq6YI/STRfaNgmZCI/AAAAAAAAC8c/JRUxbKRYN9c/s720/P1050666.JPG)

After hours of wirewheeling

(http://lh3.ggpht.com/_p7bewmqq6YI/STRfajRcPCI/AAAAAAAAC8k/z9-K_02Is-o/s720/P1050688.JPG)

Primed with Hammerrite's Special Metals primer and then topcoated

(http://lh6.ggpht.com/_p7bewmqq6YI/STRfaxFa47I/AAAAAAAAC8s/QWK_GEkwFoI/s720/P1050689.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/STRfbF3DM7I/AAAAAAAAC80/rlmP7vrZB7s/s720/P1050744.JPG)

Then tonight after torquing the flywheel etc it was finally time to re-unite the motor and boxes with the help of a crane that I borrowed from JB. Thanks again JB  :thumright:

(http://lh4.ggpht.com/_p7bewmqq6YI/STRZksid5pI/AAAAAAAAC70/2QvWObad81w/s720/P1050818.JPG)

And then I found out that sometimes daughters' boyfriends can actually be usefull creatures if you intimidate them enough  :twisted:

(http://lh5.ggpht.com/_p7bewmqq6YI/STRZkmSmmuI/AAAAAAAAC78/wUtDyRmhjBk/s720/P1050824.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/STRZlJQSuwI/AAAAAAAAC8E/JAHi7saR-7Y/s720/P1050826.JPG)

And suddenly it was done  :cheers:

(http://lh3.ggpht.com/_p7bewmqq6YI/STRZlkxEMWI/AAAAAAAAC8M/rLYNWvPh1-A/s720/P1050832.JPG)

Next up, some detail/cosmetic work on the motor and boxes etc, but first a much needed Xmas break
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:16:22 PM
Since getting back from a long holiday, the progress has been very slow in spite of long hours. The pics tell the story
 
(http://lh4.ggpht.com/_p7bewmqq6YI/SXOSCCysAXI/AAAAAAAADBk/E7aHQ2-qUA4/s720/P1050638.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SXOMVPTPU6I/AAAAAAAAC90/Td1rFMtprxI/s720/P1050840.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/SXONchLcOpI/AAAAAAAAC94/USe4vJ7rNQM/s720/P1050956.JPG)

Tensioner pully needed a new bearing

(http://lh5.ggpht.com/_p7bewmqq6YI/SXOOMmErcRI/AAAAAAAAC-U/3RrNCAYC_JA/s720/P1050987.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SXOQarV_fdI/AAAAAAAADAk/NGPQ7K-Nv8E/s720/P1060060.JPG)

All done and ready to be installed

(http://lh3.ggpht.com/_p7bewmqq6YI/SXdxJ8JY0nI/AAAAAAAADDQ/vAifKGQELTA/s720/P1060074.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SXOPHExn0kI/AAAAAAAAC_M/8MmV_47XBDI/s720/P1060032.JPG)

Both cleaned and prepped

(http://lh5.ggpht.com/_p7bewmqq6YI/SXOQNtN3kMI/AAAAAAAADAg/OJkSQEEKDYk/s720/P1060055.JPG)

Done

(http://lh6.ggpht.com/_p7bewmqq6YI/SXdzmL4eIlI/AAAAAAAADEQ/gctprhvUVAY/s720/P1060084.JPG)

Clutch release cylinder needed a rebuild kit  and paint

(http://lh4.ggpht.com/_p7bewmqq6YI/SX9xoP-QHzI/AAAAAAAADKE/O-VgRFTGxck/s720/P1050671.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SX9y4QJw_TI/AAAAAAAADKg/pmdiME_HjAs/s720/P1060063.JPG)

Fortunately the Starter only needed a good clean , some new grease and some paint ..

Before
(http://lh3.ggpht.com/_p7bewmqq6YI/SXOUdwBkd8I/AAAAAAAADCE/TSYxKthDNyc/s720/P1030875.JPG)

After
(http://lh3.ggpht.com/_p7bewmqq6YI/SXOQiOYDapI/AAAAAAAADAo/Ha7JsFJpJP8/s720/P1060061.JPG)

Timing gear cover and crank pully

(http://lh5.ggpht.com/_p7bewmqq6YI/SXOQwwQCqBI/AAAAAAAADAs/u_qCPlHHFX8/s720/P1060066.JPG)

Waterpump housing

(http://lh3.ggpht.com/_p7bewmqq6YI/SXdyKKb3BcI/AAAAAAAADDY/oz9xhl8_lDg/s720/P1060079.JPG)

Thermostat housing

(http://lh6.ggpht.com/_p7bewmqq6YI/SXdyQ2ejuNI/AAAAAAAADD0/U_jbdjRNGlc/s720/P1060078.JPG)

Next it was the turn of the crankcase ventcover

(http://lh4.ggpht.com/_p7bewmqq6YI/SX9sTtpONUI/AAAAAAAADGE/veLXy5n6nK0/s720/P1060144.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SX9stb8GM5I/AAAAAAAADGI/dekW21xcVCI/s720/P1060156.JPG)

After hours of sanding

(http://lh5.ggpht.com/_p7bewmqq6YI/SX9tDddMilI/AAAAAAAADGk/lOvtCi8xO1Y/s720/P1060161.JPG)

Finally done

(http://lh6.ggpht.com/_p7bewmqq6YI/SYCytTFIgeI/AAAAAAAADL8/TGglxa4h7HM/s720/P1060217.JPG)

Next up the Rocker cover

(http://lh3.ggpht.com/_p7bewmqq6YI/SX9tYBkrWzI/AAAAAAAADHA/snOhHO1S3_U/s720/P1060166.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SX9t1bomCcI/AAAAAAAADHc/fv7Nmlh5FHI/s720/P1060174.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SX9uHB3t3YI/AAAAAAAADH4/QRsmH7OX3XM/s720/P1060173.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SX9ucU-yy0I/AAAAAAAADIU/9TJBCXnVlZk/s720/P1060191.JPG)

After 2 hrs of sanding ..
(http://lh6.ggpht.com/_p7bewmqq6YI/SYCxTrzLg4I/AAAAAAAADLE/n1Rlzl9lJfM/s720/P1060195.JPG)

About 5 hrs ..
(http://lh6.ggpht.com/_p7bewmqq6YI/SYCxpoZTv1I/AAAAAAAADLg/aMmkLQy3OIA/s720/P1060207.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:19:39 PM
Inbetween the sanding and painting odd bits and pieces ..

(http://lh4.ggpht.com/_p7bewmqq6YI/SYYKMc6seKI/AAAAAAAADNI/XwLpiftmh2M/s720/P1060234.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SYYKwVEx99I/AAAAAAAADNk/6egT5UREGSc/s720/P1060244.JPG)

.. I got a few other issues resolved this weekend. My old shocks were totally shot but I couldn't go buy new untill I had decided on and physically received my new leafs.So I needed a temprory fix.Luckily help came in the form of a "wheetbix loving closet elitist" who gave me a good set of 2nd handshockies off his 79 ser. Although the shockies could compress and extend further than my old ones, the front shockies needed some modification ...

(http://lh6.ggpht.com/_p7bewmqq6YI/SYYLWmFVOhI/AAAAAAAADOA/xajfP3uoUGI/s720/P1050919.JPG)

I cut the eyes from the old shocks

(http://lh6.ggpht.com/_p7bewmqq6YI/SYYL2Mb7I0I/AAAAAAAADOE/34wuuhR5lF4/s720/P1050929.JPG)

and welded them to the "new" ones. Welding to the shaft-side of the shockies was fine but on the tube-side we had to be very slow & carefull not to get the seals damaged from the heat.

All done and painted...

(http://lh6.ggpht.com/_p7bewmqq6YI/SYYNQrrZtEI/AAAAAAAADO4/gxOVFkELZXw/s720/P1060242.JPG)

Obviously nothing is ever plain sailing and so I had to get some custom bushes made. Swambo's hand clearly visible in this regard ....  :oops:

Note how accurately the mould is made that even the part no #'s are the same

(http://lh4.ggpht.com/_p7bewmqq6YI/SYYNfdCsLUI/AAAAAAAADO8/4BJnWlRX2Is/s720/P1060235.JPG)

All done

(http://lh4.ggpht.com/_p7bewmqq6YI/SYYN2Ce1gsI/AAAAAAAADPY/N5P0r2Ho52I/s720/P1060247.JPG)

Not too bad for a temporary fix untill my new leafs arrive from the US ?

(http://lh3.ggpht.com/_p7bewmqq6YI/SYYOQtzmFvI/AAAAAAAADP0/JqESFFHScHw/s720/P1060254.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:21:42 PM
In spite of the heatwave of the last two days I got a bit done ...

After sanding with 800 grit

(http://lh4.ggpht.com/_p7bewmqq6YI/SY3ZZYZpwVI/AAAAAAAADRc/bRxoeVK8-u8/s720/P1060257.JPG)

.... 1000

(http://lh5.ggpht.com/_p7bewmqq6YI/SY3Zoh5NrgI/AAAAAAAADRg/q6bIEJsdzv8/s720/P1060260.JPG)

..... 1200

(http://lh3.ggpht.com/_p7bewmqq6YI/SY3Z8RwwyHI/AAAAAAAADRk/pQ5bmI7xenc/s720/P1060266.JPG)

.. and finally 1500.

(http://lh4.ggpht.com/_p7bewmqq6YI/SY3ZED7erbI/AAAAAAAADRA/lF60qTZ5yTc/s720/P1060272.JPG)

Fitted the crankcase vent cover after all of the last bits were painted

(http://lh5.ggpht.com/_p7bewmqq6YI/SY3anauK3tI/AAAAAAAADSA/wCF9e6_yQvo/s720/P1060274.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SY3bBsjNgtI/AAAAAAAADSg/kVcJc5zVXJc/s720/P1060275.JPG)

Oil pressure and low pressure cut-out sensors

(http://lh3.ggpht.com/_p7bewmqq6YI/SY3bPcxkC3I/AAAAAAAADSo/h7IbNLJUE-A/s720/P1060277.JPG)

The result sofar ...

(http://lh5.ggpht.com/_p7bewmqq6YI/SY3cDBOH4XI/AAAAAAAADTE/TvSHqbaXpRc/s720/P1060283.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/SY3cR9Q1NZI/AAAAAAAADTg/3eQPOzK4PCQ/s720/P1060286.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SY3dGEoqu5I/AAAAAAAADTk/rhNyirot7_0/s720/P1060289.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SY3dZl1F3OI/AAAAAAAADUA/J4GKA4waYvM/s720/P1060290.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:23:34 PM
Time for an update. The bad news first ...

(http://lh3.ggpht.com/_p7bewmqq6YI/SaGdjtwrcEI/AAAAAAAADZU/OCEdRuxDibw/s720/P1050110.JPG)

It was almost bone dry and needs replacement as you cannot rebuild it  .. :(

(http://lh5.ggpht.com/_p7bewmqq6YI/SaGeBpDZnmI/AAAAAAAADZY/99G2LO-B4cA/s720/P1060297.JPG)

Vacuum pump seal

(http://lh6.ggpht.com/_p7bewmqq6YI/SaGeiCWsjvI/AAAAAAAADZ0/vRO6yfOEnDE/s720/P1060324.JPG)

Both are not in stock in ZA and are now on backorder from Japan.  This setback forced me to deviate from my original plans, as the waiting period could be 4 - 6 weeks  :(

Anyway there was enough other stuff to do, where parts/seals/O-rings etc were in stock ...

(http://lh3.ggpht.com/_p7bewmqq6YI/SaGQPWbEniI/AAAAAAAADVI/tV5SS0YY1ME/s720/P1060339.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SaGQp1LCrbI/AAAAAAAADVM/5o24J31y-xs/s720/P1060367.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGRF30vmzI/AAAAAAAADVQ/Agyl1lc-Qss/s720/P1060496.JPG)

All done

(http://lh3.ggpht.com/_p7bewmqq6YI/SaGPkvRjdJI/AAAAAAAADVE/tQVyPZPLWko/s720/P1060510.JPG)

Fitted

(http://lh5.ggpht.com/_p7bewmqq6YI/SaGRkPObfSI/AAAAAAAADVU/PJhnvODaogQ/s720/P1060515.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SaGR8daYAWI/AAAAAAAADVw/To59VvxCO-w/s720/P1060525.JPG)

Before ..

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGYh7Rr5_I/AAAAAAAADXc/3GzLIkEhbnM/s720/P1040803.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGdIgucWgI/AAAAAAAADY4/1-my7DyzrzU/s720/P1040808.JPG)

After a rebuild

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGcL2dbqSI/AAAAAAAADYE/QPCXMQuoygw/s720/P1060541.JPG)

 and with the new TRE's all round

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGZQso8BFI/AAAAAAAADXg/sTJUk9IQkhs/s720/P1060522.JPG)

Also got around to fitting the rebuilt clutch release cylinder & starter

(http://lh4.ggpht.com/_p7bewmqq6YI/SaGXdjbk__I/AAAAAAAADXA/s12wpSjVJqE/s720/P1060533.JPG)

Next up,  a real nightmare

(http://lh5.ggpht.com/_p7bewmqq6YI/SaGSS0aM4tI/AAAAAAAADWM/B4d4O5xXLC4/s720/P1060529.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:25:27 PM
Heeeha got some goodies from Japan recently ....

(http://lh4.ggpht.com/_p7bewmqq6YI/SbI02o13KII/AAAAAAAADeU/NulOUO-oR1s/s720/PB140446.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SbI1APMNbAI/AAAAAAAADeY/o4Jx6bk3Qt0/s720/PB140451.JPG)

And so I could finally continue ...

(http://lh5.ggpht.com/_p7bewmqq6YI/SbI0o4IHZCI/AAAAAAAADeQ/R3c8puOW_gI/s720/PB140444.JPG)

(http://lh4.ggpht.com/_p7bewmqq6YI/SbIzDxLys0I/AAAAAAAADdU/BINEsLcHpkM/s720/P1050052.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SbIzVzuRHlI/AAAAAAAADdY/jr8PewIzcp0/s720/P1060322.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/SbIzdVaCjfI/AAAAAAAADdc/1tJRVa-xDTs/s720/P1060325.JPG)

All done and fitted ..

(http://lh3.ggpht.com/_p7bewmqq6YI/SbIrYG6AAQI/AAAAAAAADaQ/9B-3M1tdYSE/s720/PB150456.JPG)

P/S cooler lines etc

(http://lh5.ggpht.com/_p7bewmqq6YI/SbItGsjQAoI/AAAAAAAADbU/LiKbQmUDMOI/s720/PB160472.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SbIsuwefvlI/AAAAAAAADa4/RTrHF7-MlsI/s720/PB220480.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SbIxJRqvEII/AAAAAAAADb0/IANqmgvshao/s720/PB220479.JPG)

And the result

(http://lh3.ggpht.com/_p7bewmqq6YI/SbIx8wnBQJI/AAAAAAAADcc/BSHkOgVus50/s720/PB220483.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:33:30 PM
It has been a long time since my last update but not without good reason.  >:( First the bastards burglared our home and in the process drugged my loyal late night helper, which eventually culminated in his untimely death a week later   :'(


(http://lh6.ggpht.com/_p7bewmqq6YI/ScdPXmsY8wI/AAAAAAAADjY/d4W2wpRcZWE/s800/2003_0101%28019%29.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/ScdPnHpDDOI/AAAAAAAADjc/JB9GwCQufio/s800/2003_0101%28021%29.JPG)

Testing the tyres

(http://lh6.ggpht.com/_p7bewmqq6YI/SGaywd12ysI/AAAAAAAABto/WYmjrbpwWt0/s800/P1040689.JPG)

Sleeping in after a long nite in the garage..

(http://lh6.ggpht.com/_p7bewmqq6YI/ScdP7aThTYI/AAAAAAAADj4/xkk6O05Uves/s800/DSCF0462.JPG)

Go well our beloved friend , you are sorely missed everyday !  :'(

Then, no sooner had we finished the last cutting and welding on the tub and then the beater who was helping me decided to do a textbook Houdini. So there I was with only the beating ,crimping, pulling and stretching etc to be done with no panelbeater. What annoyed me the most, is the fact that I realised that my initial idea of a DIY(as far as possible) rebuild, was over. Winter was fast approaching and the Rust Bullet(with a racklife of 12 months, I was told) had to go onto the tub without further delay, so I was in a fix and started shopping around.

Enter Auto Magic M5 body and panel shop ! :D
I had read some very good reviews about them but lets be honest not many good body shops, nowadays enjoy doing restorations inbetween the normal stuff.  I phoned Gordon and his enthusiasm for this project was immediately noticed, so I was optimistic. He came to inspect the job twice even bringing his foreman with him during the 2nd visit. We agreed on a price and the work to be done and a day later they collected the tub and all panels.

Yesterday JT and I took the rolling chassis through as I want the alignment etc of the panels to be checked and done on the tub when mounted to the frame. I was pleasantly surprised/shocked when I arrived at the shop !

 
(http://www.landcruiserclub.co.za/cms/modules/coppermine/albums/userpics/10386/pb1.jpg)


(http://www.landcruiserclub.co.za/cms/modules/coppermine/albums/userpics/10386/pb3.jpg)


(http://www.landcruiserclub.co.za/cms/modules/coppermine/albums/userpics/10386/pb4.jpg)


(http://www.landcruiserclub.co.za/cms/modules/coppermine/albums/userpics/10386/pb5.jpg)


(http://www.landcruiserclub.co.za/cms/modules/coppermine/albums/userpics/10386/pb6.jpg)




A close up of the colour


(http://lh5.ggpht.com/_p7bewmqq6YI/SfIHOLlOwZI/AAAAAAAADoU/WdzlO1U0NoY/s800/P1090525.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SfIHg_KMJDI/AAAAAAAADoY/-j3mPpajFbo/s800/P1090527.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:37:32 PM
Well the Cape winter didn't play along with our plans, as we need at least 3/4 days to blast and Rust Bullet the tub and all panels and according to the latest forecasts that window period will only happen from next week Wednesday.  :x

I had a few outstanding odd jobs to do, so yesterday being workers-day, was good for me but I don't work at Auto Magic everyday. What great service again from Gordon.Not only did he open the place for us but even lent us a helping hand and bought us lunch !  8O Thanks Gordon, the sacrifices you make for your clients are amazing  8-)

I needed to to test the new custom tubmounts that we had made which meant I also had to drill the holes for the supports(and 3mm lift) I had made for the rear tubmounts.I was sceptical about the tubmounts but not anymore. They worked great and the tub was level. (Sorry about the crappy cellphone pics  :oops: )

It was good to see the tub on the chassis and to get an idea of the lift gained, from the longer shackles...

(http://lh4.ggpht.com/_p7bewmqq6YI/SfvmV6ZRe-I/AAAAAAAADwI/sH6ib8RioxM/s800/01052009%28001%29.jpg)

I also needed to drill the swivel's holes on the bib that we had modified/repaired earlier which meant we had to assemble and align the front in order to mark and drill the holes. At the end JT remarked: "That was a lot of work for 5 holes" and I have to agree.

(http://lh5.ggpht.com/_p7bewmqq6YI/Sfvmfe6gB0I/AAAAAAAADwM/eGJBIoYI5J4/s800/01052009%28002%29.jpg)

(http://lh5.ggpht.com/_p7bewmqq6YI/SfvmndAoz4I/AAAAAAAADwU/SimhSsObeuE/s800/01052009%28003%29.jpg)

(http://lh4.ggpht.com/_p7bewmqq6YI/SfvmteWDObI/AAAAAAAADwY/pnG-dd0hpgQ/s800/01052009%28005%29.jpg)

(http://lh6.ggpht.com/_p7bewmqq6YI/SfvlpBayQsI/AAAAAAAADvo/rarlUEI8mz8/s800/01052009%28006%29.jpg)

(http://lh3.ggpht.com/_p7bewmqq6YI/SfvmGZ-GklI/AAAAAAAADvs/rvaf7KeM2z0/s800/01052009%28007%29.jpg)

Thanks for offering up your time also JT, it is much appreciated.  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:40:14 PM
Time for an update: With the weather finally clearing we got our window of 4 days to blast all panels and spray the Rust Bullet. Yesterday the first load of stuff went to the blasters.It was not finished on time but that was not the worst of it. Instead of picking the tub up and turning it over the way most people would do it, these guys, in their infinite wisdom decided to roll the tub over on it's side and in the process bent one of the panels  :evil: The damage was not bad but it was already 15H30 and we still needed to weld up the few small new holes, clean the remaining seam-sealer(that OEM stuff is very tough!), panelbeat the new dent and then prep and spray the 2 coats of Rust Bullet. It is fair to say that I had a total sense of humor failure ...  >:(

(http://lh4.ggpht.com/_p7bewmqq6YI/SgBrrmPtXVI/AAAAAAAADzY/KVAh3IDvqww/s720/DSC03908%20%28Medium%29.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/SgBrxlRverI/AAAAAAAADzc/fdy6IhiHozM/s720/DSC03915%20%28Medium%29.JPG)

Enter the guys at Auto Magic again. They were fantastic ! Realising the pickle we were in with all the panels and tub being down to bare metal, they just started clicking like a unit.

(http://lh5.ggpht.com/_p7bewmqq6YI/SgBr-kQS3NI/AAAAAAAADzg/fAv50SOPQhQ/s720/DSC03920%20%28Medium%29.JPG)

I even got a shirt  :)

(http://lh3.ggpht.com/_p7bewmqq6YI/SgBsE6zj6yI/AAAAAAAADzk/xiCRYFjo3fQ/s720/DSC03922%20%28Medium%29.JPG)

While we were doing the seams Wouter set about on the beating of the tub etc. Eventually it was just the 3 of us but at 19h20 we started spraying the 1st coat of Rust bullet


(http://lh4.ggpht.com/_p7bewmqq6YI/Sf_Cnmey6SI/AAAAAAAADx8/qqGoHB7wEaw/s800/04052009.jpg)

(http://lh4.ggpht.com/_p7bewmqq6YI/Sf_C1k7GzvI/AAAAAAAADyE/4fkPiP_guV0/s800/04052009%28002%29.jpg)

With the 2nd coat on we dragged ourselves out of there at 22h40 but very glad that we had achieved what we wanted to ...

(http://lh5.ggpht.com/_p7bewmqq6YI/Sf_C8FFdy_I/AAAAAAAADyg/qPSbDZxEYmE/s800/04052009%28004%29.jpg)

(http://lh6.ggpht.com/_p7bewmqq6YI/Sf_DVht8y_I/AAAAAAAADy8/N3tqcysTtWI/s800/04052009%28006%29.jpg)

Thanks guys, you were great !

Side notes:
The quality of the blasting with fine sand is very good- no warped panels , holes blown through etc.
My tub is actually in much better condition than what most(including myself) thought, initially.
Rust Bullet silver label is too thick and we had to dilute it with Xylene(thanks again Keith)
Rust bullet amplifies all the dents and imperfections making it easy to see the areas where work is needed.
Doing this in the Cape winter time is stressfull.

Today the last panels will be blasted and sprayed 
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:45:22 PM
Now that the Rust Bullet has been sprayed it is time for the fine beating and the unavoidable filler-work. From the onset I insisted on all the panels being back on the chassis during this stage and the great bunch of guys at Auto Magic agreed. So tonight, Hendrik and I had the entire shop to ourselves and got some work done ...

(http://lh5.ggpht.com/_p7bewmqq6YI/SgCI8kz2OlI/AAAAAAAAD1o/ySIuWIJ6Ur4/s720/DSC03934%20%28Medium%29.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SgSlK_N8NSI/AAAAAAAAD3Q/ov3Otrife98/s720/07052009%28001%29.jpg)

Alignment done ..

(http://lh3.ggpht.com/_p7bewmqq6YI/SgSlhtAAr8I/AAAAAAAAD3U/jcB4NfNJVWI/s720/07052009%28003%29.jpg)

(http://lh4.ggpht.com/_p7bewmqq6YI/SgSlw86gO4I/AAAAAAAAD3Y/lDugi8fYKMU/s720/07052009.jpg)

Then the rest ..

(http://lh4.ggpht.com/_p7bewmqq6YI/SgSmVBvz6eI/AAAAAAAAD30/16v_BbN_tAs/s720/07052009%28012%29.jpg)

(http://lh3.ggpht.com/_p7bewmqq6YI/SgSmsq2Uj1I/AAAAAAAAD4U/v7BEzcb2jDs/s720/07052009%28010%29.jpg)

(http://lh4.ggpht.com/_p7bewmqq6YI/SgSm6JSXNkI/AAAAAAAAD4Y/G1mJRYS_1II/s720/07052009%28008%29.jpg)

(http://lh6.ggpht.com/_p7bewmqq6YI/SgSusHX5suI/AAAAAAAAD5Q/6DHuObN0vEM/s720/07052009%28009%29.jpg)

Last one

(http://lh6.ggpht.com/_p7bewmqq6YI/SgSnbRyEUUI/AAAAAAAAD4c/2gRTljH2JGs/s720/07052009%28005%29.jpg)

On to the next stage  ..
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:48:27 PM
I went to go check out the progress for myself this afternoon and must say it is coming along very nicely. What I like is the fact that these guys actually take note of one's input. Keep up the good work guys ...  :D

(http://lh5.ggpht.com/_p7bewmqq6YI/Sg2oicOSZ_I/AAAAAAAAD7k/F2Au9v9ceNw/s720/14052009%28001%29.jpg)

(http://lh4.ggpht.com/_p7bewmqq6YI/Sg2ovITSNGI/AAAAAAAAD7o/Kn8spWHSELI/s720/14052009%28002%29.jpg)

(http://lh3.ggpht.com/_p7bewmqq6YI/Sg2o5zaO2yI/AAAAAAAAD7s/pJOjB5ATCxM/s720/14052009.jpg)

(http://lh6.ggpht.com/_p7bewmqq6YI/Sg2pDVAbAMI/AAAAAAAAD7w/OcD4I3tTzi8/s720/14052009%28005%29.jpg)

Starting on the other side ...

(http://lh4.ggpht.com/_p7bewmqq6YI/Sg2pQNUOHHI/AAAAAAAAD70/ZIqMuCV_F3c/s720/14052009%28003%29.jpg)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:49:54 PM
Some progress pics ..

Quote from: Jonathan Tee
Quote
I never planned on the cruiser ever being so straight. Non of the bondo is thick it is just a skim coat to iron it out. It is actually gonna look kinda fake because you know they didnt come off the show room straight...

Filler on,  filler off, filler on .... it takes a lot of labour to get it just right
 
(http://lh5.ggpht.com/_p7bewmqq6YI/ShMANB_xiKI/AAAAAAAAD8o/cr1PTQwHhjk/s720/DSC04280%20%28Medium%29.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/ShMASbQ09-I/AAAAAAAAD8s/-B3JZFeHKyE/s720/DSC04279%20%28Medium%29.JPG)

Eventually after a touch-up coat of Rust Bullet. The final 2 coats will be added whewn all the beating and filler work is done

(http://lh5.ggpht.com/_p7bewmqq6YI/ShMAZ-0WZ6I/AAAAAAAAD8w/sVK9aPijGjs/s720/DSC04287%20%28Medium%29.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/ShMAi0tAdwI/AAAAAAAAD9M/skHO-549Bp0/s720/DSC04288%20%28Medium%29.JPG)

Starting on the hard top panels

(http://lh3.ggpht.com/_p7bewmqq6YI/ShQdMBvOe_I/AAAAAAAAD-w/9W1HPqK_EtI/s720/15.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/ShQdSDPFOnI/AAAAAAAAD_M/dfUGDPzbaOE/s720/16.JPG)




Then just when I thought that was the end of it, imagine the surprise I got. Gordon and his guys caught me for a sucker but it was a very nice one.  The buggers secretly started to prime and paint all the small bits that are not needed for alignment  :)


 
(http://lh4.ggpht.com/_p7bewmqq6YI/ShQbhtHdx4I/AAAAAAAAD9s/MtMG89XV-yw/s720/2.JPG)

The bezel in white

(http://lh6.ggpht.com/_p7bewmqq6YI/ShQcTZKcQOI/AAAAAAAAD9w/Z5zb0Nf5Rmg/s720/3.JPG)

And then my favourite the 6H9(Toyota Olive Grey)

(http://lh3.ggpht.com/_p7bewmqq6YI/ShQc2SO1xSI/AAAAAAAAD-k/opBSnWKCkjE/s720/11.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/ShQcjmyHzjI/AAAAAAAAD-E/lyeQgQqKx5Q/s720/8.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/ShQcnWR3orI/AAAAAAAAD-I/RLybGphDnQs/s720/9.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/ShQdBiue-4I/AAAAAAAAD-o/cQrZe50tnOU/s720/13.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:51:59 PM
... and work continues in spite of the weather slowing us down

(http://lh6.ggpht.com/_p7bewmqq6YI/SikpsIAw_5I/AAAAAAAAEAc/fu_AOJQ2TXQ/s720/DSC04486%20%28Medium%29.JPG)

The long & slow process of adding little bits and then sanding it down continues..

(http://lh4.ggpht.com/_p7bewmqq6YI/Sikpz5Df4NI/AAAAAAAAEAg/2HJii6v-RI0/s720/DSC04451%20%28Medium%29.JPG)

(http://lh6.ggpht.com/_p7bewmqq6YI/Sikp9QRTFaI/AAAAAAAAEBA/wt-DgpKLrp8/s720/DSC04453%20%28Medium%29.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/SikqJHivqzI/AAAAAAAAEBI/RHPVeJFODt4/s720/DSC04455%20%28Medium%29.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SikqNBPdN9I/AAAAAAAAEBM/ATn392pZ6iY/s720/DSC04456%20%28Medium%29.JPG)

With all the rain around we cannot cover or do touch-ups with the Rust Bullet and have started using self etching primer as a temporary measure

(http://lh4.ggpht.com/_p7bewmqq6YI/SikqRtxczEI/AAAAAAAAEBQ/L6q5onQyaYY/s720/DSC04484%20%28Medium%29.JPG)

(http://lh3.ggpht.com/_p7bewmqq6YI/SikqWfCQTPI/AAAAAAAAEBs/7JB6xqTWyvk/s720/DSC04485%20%28Medium%29.JPG)

Next week when the rain is gone we will sand the primer down and spray the Rust Bullet

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:53:27 PM
Got some very cool goodies in the mail today ... :P

(http://lh3.ggpht.com/_p7bewmqq6YI/Si1Vyvoz5II/AAAAAAAAED4/A6Rb78t4zhI/s720/07062009%28005%29.jpg)


(http://lh3.ggpht.com/_p7bewmqq6YI/Si1VjWyAoLI/AAAAAAAAED0/uvsMhJWonIw/s720/07062009%28008%29.jpg)

(http://lh5.ggpht.com/_p7bewmqq6YI/Si1VCd--HrI/AAAAAAAAEDw/oeqdZTuG6XU/s720/07062009%28001%29.jpg)

 ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:56:19 PM
Well we had a week of no rain last week, but the filler work took up most of the time.On Friday morning we still had 4 panels to go ...

(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ30S_5FoI/AAAAAAAAEGc/kTsg9aw4HYk/s720/11062009%28007%29.jpg)



(http://lh4.ggpht.com/_p7bewmqq6YI/SjZyzdNgO-I/AAAAAAAAEEY/iisa5iJzXUo/s720/11062009%28010%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZz9Be6sSI/AAAAAAAAEEc/webMuiNY5c4/s720/11062009%28008%29.jpg)



(http://lh3.ggpht.com/_p7bewmqq6YI/SjZ2gGrke6I/AAAAAAAAEGA/HEfGILJbkgU/s720/11062009%28001%29.jpg)



But true to form, by Friday afternoon they had managed to finish 3 out of the 4 panels and also made use of the good weather by finishing all the Rust Bullet touch-ups which included removing the self etching primer(temp solution)  :salut:

(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ0acN9pVI/AAAAAAAAEEk/t_S1sJKmcqE/s720/11062009%28003%29.jpg)



(http://lh3.ggpht.com/_p7bewmqq6YI/SjZ0gyIdr1I/AAAAAAAAEEo/Ca91gB7M3Fw/s720/11062009%28002%29.jpg)



Then while I was away for the weekend, some of the guys came in on Sat and made a big push by finishing both the primer coats.This was a huge but very pleasant surprise to me this morning  :P

Guide coats on and final fine sanding being done in prep for one last primer coat and then the 2 dummie coats ..

(http://lh3.ggpht.com/_p7bewmqq6YI/SjZ0v-XB69I/AAAAAAAAEEs/vCY3ZKTud0c/s720/14062009%28004%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ04s4ob4I/AAAAAAAAEEw/Bis1K2JSRao/s720/14062009%28005%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ1CFkOZOI/AAAAAAAAEE0/ZWRygVLyEIg/s720/14062009%28003%29.jpg)



(http://lh4.ggpht.com/_p7bewmqq6YI/SjZ1Mpxb-QI/AAAAAAAAEFQ/CG1YAmXVMWo/s720/14062009%28002%29.jpg)



(http://lh3.ggpht.com/_p7bewmqq6YI/SjZ1UJ0MAoI/AAAAAAAAEFU/ZtIE9dwgepE/s720/14062009%28001%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ1b1kHUsI/AAAAAAAAEFY/BnLWsH0oLIE/s720/11062009.jpg)


As I arrived this afternoon they were finishing the last primer coat on the outside of the tub, wherafter we did the seam sealer and then it was final prep for the 2 dummie coats of colour

(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ1_Ddu53I/AAAAAAAAEFk/V40CHFMEMSE/s720/14062009%28007%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ1oI9GYNI/AAAAAAAAEFc/sRkpYp8KSjs/s720/14062009%28006%29.jpg)



(http://lh5.ggpht.com/_p7bewmqq6YI/SjZ1z8ZnE_I/AAAAAAAAEFg/UYSxIzzzRhI/s720/14062009.jpg)



After a got home I received a phone call just to inform me that the 2 dummie coats went on well and that it looks "brand new" . 8-)
 
These guys have really put long hrs into this job and deserve all the credit for the finished product. You guys rock !

Tomorrow I will collect the tub in order to take it for the PU lining on the inside. Thereafter it will get a further 3 coats of colour paint   :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 21, 2009, 03:57:31 PM
Yesterday I collected the tub and this morning I dropped it off at Rainbow PU linings. At 14h00 they were finished and had done a really superb job. It was a frustrating and nervous drive back into town to drop it off during peakhour traffic.  8O



(http://lh6.ggpht.com/_p7bewmqq6YI/SjkIuR3XDSI/AAAAAAAAEKQ/XTrqODi0Qno/s720/16062009%28003%29.jpg)


(http://lh6.ggpht.com/_p7bewmqq6YI/SjkI_pDKraI/AAAAAAAAEKw/TY-fBd4tqhs/s720/16062009%28005%29.jpg)

I love the colour and in sunlight it is even better  :P


 
(http://lh3.ggpht.com/_p7bewmqq6YI/SjkI1Ik1iLI/AAAAAAAAEKs/OfasIHgqmq8/s720/16062009%28004%29.jpg)

The black and 6h9 gives a great contrast but I am thinking that the rims should be silver rather than the flat black I originally planned ?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:10:19 AM
Time for an update: Some panels being prepped for the dummy coat ....

(http://lh4.ggpht.com/_p7bewmqq6YI/SkJPwu0TXWI/AAAAAAAAELQ/g7i6_k1QuHM/s720/DSC04730%20%28Medium%29.JPG)

Stone Chip already sprayed on the underside of the front fenders

(http://lh3.ggpht.com/_p7bewmqq6YI/SkJP1U5b6hI/AAAAAAAAELU/pwVPhs5ncns/s720/DSC04731%20%28Medium%29.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SkJQBcyaltI/AAAAAAAAELw/eNekFTw8hHk/s720/DSC04736%20%28Medium%29.JPG)

Dummy coat going on ....


(http://lh5.ggpht.com/_p7bewmqq6YI/SkJQutS0SaI/AAAAAAAAEMQ/iaH2tloRYiw/s720/DSC04748%20%28Medium%29.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SkJQyStWwhI/AAAAAAAAEMU/ettha8qVsX8/s720/DSC04750%20%28Medium%29.JPG)

Small "repairs"to imperfections as highlighted by the dummy coat


(http://lh6.ggpht.com/_p7bewmqq6YI/SkJQlCxPY1I/AAAAAAAAEL0/tAPUh-PfqzU/s720/DSC04740%20%28Medium%29.JPG)

Gordon and his guys miss nothing!   :salut:

(http://lh6.ggpht.com/_p7bewmqq6YI/SkJROdTy_0I/AAAAAAAAENM/JFXBFPiVB0Y/s720/DSC04741%20%28Medium%29.JPG)


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:11:25 AM
Some panels got their final coats and are ready to be wet-sanded etc ....

(http://lh5.ggpht.com/_p7bewmqq6YI/Skajngv4eZI/AAAAAAAAEOM/Iv7NNoi8FVM/s720/P3080818.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SkakHuORt3I/AAAAAAAAEOU/pqZH3jWXIlA/s720/P3080820.JPG)

Today Hennie and I started with the Stone-Chip underneath the tub.The plan was to do 2 entire coats ...


(http://lh5.ggpht.com/_p7bewmqq6YI/Skain907ZUI/AAAAAAAAEOA/WvTMkjEsbzg/s720/P3080812.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Skai8FwZSOI/AAAAAAAAEOE/vWKnuR-BoLc/s720/P3080814.JPG)

the firewall we will do with a conventional gun for a smooth finish


(http://lh5.ggpht.com/_p7bewmqq6YI/SkajYNCKrrI/AAAAAAAAEOI/ADh1DTtt_Tk/s720/P3080817.JPG)


Eventually we had to give it up as that stuff takes too long to dry.Now we will head back there in the morning to do the 2nd coat of Stone-Chip.


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:12:16 AM
This morning we baked it for about an hour before we did the entire 2nd coat using a conventional gun.

(http://lh6.ggpht.com/_p7bewmqq6YI/SkeeWgj0yRI/AAAAAAAAEQM/VzTtx-8pTG8/s720/P3090823.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SkeeQ7sZ8LI/AAAAAAAAEQI/J7O4zAD6Ue0/s720/P3090819.JPG)


Had some cheap manual labour to help with the un-masking  8-)


(http://lh4.ggpht.com/_p7bewmqq6YI/Skeedn8WD-I/AAAAAAAAEQQ/9yOOFHozM4I/s720/P3090824.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Skec2vI4rpI/AAAAAAAAEQA/h4kl6FB5nns/s720/P3090826.JPG)


I had done some filler work on a few small bits previously and couldn't wait to see how they would turn out. Pretty happy with most of the results ...


(http://lh6.ggpht.com/_p7bewmqq6YI/SkehevHU5eI/AAAAAAAAEQw/00WfGmJPce8/s720/P3090819.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SkehuoLpCrI/AAAAAAAAEQ0/rKmRJKgiCqg/s720/P3090812.JPG)


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:13:16 AM
Happiness is .......

collecting and taking your tub and chassis home !  :cheers:


(http://lh6.ggpht.com/_p7bewmqq6YI/Sk9ztzTPjPI/AAAAAAAAESY/J5hxDBFG9p8/s720/04072009%28003%29.jpg)


(http://lh5.ggpht.com/_p7bewmqq6YI/Sk97_N4l0-I/AAAAAAAAETo/i2IWRgqtz6A/s720/P3150831.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sk964F2WKoI/AAAAAAAAETM/E4o_gPVaRug/s720/P3150830.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Sk96Vm9uuYI/AAAAAAAAETI/AAGlglGzchQ/s720/P3150826.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sk95eMt6OrI/AAAAAAAAETE/7ZmWvRa2TKQ/s720/P3150824.JPG)


Stone Chip with colour

(http://lh3.ggpht.com/_p7bewmqq6YI/Sk92_p05lkI/AAAAAAAAES8/PzPv6wJp9R8/s720/P3150835.JPG)


Now the fun starts 
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:14:38 AM
With the tub back on the real work could start. One of my concerns was getting the main tank back in while the tub was on. Initially I had planned on fitting the tank to the tub before putting the tub back on the chassis but unfortunately things don't always work out the way you plan ...


The tank was in perfect condition but very dirty from the aussie desert dust and in dire need of a good clean and paint.


(http://lh3.ggpht.com/_p7bewmqq6YI/SlhRT28DCuI/AAAAAAAAEUc/9Dd8-JRmDEk/s720/P1040675.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SlhSnKG6r3I/AAAAAAAAEVA/Il3ot4IDTJI/s720/P1030279.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SlhSE5o3gDI/AAAAAAAAEU8/TJHRtQme4r8/s720/11052009.jpg)


For some reason mine had metal spacers for the straps.


(http://lh3.ggpht.com/_p7bewmqq6YI/SlhRpPhGDxI/AAAAAAAAEUg/W2zi7BG1o6k/s720/P1040696.JPG)



I replaced these and all the felt material with heavy duty threaded rubber of various thickness


(http://lh3.ggpht.com/_p7bewmqq6YI/SlhT71pfcEI/AAAAAAAAEVg/ehjX-9WINQw/s720/P3190826.JPG)



Getting it back in place proved to be a real challenge ...


(http://lh4.ggpht.com/_p7bewmqq6YI/SlhUVUVSfII/AAAAAAAAEV8/ZhhdL7xZ8xI/s720/P3190830.JPG)


All done ...


(http://lh4.ggpht.com/_p7bewmqq6YI/SlhUoqPlVhI/AAAAAAAAEWA/c-IavEj1tAk/s720/P3190831.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SlhU_fH7IPI/AAAAAAAAEWE/FS2jBwq_Ecc/s720/P3190833.JPG)


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:15:35 AM
Started fitting the Hell Creek springs ...


(http://lh5.ggpht.com/_p7bewmqq6YI/SloXNpxUdhI/AAAAAAAAEW4/Vo2R7GUdriY/s720/P3200811.JPG)


The new springs are quite a bit longer than the old ones


(http://lh4.ggpht.com/_p7bewmqq6YI/SloXrnJDwMI/AAAAAAAAEW8/QpzULqiU2Wg/s720/P3200820.JPG)


They also droop much further.I had to remove the shocks to get the axle onto the springs. New shocks are definately on the cards ...


(http://lh3.ggpht.com/_p7bewmqq6YI/SloYKcZraII/AAAAAAAAEXA/FFSQGNB0LYM/s640/P3200821.JPG)


All done


(http://lh6.ggpht.com/_p7bewmqq6YI/SloYtQdaiwI/AAAAAAAAEXc/5d4t8KyxQCE/s720/P3210832.JPG)

I started the rear ...


(http://lh3.ggpht.com/_p7bewmqq6YI/SloZPxfxbKI/AAAAAAAAEXk/VOjn0m9Eweo/s720/P3210833.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/Sloa6jZGd8I/AAAAAAAAEYA/_AiX09-ZHRY/s720/P3210837.JPG)


.. but ran into a snag with the shackle plates. I had earlier model shackles in the rear but I didn't want to go the custom bushes route again. I managed to find a set of later model greasable pins that fit on the threaded holes in the plates. The non-threaded holes just needs to be drilled 2mm bigger. Unfortunately my biggest drill-bit was still 1mm to small,so tomorrow I will go shopping again   ::)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2009, 08:17:18 AM
Well after work today I finished up converting the early model Haystee shackles into later model ones, by fitting OME greasable pins - heeha no more custom pink bushes.  :theo: With that done it was just a case of fitting the springs ..



(http://lh5.ggpht.com/_p7bewmqq6YI/Slt67Nwpp3I/AAAAAAAAEY0/R0LB5KEKbZU/s720/P3220812.JPG)


...dropping the axle back onto the springs ...


(http://lh6.ggpht.com/_p7bewmqq6YI/Slt7ke5VmUI/AAAAAAAAEZQ/-PDVCXGqikg/s720/P3220815.JPG)

..and the result ...


(http://lh5.ggpht.com/_p7bewmqq6YI/Slt8BhODhPI/AAAAAAAAEZs/uCP95DxymvE/s720/P3220817.JPG)


Those 31" tyres now look decidedly tiny. Time to redo the rims and fit those new 33" that have been gathering dust !


(http://lh3.ggpht.com/_p7bewmqq6YI/Slt8S_jw4SI/AAAAAAAAEZw/LcrvO_05YFY/s720/P3220823.JPG)


I gained 5.5 cm lift in the front and 6cm in the rear but I suspect it will settle a bit as I continue to add the weight to it. Overall I like the product and the look  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 06, 2009, 12:25:55 AM
Between sourcing parts , waiting for the yellow passivating and some home renovations, progress has been very slow, frustratingly so !
Some before and after pics tells a story ...

(http://lh5.ggpht.com/_p7bewmqq6YI/Smvw7PC1UQI/AAAAAAAAEak/mFypi-YSEMI/s720/DSC_0413.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/Smv0gE9m4RI/AAAAAAAAEbE/aDbBPESAJmU/s720/DSC_0414.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Smv0zfB4C8I/AAAAAAAAEbI/wIsJLHzCqG8/s720/DSC_0416.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SnnzImW9IqI/AAAAAAAAEeM/7jJ7fSwfb5s/s720/DSC_0106.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SnnzmjI0ewI/AAAAAAAAEeo/iKEB0eGbCO8/s720/DSC_0107.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Snn698WQVhI/AAAAAAAAEig/ggw8m819QDc/s720/P1020004.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Snn52FfiovI/AAAAAAAAEho/pLHh4x6_rDk/s720/P1030441.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Snnw0ZA2KqI/AAAAAAAAEdE/Zy_Qqn6k4ZA/s720/DSC_0065.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SnnxJLQWkOI/AAAAAAAAEdI/S0mb-NJ_qSk/s720/DSC_0084.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SnnwibtpAhI/AAAAAAAAEdA/yrCR9typtuM/s720/DSC_0061.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Snn49Gar9II/AAAAAAAAEgw/7xYAUfjR0JY/s720/DSC_0090.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Snn4gny4LVI/AAAAAAAAEgs/BBhdFDOOZPg/s720/DSC_0093.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/Snn6OXujPpI/AAAAAAAAEiE/5P8h2ZCz6ig/s720/P1030482.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SndEodpSB5I/AAAAAAAAEcE/dIdYaGXmfYA/s720/DSC_0040.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SndE58ZKOsI/AAAAAAAAEcI/vwSqJEUlfSk/s720/DSC_0039.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SndEQalaJyI/AAAAAAAAEcA/Es0YrW0p7w4/s720/DSC_0051.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SndD35-g4wI/AAAAAAAAEb8/JcEqQf-LbfM/s720/DSC_0035.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 06, 2009, 07:28:24 AM
Eish, lookin very  8) thanks for sharing  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 06, 2009, 10:24:12 AM
Theo

Its really looking good  :P
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 06, 2009, 11:59:12 AM
great job...  :theo: great job... dont forget my gutter!!  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 07, 2009, 09:13:40 AM
Thanks guys  :drinks:

I won't Mark  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 10, 2009, 07:25:25 AM
Progress has been slow ....

(http://lh5.ggpht.com/_p7bewmqq6YI/Sn7zFvM0WEI/AAAAAAAAEnQ/vOX8qnKk8WU/s720/P1030685.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Sn7zN7mCv2I/AAAAAAAAEns/eVUstmb8qVc/s720/P1030691.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Sn7tvNOmuEI/AAAAAAAAEj8/CEgkHOOQ-Vw/s720/DSC_0121.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/Sn7ue7F1pVI/AAAAAAAAEkE/FrBVfy96J_E/s720/DSC_0130.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/Sn7tCsKAs3I/AAAAAAAAEjw/BgS9s8KIbyE/s720/DSC_0114.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Sn70jXfU1yI/AAAAAAAAEoI/gJGZDw480VE/s720/DSC_0141.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Sn7slXhZtcI/AAAAAAAAEjs/HWBYOMSSQfA/s720/DSC_0025.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Sn7wSfItlEI/AAAAAAAAElM/-g98oatgt1U/s720/DSC_0145.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Sn7wvCzJBfI/AAAAAAAAElo/KkPvflunRr0/s720/DSC_0149.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/Sn7xEpyO9FI/AAAAAAAAEmE/D_9Co8_fQCw/s720/DSC_0150.JPG)


Spot the problem ?


(http://lh6.ggpht.com/_p7bewmqq6YI/Sn7u1A_rjsI/AAAAAAAAEkI/fdUjsB_xT8E/s720/DSC_0137.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sn7x4acayYI/AAAAAAAAEmk/UVzMkVHS6pg/s720/DSC_0158.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sn7y8T9uXhI/AAAAAAAAEnM/8qCLva6vJsc/s720/P1030623.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Sn7ySCSVuOI/AAAAAAAAEnE/bn12C5WcKwM/s720/DSC_0168.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 10, 2009, 10:33:09 AM
Looking good Theo.. very good!  That inlet manifild needs a bit of a clean ...  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 10, 2009, 02:18:27 PM
I know ...  :-[
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on August 11, 2009, 10:10:22 AM
 :theo: Looking A1+. 8) 8)

Is the project affecting your social  :drinks: life with all the hours put into it? :jt:

Are you replacing the wire loom?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 11, 2009, 11:02:19 AM
Thanks !

I will only replace the loom if I have to, Pierre. I have been avoiding that part of the rebuild but will have to face-up to it soon as I am running out of "other" things to do ...  :-[
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 15, 2009, 10:34:29 PM
I am slowly getting used to the "same old , same old" routine of rebuild/clean , prep,  paint, watch paint dry and then fit ....

(http://lh5.ggpht.com/_p7bewmqq6YI/SobaI0ZHyMI/AAAAAAAAEp0/CNs4ZyN6ksM/s720/DSC_0174_002.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SobgNmpPu5I/AAAAAAAAEug/qJykylSZFSM/s720/DSC_0261_089.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SobgeREVxxI/AAAAAAAAEuk/POYkBxoMmB8/s720/DSC_0266_094.JPG)


I had a problem with one of the isolators of the glow system and needed to find a part, preferably local.


(http://lh5.ggpht.com/_p7bewmqq6YI/Sobg1otMyAI/AAAAAAAAEuo/D9pcIXqo7L0/s720/DSC_0240_068.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SobhNCtU5QI/AAAAAAAAEvE/HcnFmLkAumA/s720/DSC_0243_071.JPG)


Luckily JB helped and we found that the OEM 3L(2.8L) motor uses the exact same part as my 3B ! 


(http://lh5.ggpht.com/_p7bewmqq6YI/SobherA0-MI/AAAAAAAAEvg/HLTVLQOH0HA/s720/DSC_0244_072.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sobh0pHRK0I/AAAAAAAAEv8/MAAV6uY_ZOs/s720/DSC_0245_073.JPG)


Today I discovered that whoever replaced the ones on my vehicle in Aus, had mixed them up and fitted the wrong one at the bottom, which kinda explains the reason why it was crushed ...


(http://lh4.ggpht.com/_p7bewmqq6YI/SobiMSIMW-I/AAAAAAAAEwA/OPd9FMz6gso/s720/DSC_0249_077.JPG)


Correct one at the bottom


 (http://lh6.ggpht.com/_p7bewmqq6YI/SobimlFJBqI/AAAAAAAAEwg/x9PU-F47H4s/s720/DSC_0250_078.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Sobi9wbui-I/AAAAAAAAEw8/_iDhjuLEmkg/s720/DSC_0251_079.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SobjWiyXgtI/AAAAAAAAExY/EepLzM3dm6g/s720/DSC_0253_081.JPG)


I was also waiting for a small part to finish a few other things ......


(http://lh5.ggpht.com/_p7bewmqq6YI/SobafPZeRsI/AAAAAAAAEp4/Onzg4jf1r88/s720/DSC_0192_020.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Soba-ANNpiI/AAAAAAAAEqU/sw2oNT02ilk/s720/DSC_0193_021.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SobbPj255pI/AAAAAAAAEqw/K4LiiuhHEhE/s720/DSC_0196_024.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SobcC2W9CFI/AAAAAAAAErU/OzJ_bFU04jk/s720/DSC_0207_035.JPG)


Somehow this breather tank cover just didn't "feel" right but Keith will probably say it was just me being anal gain ..   :jt:


 
(http://lh4.ggpht.com/_p7bewmqq6YI/SobccBjZy9I/AAAAAAAAErY/6Lmxj5SqeAQ/s720/DSC_0232_060.JPG)


So I sourced some rubber to round things off a bit ...


(http://lh3.ggpht.com/_p7bewmqq6YI/Sobc08rt6SI/AAAAAAAAEr0/31TbJDDlcSk/s720/DSC_0234_062.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SobdFjE0GXI/AAAAAAAAEsQ/20dx2hKcrPw/s720/DSC_0237_065.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/Sobf--3UEDI/AAAAAAAAEuc/aM8mMbPHNWU/s720/DSC_0258_086.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SobfE73X4pI/AAAAAAAAEtg/d9zll75P6Ek/s720/DSC_0271_099.JPG)


 :drinks:

Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 16, 2009, 05:16:52 PM
Theo

Just out of curiosity what did Yota charge for those glow plug insulators
Why dont you ask ? ? ? ? ?
Those insulators are standard in the electrical industry and come in a multitude of sizes and are available from most specialist electrical connector suppliers and they cost only a few cents each. And, , , , you can chose from either bakelite, nylon, or even porcelain.   :jt:

Also that gasket on the breather cover looks cool - but un-necessary or Yota would have put one there, and besides mine had a gasket - was your gasket missing ?  :o :o :o

But - keep up the good work -  8)

I cant wait for it to be finished so you can come on the Legends Trip, and I will be the first one with the camera to record your tears when you get your first case of "Bush Rash"  ;D ;D ;D

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 17, 2009, 08:29:22 AM
Keith.

1. I don't know what they cost as JB didn't want to give me the invoice. He said it is too little and therefore just put it on a tab that I didn't even know I had  :o

2. Mine didn't have a gasket as such, just some sticky seam sealer ???

3. I think I better wear a mask on that trip  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 18, 2009, 12:38:06 PM
Theo

This is the part number for the rubber gasket that goes behind the Breather cover
(but youve made your own)

61683 PACKING, REAR BODY REAR SIDE SERVICE HOLE COVER
61683-90300 BJ4*, HJ47, FJ4*..V, TP 1 € 25.11


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 25, 2009, 10:28:08 AM
Some progress ...

(http://lh3.ggpht.com/_p7bewmqq6YI/SpOCVlsBNWI/AAAAAAAAEyQ/UAQGR8C0TSI/s800/DSC_0293_121.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SpOCs6QUAJI/AAAAAAAAEyY/jt3R_YnGk4Q/s720/DSC_0295_123.JPG)



But eventually I could no longer avoid the wiring looms - easily my biggest fear on this project. I decided to start with the rear part and it was not a pretty sight...



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOTMssO5DI/AAAAAAAAE38/_WKkg-S3MSU/s720/DSC_0318_146.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SpODtHHOkVI/AAAAAAAAEyc/UNxMnh6iFjM/s720/DSC_0319_147.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOEJxeVUgI/AAAAAAAAEyg/WXG3UFXnHuc/s720/DSC_0321_149.JPG)



The leftovers ...


(http://lh4.ggpht.com/_p7bewmqq6YI/SpOEs-btdAI/AAAAAAAAEyk/YIiIlgtPAkQ/s720/DSC_0324_152.JPG)



The wiring itself was fortunately still in perfect condition so after a good clean I could tape it up with some high quality tapes that a good friend sent me   8)



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOFJuwEJ6I/AAAAAAAAEys/b1tFHyT_8zQ/s720/DSC_0397_225.JPG)



Thanks Keith, you da man !   :-*




(http://lh3.ggpht.com/_p7bewmqq6YI/SpOF20TYyUI/AAAAAAAAEzI/VbRoproWuKs/s720/DSC_0328_156.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SpOGYwyG9yI/AAAAAAAAEzk/dXXrD1l1ClY/s720/DSC_0331_159.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOG9Z4LynI/AAAAAAAAE0A/ERLqSdwenW4/s720/DSC_0334_162.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOHeSixJfI/AAAAAAAAE0g/xrF1ZuN0I3k/s720/DSC_0336_164.JPG)



And then installing it back in place ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOMKOXoBVI/AAAAAAAAE2Q/LUkUTvC31CE/s720/DSC_0383_211.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOMnJUq0wI/AAAAAAAAE2s/UQnpMAzqazg/s720/DSC_0387_215.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SpOLk8nAP9I/AAAAAAAAE2I/aqz--ZRrdXg/s720/DSC_0382_210.JPG)



Which brought me to the rear lights.



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOH2MKEpfI/AAAAAAAAE0k/H3AecPHe8D4/s720/DSC_0337_165.JPG)



My old ones were not good and I knowingly bought some chinese(?) replacements from N1 4x4.



(http://lh3.ggpht.com/_p7bewmqq6YI/SpOIK5-M-GI/AAAAAAAAE0o/Nir4uPP9AS4/s720/DSC_0338_166.JPG)



In some respects the quality was not good but that was not the only problem ...



(http://lh3.ggpht.com/_p7bewmqq6YI/SpOIgVo2EJI/AAAAAAAAE0s/ytW3ReYnq4o/s720/DSC_0340_168.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOIsmUKMBI/AAAAAAAAE0w/ENqTqn3N6E0/s720/DSC_0353_181.JPG)



So I decided to use the 5 pin OEM wiring and contact-points with the new housing, which needed some serious rust-proofing.



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOI-uLY4jI/AAAAAAAAE00/K1et8IIHW1M/s720/DSC_0359_187.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOJXkRg0pI/AAAAAAAAE08/st2cLCSXmuM/s720/DSC_0361_189.JPG)



Spot the earthing solution



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOJtQeLAhI/AAAAAAAAE1A/2vzmf8TXBkg/s720/DSC_0362_190.JPG)



I was also not entirely happy with the rubber gasket. The front was OK but the back not so i decided to beef it up a bit with some HD fibre rubber...



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOKNJJuQPI/AAAAAAAAE1c/sA7vYs1r0Nc/s720/DSC_0366_194.JPG)



I also changed the flimsy mounting screws with nuts and bolts which will bne used as the new earth contact  



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOKetFOF0I/AAAAAAAAE1g/S5vizT1b-V8/s720/DSC_0368_196.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOKzhXysrI/AAAAAAAAE1k/frKHRpJLJc0/s720/DSC_0371_199.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOLRGbIv6I/AAAAAAAAE2E/nDv0vG-g-y4/s720/DSC_0385_213.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/SpOOnF8GFXI/AAAAAAAAE3U/scbByoT_QV0/s720/DSC_0403_231.JPG)



All done ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SpOL0mWuVpI/AAAAAAAAE2M/7qdA9W995W4/s720/DSC_0378_206.JPG)



They do stand out about 4mm more than before but I am happy that the sealing and shock absorbing is better than before :wink:



Next nightmare the Main Loom !  



(http://lh3.ggpht.com/_p7bewmqq6YI/SpOOO58UdvI/AAAAAAAAE3Q/JCFYGbM_OO4/s720/DSC_0399_227.JPG)


 :o
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 25, 2009, 10:55:19 AM
Theo

The guy doing your YP is doing a k@k job - especially your pedals and light covers

His tanks need a good cleaning

JT - be careful if you plan to use the same guy
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 15, 2009, 11:07:19 PM
Visible progress has been very slow as I am getting to the stage where you find out how much time it actually takes ....

The wiring and all aspects of it, was my biggest fear from the start of this project



(http://lh4.ggpht.com/_p7bewmqq6YI/SqVodptwiGI/AAAAAAAAFAI/2j4RRWnnmVs/s720/DSC_0419_247.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SqVo--v2EpI/AAAAAAAAFAM/YxKu70s_ry8/s720/DSC_0429_257.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SqVsDnFY3KI/AAAAAAAAFBo/EOy1AlOko7o/s720/DSC_0405_233.JPG)



But bit by bit I managed to wrestle myself through it ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SqVsaSS1i2I/AAAAAAAAFCE/h0aI47ksCw4/s720/DSC_0406_234.JPG)



 As allways the self-amalgamating HV tape first and then the other stuff ..



(http://lh5.ggpht.com/_p7bewmqq6YI/SqVpniahMXI/AAAAAAAAFAQ/sWRJ0YnlUSU/s720/DSC_0431_259.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SqVqS6CCOtI/AAAAAAAAFAw/-HJw73EVpBg/s720/DSC_0438_266.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SqVqz1sa3FI/AAAAAAAAFA0/0eyfc__cyQc/s720/DSC_0442_270.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SqVuI1Cp0sI/AAAAAAAAFCw/2OCJCJMXSj4/s720/DSC_0471_299.JPG)


Along the way I found that main loom and some relays etc had been incorrectly fitted and that some stuff was completely out of place  :?



(http://lh5.ggpht.com/_p7bewmqq6YI/Sq_kg2S6NKI/AAAAAAAAFKk/qoRpWIJoS5U/s640/P1020842.JPG)



Some of the relays had some surface rust on the outside.Instead of normal paint I chose to go with a clearcote rust coverter primer combination so as to retain the OEM look.It may not be as pretty as new silver paint but troubleshooting should be easier if I can read the inscriptions clearly and besides, they are all hidden out of sight anyway. I also made rubber "washers" for all areas of contact, just to add a bit of cushioning etc



(http://lh5.ggpht.com/_p7bewmqq6YI/Sq_h19OavJI/AAAAAAAAFJw/nvZQSloOJPI/s720/DSC_0474_302.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Sq_iGXM8iGI/AAAAAAAAFJ0/njlVOTQ-TBM/s720/DSC_0475_303.JPG)


I have taken some flack for putting back the ugly old OEM heat and sound matting, seeing that I covered the entire firewall in stick-on matting already. However when I am finished, very little of theo ugly matting will be visible but it will still be functional ...



(http://lh3.ggpht.com/_p7bewmqq6YI/Sq_ijIdDTwI/AAAAAAAAFJ4/GO70H9VOoCQ/s720/DSC_0478_306.JPG)



I didn't like those sharp edges on the sides of the cubbyhole especially since some wiring runs in those areas ..



(http://lh3.ggpht.com/_p7bewmqq6YI/Sq_i14UwW5I/AAAAAAAAFJ8/n8TZldSL46w/s720/DSC_0480_308.JPG)


and fixed it with some moulded rubber



(http://lh5.ggpht.com/_p7bewmqq6YI/Sq_jL6f66hI/AAAAAAAAFKE/UOSZnXG0UF0/s720/DSC_0485_313.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Sq_jhj_KgeI/AAAAAAAAFKI/7w0kAL6iYhs/s720/DSC_0484_312.JPG)




During stripdown I found that my gearlever "bushes" were shot.



(http://lh6.ggpht.com/_p7bewmqq6YI/Sq_nN9CTbzI/AAAAAAAAFMM/_H1l2iBqtjU/s720/P1030498.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/Sq_nU74jT0I/AAAAAAAAFMQ/hfAwaoFW0nQ/s720/P1030499.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/Sq_cUVIVegI/AAAAAAAAFF8/Crec3hk59DA/s720/DSC_0584_410.JPG)


The flat black levers also came out real stealthy looking 



(http://lh3.ggpht.com/_p7bewmqq6YI/Sq_gNom9dYI/AAAAAAAAFIg/wqpCDpWJS6s/s720/DSC_0586_412.JPG)




Which brought me to the skinny pedal and the hand throttle ..



(http://lh4.ggpht.com/_p7bewmqq6YI/Sq_laA3kMhI/AAAAAAAAFLY/YzpBeaaBp3c/s720/DSC_0561_387.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/Sq_d3Fc3VkI/AAAAAAAAFG0/IScRY-skcIw/s720/DSC_0589_415.JPG)



Not all my YP stuff came out as expected and it seems as if areas which had rust do not come out shiny. Maybe I should have sanded it all before the time ? At least the rust is gone ...



(http://lh5.ggpht.com/_p7bewmqq6YI/Sq_dvJ4JoKI/AAAAAAAAFGY/DNNG-rl87-E/s720/DSC_0588_414.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/Sq_eTdESS4I/AAAAAAAAFG4/ZkhJ2Tzg6Ok/s720/DSC_0590_416.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/Sq_egohYr1I/AAAAAAAAFG8/23QnYGj6yCc/s720/DSC_0592_418.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/Sq_e6RAXZrI/AAAAAAAAFHY/nab3e_cKeq0/s720/DSC_0594_420.JPG)


 
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 18, 2009, 05:51:24 PM
Got a bit more done ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SrOA5v6ue0I/AAAAAAAAFOY/CHJJeY2B8Dg/s720/DSC_0495_323.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SrOBOY8DIiI/AAAAAAAAFOc/EiADHFHS6DA/s720/DSC_0497_325.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SrOBo3sGMdI/AAAAAAAAFOk/qUOQ2Zz8lqk/s720/DSC_0498_326.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SrOCEA4qH1I/AAAAAAAAFPA/FVL8ryJ_Z98/s720/DSC_0501_329.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SrOCWJJtjJI/AAAAAAAAFPE/1fzGA4CJyDk/s720/DSC_0159_442.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/SrOChni5a_I/AAAAAAAAFPg/Ch5V9-8-vhE/s720/DSC_0160_443.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SrN-6I4BzBI/AAAAAAAAFNM/8T67dtzObjs/s720/DSC_0144_427.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SrN_mKfY9XI/AAAAAAAAFNc/a3wnKPqvmAU/s720/DSC_0150_433.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/SrOAI8ecxbI/AAAAAAAAFN8/YEn-_tmPNXs/s720/DSC_0157_440.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SrN_G7TDMoI/AAAAAAAAFNU/rNIf0NqOZHs/s720/DSC_0146_429.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SrN_05HVAZI/AAAAAAAAFNg/k--ASD_ll9E/s720/DSC_0152_435.JPG)


  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 21, 2009, 07:44:56 AM
 8) and thanks for the  :meeting: on Sat.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 29, 2009, 09:38:27 PM
Time for an update ...

(http://lh4.ggpht.com/_p7bewmqq6YI/Sr0ekUoRZxI/AAAAAAAAFSs/qqiZi0XDkYo/s800/DSC_0192_473.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sr0e2a_7OAI/AAAAAAAAFSw/WuZW7wOk0l4/s800/DSC_0193_474.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/Sr0fMo4tMKI/AAAAAAAAFS4/ZWfW7oIwr7M/s800/DSC_0308_589.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SsJFQeCNpGI/AAAAAAAAFWg/20rS83QqLDw/s800/DSC_0007_596.JPG)


My heater was in a bad state of disrepair.



(http://lh3.ggpht.com/_p7bewmqq6YI/SsJHfyUJM2I/AAAAAAAAFXU/xNjirWxWSCk/s800/P1020479.JPG)

The vents were glued to the bottom of the dash for obvious reasons ....


(http://lh6.ggpht.com/_p7bewmqq6YI/SsJIkxX8MBI/AAAAAAAAFXw/8WwoKdEbGRQ/s800/DSC_0200_481.JPG)

It needed a total rebuild as the foam rubber was shot.


(http://lh5.ggpht.com/_p7bewmqq6YI/Sr0hv99IwaI/AAAAAAAAFUw/uST05NrUBGU/s800/DSC_0298_579.JPG)


Fortunately the core was only dirty but very good  :wink:


(http://lh3.ggpht.com/_p7bewmqq6YI/Sr0g_WMQduI/AAAAAAAAFT0/UkNadrkRGjs/s800/DSC_0280_561.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/Sr0h_KL-_-I/AAAAAAAAFVM/o474Bfeqb1k/s800/DSC_0300_581.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sr0iJWzbueI/AAAAAAAAFVQ/ogGHswsLbr8/s800/DSC_0301_582.JPG)


It is advisable to bake the UHT paint but you do so entirely at your own risk !


(http://lh5.ggpht.com/_p7bewmqq6YI/SsJJhVh10EI/AAAAAAAAFYs/DaclJuK1hFU/s800/DSC_0001_590.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SsJKhjPKoJI/AAAAAAAAFY4/9xCxn7fJmag/s800/DSC_0016_605.JPG)

 :hillbilly:


When you only have 2 hands you have to make a plan to drill & poprivet the unwilling broken parts  ..

(http://lh6.ggpht.com/_p7bewmqq6YI/SsJJ-zR4EQI/AAAAAAAAFYw/V5o7x7JB2QM/s800/DSC_0010_599.JPG)


New foam

(http://lh6.ggpht.com/_p7bewmqq6YI/SsJKQ3PUc9I/AAAAAAAAFY0/2_XF2qmlivc/s800/DSC_0004_593.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SsJKyRDIK7I/AAAAAAAAFZU/A7CzpW4nrYY/s800/DSC_0018_607.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SsJLbNWZ1qI/AAAAAAAAFZY/Ovv7oOnf7Gk/s800/DSC_0021_610.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SsJLtujeuJI/AAAAAAAAFZc/h2PN3a9BbkQ/s800/DSC_0028_617.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SsJL6DxAvLI/AAAAAAAAFZk/QOhkGVyvWy0/s800/DSC_0029_618.JPG)

Then the other bits ...


(http://lh4.ggpht.com/_p7bewmqq6YI/SsJMOO6ZRWI/AAAAAAAAFaA/zyUK52R-jYY/s800/DSC_0035_624.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SsJMdHjzgQI/AAAAAAAAFaE/k7pEx-u5UC4/s800/DSC_0047_636.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SsJMy9Sr0oI/AAAAAAAAFaI/cbM9r2VLSK8/s800/DSC_0054_643.JPG)


Cab light door activators from a box shape Hilux- a perfect match  :wink:

(http://lh4.ggpht.com/_p7bewmqq6YI/SsJNW_6qc_I/AAAAAAAAFak/VprU2meBl0c/s800/DSC_0061_650.JPG)


Yug, who wants old flaky and dirty knobs.

(http://lh6.ggpht.com/_p7bewmqq6YI/Sr0ZszeFqqI/AAAAAAAAFQU/WteptZYgQtw/s800/DSC_0162_445.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/Sr0csuJzxGI/AAAAAAAAFR0/tsQgHtgnGHI/s800/DSC_0171_452.JPG)


all done and ready for install ...


(http://lh5.ggpht.com/_p7bewmqq6YI/Sr0bbjxt9OI/AAAAAAAAFRQ/rcUgFTCtMC0/s800/DSC_0177_458.JPG)

To go with the other freshly painted & rebuilt bits

(http://lh6.ggpht.com/_p7bewmqq6YI/Sr0b0bHnB0I/AAAAAAAAFRU/zmgX-7kpkNc/s800/DSC_0185_466.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/Sr0cCo5nuQI/AAAAAAAAFRY/p10SrcOCKJ8/s800/DSC_0191_472.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SsJNrdU6d2I/AAAAAAAAFao/dahzN2lpn-I/s800/DSC_0068_657.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SsJN8rAq92I/AAAAAAAAFas/MI2hbifK5mQ/s800/DSC_0069_658.JPG)


Now it is back to the engine side of things   :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 30, 2009, 07:30:50 AM
:drinks: well done
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on September 30, 2009, 02:01:08 PM
Theo

BTW - you are supposed to fit the Low range and gear lever boots AFTER you have fitted the carpets

Nice Work ! ! ! !
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on October 01, 2009, 08:37:46 AM
Thanks Keith, allways value your input . :jt:

Maybe my carpets were different but the carpet just slides in underneath the gearlever boot and was not bolted down, as such  ???
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on October 02, 2009, 09:04:09 AM
Looking stunning Theo.. btw.. the remaining two (switch) holes in the cantre dash.. what goes into these two?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on October 02, 2009, 11:10:35 AM
OEM the one on the RHS is for the choke in the petrol models and thus blank in the diesels. The LHS one used to have my A/C switch but IIRC it is also supposed to be blank. I will plug both with grommets   :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 03, 2009, 09:58:18 PM
With my Fuel Control Relay woes threatening to halt my project for 2.5 months, it got some other positive injection today ..


(http://lh6.ggpht.com/_p7bewmqq6YI/SvBYBGYxpmI/AAAAAAAAFq0/JAQmH5o-CIo/s720/DSC_0361_950.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SvBYgnIVTRI/AAAAAAAAFrQ/ecIUvamST4M/s720/DSC_0365_954.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SvBZX4r405I/AAAAAAAAFrc/oikUiCOZYDw/s720/DSC_0371_960.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SvBY6xxxIWI/AAAAAAAAFrU/aS7uxKKWlL0/s720/DSC_0370_959.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SvBZ1E8wedI/AAAAAAAAFrg/g_JWoW8JqIc/s720/DSC_0369_958.JPG)


Man I love that tall and skinny look  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 04, 2009, 10:35:31 AM
Theo

Dont be so disheartened, you can still continue with the rebuild and assemble everything and sort ou the FCR once it arrives

You are so close now - get cracking ! ! ! !
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 04, 2009, 05:29:27 PM
looking good thanks for sharing, tell us more about the 'fake' beadlocks
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 05, 2009, 06:14:24 PM
  :theo: I thought you stopped smoking? What is all the sig butts doing under there? :o
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 06, 2009, 07:29:43 AM
 :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 06, 2009, 08:10:40 AM
.. tell us more about the 'fake' beadlocks

They are fully functional and custom made by some local experts  ;)


  :theo: I thought you stopped smoking? What is all the sig butts doing under there? :o

Old ones - I only tidy up when  :theo: complains too much or if I get pesky curious visitors  :jt:

Spose I better watch what pics I post from now on ...   :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 06, 2009, 08:23:54 AM
I thought you already were :jt:

Thanks for the beadlock info, good news indeed
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 19, 2009, 10:43:13 PM
With the Fuel Control Relay woes over I could move forward again ...

(http://lh6.ggpht.com/_p7bewmqq6YI/SwWfWV0vwII/AAAAAAAAFvg/dl6iIzmXsu8/s720/DSC_0010_1100.JPG)


(http://lh3.ggpht.com/_p7bewmqq6YI/SwWfuTGE_FI/AAAAAAAAFvk/1JDG7KJSUcc/s720/DSC_0018_1108.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SwWgC-et74I/AAAAAAAAFvo/NqNUH2JlPCk/s720/DSC_0020_1110.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SwWgZFA67zI/AAAAAAAAFvs/dmiwGa6RaNI/s720/DSC_0022_1112.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SwWg0MMH9EI/AAAAAAAAFv0/HbALn_-XyWw/s720/DSC_0023_1113.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/SwWjuipUqoI/AAAAAAAAFwU/sCGnjJIjCYk/s720/DSC_0058_1148.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/SwWj8kgpzaI/AAAAAAAAFwY/ld9fgfORPs0/s720/DSC_0075_1165.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SwWlLQJdVBI/AAAAAAAAFxA/3LpAKbkVA6Q/s720/DSC_0062_1152.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SwWnqYnLfiI/AAAAAAAAFxk/lbaIlD00JHg/s720/DSC_0094_1184.JPG)



Tonight I started alignment of the panels which is proving to be difficult if attempted without help !   :-X


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Dan Slaven on November 19, 2009, 11:00:33 PM
Cruiser porn, Theo!  ;D :o 8)

Super work!

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 19, 2009, 11:06:50 PM
Thanks Dan !  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Trevor Roux on November 20, 2009, 06:31:23 AM
This KK looks stunnnninnng!! :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 20, 2009, 06:52:23 AM
Looking great  :theo: and damn that camera makes nice pictures ;)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 20, 2009, 10:30:06 AM
Eish, so nice. 8) Are these pics also from MUD?

 At least the sig butts have been removed ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 20, 2009, 12:16:08 PM
Only problem with that camera is the white balance - because it makes the green look destinctly k@ki
Doesnt even look like the green.
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on November 20, 2009, 02:17:19 PM
Nice going there Feo!  8)  Did you already install Turbo ??
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 20, 2009, 02:54:28 PM
Thanks guys  :-*

. Did you already install Turbo ??

Not yet Adolf. It requires some major exhaust work from Roddy so I need to get her mobile asap ! But I am working on a plan ...  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 23, 2009, 09:50:18 PM
Getting those panels to line-up everywhere can be a real PITA !


(http://lh5.ggpht.com/_p7bewmqq6YI/SwrV9eENwSI/AAAAAAAAFy0/yMPzenbX1rg/s720/DSC_0115_1205.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SwrWTGkaCbI/AAAAAAAAFy4/7ylpTYu97NU/s720/DSC_0117_1207.JPG)



(http://lh6.ggpht.com/_p7bewmqq6YI/SwWhFrQmioI/AAAAAAAAFwQ/XENcYcbWfew/s720/DSC_0030_1120.JPG)




But eventually it looks better ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SwrWuoP_yyI/AAAAAAAAFzA/iIzqoHsEcN0/s720/DSC_0118_1208.JPG)




Also got my seats back from the upholsteror. What a feeling to be sitting in my own truck for the 1st time in 19 months !


(http://lh5.ggpht.com/_p7bewmqq6YI/SwrX_dRpWcI/AAAAAAAAF0A/0g9kK68KhHw/s720/DSC_0134_1224.JPG)



And as allways, prep & paint continues ....



(http://lh3.ggpht.com/_p7bewmqq6YI/SwrXgLikKkI/AAAAAAAAFzk/aHva3pTBe1s/s720/DSC_0127_1217.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SwrZ8bPYrhI/AAAAAAAAF1g/kvgE6TgyDF0/s720/DSC_0143_1233.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SwraV1Evg7I/AAAAAAAAF1k/Nzok1UQFwqU/s720/DSC_0148_1238.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/Swraw3grf_I/AAAAAAAAF1o/1rWlvvv5OJA/s720/DSC_0149_1239.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SwrbLXzwnSI/AAAAAAAAF1s/-2nhnK2mnq4/s800/DSC_0152_1242.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SwrbbfZy8KI/AAAAAAAAF10/QXLD3UOFNM4/s720/DSC_0154_1244.JPG)


Testing testing ....   ;D



(http://lh5.ggpht.com/_p7bewmqq6YI/SwrcQLWKc5I/AAAAAAAAF2U/MlWc1ecRD9E/s720/DSC_0162_1252.JPG)




And then just as you think you are nearing the end, the next setback & delay comes along ..  ::)



(http://lh6.ggpht.com/_p7bewmqq6YI/SwrcyijJxZI/AAAAAAAAF2w/98KzU9BwXS8/s720/DSC_0172_1262.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SwrdC2O7xnI/AAAAAAAAF20/W_9m7OFLYwE/s720/DSC_0182_1272.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/SwrdV2tib2I/AAAAAAAAF24/Cmc7DlvBVA4/s720/DSC_0176_1266.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SwrdgzLf9LI/AAAAAAAAF3A/xapT2sh5nSU/s720/DSC_0175_1265.JPG)


I am so gatvol of unexpected delays ..  >:(
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 23, 2009, 11:00:15 PM
How do you expect me to go to sleep after this.   8) 8) 8) :theo:

What seats do you have in there?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 23, 2009, 11:07:17 PM
Thanks  ;D



What seats do you have in there?

Those are the old ones that came with the car from Aussie. They were so comfortable that I decided to redo & keep them rather than replacing them with these typical racing type seats  :jt:

IIRC they came out of a "chev" Commodore or something like that  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Salo de Swardt on November 24, 2009, 06:13:55 AM
Theo, really looking good - I have the exact same seats in the Fordty - They just dont look that  8)
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 24, 2009, 12:01:02 PM
Theo

What seats are those (out of which car)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 24, 2009, 12:40:59 PM
Thanks  ;D

Those are the old ones that came with the car from Aussie. They were so comfortable that I decided to redo & keep them rather than replacing them with these typical racing type seats  :jt:

IIRC they came out of a "chev" Commodore or something like that  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 24, 2009, 01:03:01 PM
Keith, Daniel said they are out of a Commadore something like that. Apparently very popular inAussie as replacement seats and I have to say that I understand why. Have you forgotten that you have seen and felt them before ?  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 25, 2009, 11:37:03 AM
They didnt look like that when I saw them last

I was thinking about getting a set of COBRA bucket seats and having them upholstered in Black alcantarra leather with silver piping
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 25, 2009, 03:35:19 PM
I considered a few colours but eventually settled for the pewter with light stitching as opposed to piping  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 25, 2009, 06:50:07 PM
Theo, where are the bottle repair pics? ::)
Title: Re: Our BJ42 LX rebuild
Post by: Trevor Roux on November 26, 2009, 07:30:14 AM
Theo i might just have a spare bottle for you,give me 2 days to search for it :o i hope i can find it ::)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 26, 2009, 10:26:51 PM
Against all expectations I managed to find 3 new OEM radiator overflow bottles, unfortunately only Ex Japan which translates to about 8 weeks waiting. Keith also managed to find me the same but went one better by also finding a washer bottle ex Aussie - thanks Keith!. Untill those arrive my patchwork will have to do...
 
I found a product by Fibretech that moulds into an almost plastic-like substance and when dry , even looks like old plastic!   :o  Apparently it can be machined but I am not concerned about the looks , this time !



(http://lh6.ggpht.com/_p7bewmqq6YI/SwxB5IJZGgI/AAAAAAAAF38/KrhAgbiXmx0/s720/DSC_0184_1274.JPG)



With those done I could move onto the airfilter housing etc ...




(http://lh5.ggpht.com/_p7bewmqq6YI/SwxEKBVEyFI/AAAAAAAAF5U/8tbiB3L4f3k/s720/DSC_0188_1278.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/SwxCrXUKEmI/AAAAAAAAF4c/fvuQKpeuDsU/s720/DSC_0194_1284.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/Sw7OGmj348I/AAAAAAAAF5w/OXFPt6vhuo0/s720/DSC_0196_1286.JPG)



And then move on to the windscreen ...



(http://lh6.ggpht.com/_p7bewmqq6YI/Sw7PSgel28I/AAAAAAAAF6o/CkRVvoJBPLY/s720/DSC_0206_1296.JPG)



Drenched in new Tectyl ..



(http://lh3.ggpht.com/_p7bewmqq6YI/Sw7PtYhXXFI/AAAAAAAAF6s/gqDbLKvpxTs/s720/DSC_0212_1302.JPG)



The obligatory tapping ...




(http://lh4.ggpht.com/_p7bewmqq6YI/Sw7QDJTZj9I/AAAAAAAAF6w/XhkjtfLrFvo/s720/DSC_0213_1303.JPG)



Ready for install



(http://lh6.ggpht.com/_p7bewmqq6YI/Sw7QbEoPnJI/AAAAAAAAF60/QoPn6qmXXlg/s720/DSC_0216_1306.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/Sw7S6OkJmCI/AAAAAAAAF7s/N8EnMcf4FA4/s720/DSC_0249_1339.JPG)




And then the dreaded bonnet  but first some new goodies ...




(http://lh6.ggpht.com/_p7bewmqq6YI/Sw7RBoZpjHI/AAAAAAAAF7A/H7gOChl3Fik/s720/DSC_0231_1321.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/Sw7VAiZ7NqI/AAAAAAAAF8I/xFIJnqOw96s/s720/DSC_0253_1343.JPG)





(http://lh3.ggpht.com/_p7bewmqq6YI/Sw7RvV_PS5I/AAAAAAAAF7I/_h6VDaNoGsY/s720/DSC_0235_1325.JPG)





(http://lh5.ggpht.com/_p7bewmqq6YI/Sw7TZHsSY8I/AAAAAAAAF70/K_apvgGz2AI/s720/DSC_0242_1332.JPG)





(http://lh5.ggpht.com/_p7bewmqq6YI/Sw7V3qS0wBI/AAAAAAAAF8Q/wqXzk3zW_MM/s720/DSC_0240_1330.JPG)





(http://lh3.ggpht.com/_p7bewmqq6YI/Sw7Vcz7JwtI/AAAAAAAAF8M/Oq_Vkmzr5hg/s720/DSC_0239_1329.JPG)




  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 27, 2009, 07:24:21 AM
Quote
Drenched in new Tectyl ..

What is the purpose of doing this?
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 27, 2009, 07:40:19 AM
prevents corrosion
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 27, 2009, 11:12:18 AM
OK, but if you have a newly painted part, what does it help to spray it over the paint. If the paint comes off the rust will again eat raw metal?? Help me out if I'm missing something here. :-\
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 27, 2009, 12:08:21 PM
Don't spray it on painted parts :jt:

It is usually used in doors and cavities, the reason, it is none hardening and flows into gaps where panels are joined etc when warm, filling and coating the surface preventing contact with air and therefore corrosion.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 27, 2009, 12:19:20 PM
Pierre, when you strip your's you will see where Mr Yoda, in his infinite wisdom, saw it fit to put Tectyl. The W/S surround is not the most waterproof part on the truck and you cannot always get paint into all the little spots.This time I just copied OEM  ;D  
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on November 27, 2009, 01:38:48 PM
I warmed it up a little for you

(http://lh6.ggpht.com/_feFahMMGRDU/Sw-5xvaAvfI/AAAAAAAAAjg/3b2NQgf0dFc/s800/theowarm.jpg)

Before:
(http://lh3.ggpht.com/_p7bewmqq6YI/Sw7Vcz7JwtI/AAAAAAAAF8M/Oq_Vkmzr5hg/s720/DSC_0239_1329.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 27, 2009, 01:41:15 PM
Still looks too much like dune beegie - must be the white balance setting on Fheo's camera
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 27, 2009, 01:41:35 PM
Must be the camera. :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 27, 2009, 01:42:52 PM
Or the flourescant lighting in the garage
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 27, 2009, 01:48:13 PM

Doesnt even look like the green.

6H9 is oficially Olive Grey/ Greyish Olive and not green  :P
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on November 27, 2009, 03:28:55 PM
Looking great Theo, is the pink towel/blanket to match the pink bushes?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 27, 2009, 03:31:33 PM
Julle bleddie ooms is almal fekkin kleurblind!  ;D

Daai is Maroon oom !  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 28, 2009, 05:08:29 PM
 ;D

   16H28    ;D


 :drinks: :drinks:

 :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 29, 2009, 10:02:14 AM
We got some OOT visitors and around the breakfast table it was decided (on my behalf  ::) ), that the 40 needed to run before they returned home. This left me with quite a bit to do .....



(http://lh3.ggpht.com/_p7bewmqq6YI/SxH0Y2wWyVI/AAAAAAAAF9I/bkI_KuWvCDI/s720/DSC_0264_1355.JPG)





(http://lh3.ggpht.com/_p7bewmqq6YI/SxH5tFpluCI/AAAAAAAAF_k/dlIjFUiZYUU/s720/DSC_0266_1357.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SxH0n-lx-8I/AAAAAAAAF9k/M_sUPbV3V00/s720/DSC_0267_1358.JPG)



Appart from bleeding the brakes, fuel, clutch and power steering, I also had to fit a few bits ....




(http://lh5.ggpht.com/_p7bewmqq6YI/SxH1H8yACOI/AAAAAAAAF9o/o-DapBBaQlo/s720/DSC_0274_1365.JPG)




And suddenly it was time ! She was too high for the garage door, even after dropping tyres to 0,8 bar so .....




 (http://lh3.ggpht.com/_p7bewmqq6YI/SxH1iimb9fI/AAAAAAAAF-E/sFi71LFyXG8/s720/DSC_0277_1368.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/SxH18l17ujI/AAAAAAAAF-M/rX2hGKWzjeM/s720/DSC_0278_1369.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SxIhMM4LitI/AAAAAAAAGAg/1ESMl9ND2MM/s720/DSC03202.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SxH2VUPetFI/AAAAAAAAF-o/EEKEhLRHGyA/s720/DSC_0281_1372.JPG)




And it did call for the shampers 




(http://lh5.ggpht.com/_p7bewmqq6YI/SxH3OQtWSPI/AAAAAAAAF-w/bmEFt1Tvp0s/s720/DSC_0284_1375.JPG)





(http://lh5.ggpht.com/_p7bewmqq6YI/SxH4ujbFA0I/AAAAAAAAF_c/LsynH9MavNw/s720/DSC_0285_1376.JPG)




And then it was time for that first run ....




(http://lh5.ggpht.com/_p7bewmqq6YI/SxIhaFka18I/AAAAAAAAGA8/a_aDnZ9l5no/s720/DSC03223.JPG)





(http://lh6.ggpht.com/_p7bewmqq6YI/SxH23bYTLgI/AAAAAAAAF-s/pjs4wyXoHs0/s720/DSC_0291_1382.JPG)




And the passengers just kept coming ...


(http://lh5.ggpht.com/_p7bewmqq6YI/SxIipSlNazI/AAAAAAAAGBg/roUW6KrJ4Og/s720/DSC03236.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/SxH3azGJuyI/AAAAAAAAF-4/7yskYBsOzLg/s720/DSC_0297_1388.JPG)





(http://lh5.ggpht.com/_p7bewmqq6YI/SxImuK6mvkI/AAAAAAAAGC0/IkKumOjUUg4/s720/DSC_0301_1392.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SxH3prG42YI/AAAAAAAAF-8/K5P61W1cuKs/s720/DSC_0303_1394.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SxH378T9bYI/AAAAAAAAF_A/7Ken2azH1V8/s720/DSC_0305_1396.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/SxIiJDb7IcI/AAAAAAAAGBA/1ocGYnRlr58/s720/DSC03253.JPG)




 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Johann Meyer on November 29, 2009, 01:40:28 PM
Congrats Theo :drinks:, where were me  :'(
And whats that sigarette but doing in front of the wheel.  :jt:
See its heavy o fuel, tank empty already  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 29, 2009, 05:35:19 PM
Well Done Theo  :drinks:

But - you must chuck those fugly yellow  peices of crap under the truck  :jt:

Also - Is that hole in the back panel for the LRT - did yours have a LRT - just a question, cos its going to be really really difficult to fit the LRT with the tub on.  :o   :o
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on November 29, 2009, 06:38:59 PM
 :drinks: :drinks: :drinks:
lekker man!!! and so, how did it feel??  ;D

as for those yellow things..  8)  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 29, 2009, 06:50:16 PM
Mark

FOFF
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on November 29, 2009, 06:56:54 PM
 :o
Theo.. dont listen to Oom Ginny!!  :-X 

Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on November 29, 2009, 07:08:51 PM
Theo

Another word of advice - coat the inner side of your wheel arches (wheel wells) with stone chip or else all that nice paint will chip off and then it'll rust

Or

Did you coat it before you painted it.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 29, 2009, 08:45:53 PM
Thanks guys !


Also - Is that hole in the back panel for the LRT - did yours have a LRT - just a question, cos its going to be really really difficult to fit the LRT with the tub on.  :o   :o

Yep it is, mine came with an Aussie longranger already fitted. Oh well if it proves to be difficult I will just rely on the combined knowledge of this club- like usual  :drinks:

:drinks: :drinks: :drinks:
lekker man!!! and so, how did it feel??  ;D

as for those yellow things..  8)  :jt:


It felt great bar those shocks. They are 79 ser and even though I cut my 4x4 teeth on a SFA Hilux, these things are tooo short and bumpy. Remember they were just there as a temporary measure as they looked much better in the pics than the old frot aussie shocks  

..
Did you coat it before you painted it.

Yep already stone chipped before paint and on the fenders and a few other places the SC was applied with a conventional gun for a smooth finish  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on November 30, 2009, 07:30:37 AM
Nou Ja! I have nothing to say. >:(  :drinks: :theo: 8)
Title: Re: Our BJ42 LX rebuild
Post by: Trevor Roux on November 30, 2009, 09:07:35 AM
Nee wat Theo just ABSOLUTELY AMAZING,and enjoy every moment of it :drinks: :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on November 30, 2009, 10:12:46 AM
Stunning! Congrats Theo and Coleen!  :drinks:

I am sure you both waited in great anticipation for that moment!  8)
Title: Re: Our BJ42 LX rebuild
Post by: Gerhard Bolt on December 01, 2009, 08:10:20 AM
Baie geluk  8) Daai 42 gaan die koppe laat draai!!! Gaan jy 'n nuwe garage bou  ???
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 01, 2009, 09:05:00 AM
Gaan jy 'n nuwe garage bou  ???

Nope, will rather sell the house  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 07, 2009, 08:31:55 PM
For JT and TIA !   :-*

(http://lh3.ggpht.com/_p7bewmqq6YI/Sx1CzV6w1UI/AAAAAAAAGGw/k_7PEFPArNQ/s720/DSC_0100_1498.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/Sx1DINfg_3I/AAAAAAAAGG0/FM0lgQNXzV8/s720/DSC_0103_1501.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on December 08, 2009, 07:24:00 AM
for Theo  :-*

(http://www.landcruiserclub.co.za/images/jtpics/theo3.jpg)

(http://www.landcruiserclub.co.za/images/jtpics/theo4.jpg)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on December 08, 2009, 07:27:23 AM
(http://www.landcruiserclub.co.za/images/jtpics/theo5.jpg)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on December 08, 2009, 07:49:24 AM
(http://www.landcruiserclub.co.za/images/jtpics/theo6.jpg)

(http://www.landcruiserclub.co.za/images/jtpics/theo7.jpg)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 08, 2009, 08:19:33 AM
Thank you very much JT  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on December 08, 2009, 09:55:37 AM
And the proud father!  8)

(http://lh3.ggpht.com/_Ji_2YKqEvNA/Sx4F1R2bcjI/AAAAAAAAD68/ZdeaAR3uvYo/IMG_1465.jpg)

Tell us more about that winch cable!?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on December 08, 2009, 02:10:57 PM
Theo - your tie doesnt match the colour of the truck  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on December 08, 2009, 04:45:03 PM
will need to repaint the truck   :jt:

Theo.. looking stunning boet..  :-*
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 13, 2009, 12:27:55 PM
And the work continues ...  :-X



In order to fit the new wipers I needed to source universal clips to marry the old with the current  ...




(http://lh5.ggpht.com/_p7bewmqq6YI/Sx_5dJkh4-I/AAAAAAAAGRk/gLx-fCrBLHM/s720/DSC_0027_1426.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_5vIiPOnI/AAAAAAAAGSc/OAU-4qUj02M/s720/DSC_0031_1430.JPG)




I sourced a new rearview mirror from Aussie which was a mistake ...



(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_6mQsiDDI/AAAAAAAAGTM/BsAvZXmxcpo/s720/DSC_0036_1435.JPG)



as it missed all the bits and pieces required to fit. I ended up refitted the old OEM one ....




(http://lh4.ggpht.com/_p7bewmqq6YI/Sx_6-pPmYII/AAAAAAAAGTY/ElRT3U9R6ME/s720/DSC_0040_1439.JPG)




I was not convinced about the 2" over stock lenth Haystee shackles and as a test refitted the OEM shackles.





(http://lh3.ggpht.com/_p7bewmqq6YI/SxVOf0v-65I/AAAAAAAAGEA/UoQRx4wQPSI/s720/DSC_0021_1420.JPG)



 I liked it so much that we shortened the Haystee shackles to stock lenth





(http://lh3.ggpht.com/_p7bewmqq6YI/SxgikBqyxPI/AAAAAAAAGF4/HBa-2ktbHk0/s720/DSC_0057_1455.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/Sx_7cjXr6iI/AAAAAAAAGTg/r-GCkl8DEHM/s720/DSC_0062_1460.JPG)




Then came the new shocks which made the single biggest improvement ...


For the front


(http://lh4.ggpht.com/_p7bewmqq6YI/Sx_4G1p5LCI/AAAAAAAAGQ4/G4GHMZ0tSKY/s720/DSC_0070_1468.JPG)



And OME N75F in the rear   ;)


The ARB "maskbar" was just too big for my liking ....


(http://lh6.ggpht.com/_p7bewmqq6YI/Sx1DINfg_3I/AAAAAAAAGG0/FM0lgQNXzV8/s720/DSC_0103_1501.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/Sx_mpjQut8I/AAAAAAAAGIk/bVarPmWbCMA/s720/DSC_0109_1507.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_m7oItteI/AAAAAAAAGJI/Z7yqRzN21Wc/s720/DSC_0114_1512.JPG)




A temp fix to keep the rust away while I figure out what I want ontop ..


(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_noC_PuBI/AAAAAAAAGJ0/q5gAqq-tkAk/s720/DSC_0116_1514.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_of9igKoI/AAAAAAAAGLE/FjB0uOtwOq4/s720/DSC_0121_1519.JPG)




Not bad for now ..


(http://lh3.ggpht.com/_p7bewmqq6YI/Sx_pBNJDdwI/AAAAAAAAGL0/itB5mIRSQ10/s720/DSC_0126_1524.JPG)



I have started with some crude ideas .....


(http://lh4.ggpht.com/_p7bewmqq6YI/SyKd6fvseMI/AAAAAAAAGaQ/MubHc_zUUT4/s720/DSC_0146_1544.JPG)



While the  :hillbilly:  juices were strong I made some plans to improve the fitment of the new rear reflectors ...



(http://lh4.ggpht.com/_p7bewmqq6YI/Sx_mDPm0dNI/AAAAAAAAGH0/t5DX28Yr1yQ/s720/DSC_0107_1505.JPG)



Then it was time for the old snorkle which had been galvanized with the chassis and other bits ...



(http://lh4.ggpht.com/_p7bewmqq6YI/SyKckQX4t3I/AAAAAAAAGZo/nkusSXXYI5U/s720/DSC_0130_1528.JPG)




The galv ruined any realistic chance of a good finish so I decided to go for a hamered finish paint ...


 (http://lh6.ggpht.com/_p7bewmqq6YI/SyKc3_7MBAI/AAAAAAAAGZs/WoLdo7j3GrE/s720/DSC_0132_1530.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/SyKdR9TC5gI/AAAAAAAAGZw/3S_YKBX3WIM/s720/DSC_0134_1532.JPG)




Some better rubber to replace the old stuff ..


(http://lh3.ggpht.com/_p7bewmqq6YI/SyKdhyBhA7I/AAAAAAAAGZ0/oi7_0s39Yvw/s720/DSC_0136_1534.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/SyKfQ2b-mRI/AAAAAAAAGa8/3NsBE5M4guk/s720/DSC_0161_1559.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SyKe9O7uOsI/AAAAAAAAGa4/vwJo-vqlW0A/s720/DSC_0157_1555.JPG)



I also got some decent SABS approved lap belts ....


(http://lh6.ggpht.com/_p7bewmqq6YI/Sx_wB143n7I/AAAAAAAAGNE/cFfk8I3rtlw/s720/DSC_0117_1515.JPG)





(http://lh5.ggpht.com/_p7bewmqq6YI/Sx_peHiNm5I/AAAAAAAAGMc/eNqJ2tSh0o8/s720/DSC_0127_1525.JPG)




Then I got a very early surprise from Mr Yoda in Japan ....



(http://lh4.ggpht.com/_p7bewmqq6YI/SySoixiAZaI/AAAAAAAAGcQ/xJ1QDnvN2ts/s720/DSC_0177_1575.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/SySo2vX-MsI/AAAAAAAAGcU/lZbG5Y6Ttno/s720/DSC_0179_1577.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SySpIqhqmRI/AAAAAAAAGcw/l9exP9LSQeA/s720/DSC_0184_1582.JPG)



Unfortunately Mr Yoda only had 2 left and no caps at all !




(http://lh6.ggpht.com/_p7bewmqq6YI/SySqOVmUBFI/AAAAAAAAGdU/tgfnlDV1V7Y/s720/DSC_0186_1584.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/SySq41w1s4I/AAAAAAAAGdc/pfjMjJAeSjI/s720/DSC_0194_1592.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/SySrWqzBogI/AAAAAAAAGd4/fPFy-pPViQw/s720/DSC_0195_1593.JPG)



 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on December 14, 2009, 07:08:47 AM
Well done Theo, while everyone (or nearly) is away on holiday you have been hard at work. Now it's really coming together  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on December 14, 2009, 07:17:39 AM
Looks grand  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on December 14, 2009, 07:26:09 AM
All the small bits take time but dresses her up nicely. 8).
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 22, 2009, 04:30:33 PM
Thanks guys, much appreciated !

I have been so busy driving her that progress has almost come to a complete halt   ;D


New radiator expansion tank cap ....



(http://lh3.ggpht.com/_p7bewmqq6YI/SzDQzLcqyiI/AAAAAAAAGew/dMP2Dy8oK30/s720/DSC_0005_1756.JPG)




Rounds it off much better than before ?




(http://lh6.ggpht.com/_p7bewmqq6YI/SzDQ_G2RvhI/AAAAAAAAGe0/fhR7s4gH48A/s720/DSC_0006_1757.JPG)



That rattling OEM sparewheel carrier used to drive me nuts ...    ;)




(http://lh6.ggpht.com/_p7bewmqq6YI/SzDSq0NyH5I/AAAAAAAAGfY/DQEcBrNaZK8/s720/DSC_0198_1596.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/SzDTBvUQt_I/AAAAAAAAGf0/tkg3g7yol-A/s720/DSC_0203_1601.JPG)

 :drinks:


Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 08, 2010, 09:45:15 AM
A buddy gave me a set of full doors a while back. They were badly rusted and warped but I decided (against all advice) to use them to make some half doors. They got almost the same treatment as all the other panels ...

(http://lh3.ggpht.com/_p7bewmqq6YI/SjZ1UJ0MAoI/AAAAAAAAEFU/ZtIE9dwgepE/s720/14062009%28001%29.jpg)


 ..and came out looking ok, BUT because I had to cut them without being able to measure the height for the latches, I had to modify the latches quite a bit in order to get them working. The latches also influenced the alignment adversely and so the general fitment is very poor and I will try to find another set of donor doors. Once I realised that the doors would not look good , no matter what I did , I decided to rather concentrate on making them rattle-free by using some serious rubber. However the doors definately made the vehicle feel safer and Swambo is much happier ..

  (http://lh6.ggpht.com/_p7bewmqq6YI/S0bXox38NhI/AAAAAAAAGhI/rZRL-EJWnFw/s720/DSC_0005_2006.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S0bYKkWrbNI/AAAAAAAAGhM/jXvPsttdVLw/s720/DSC_0008_2009.JPG)


Now to make a plan about that open rear section ...


(http://lh5.ggpht.com/_p7bewmqq6YI/S0bYt85_l-I/AAAAAAAAGhQ/XD2wisrUyNU/s720/DSC_0010_2011.JPG)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on January 08, 2010, 04:07:57 PM
For Theo. Easy to make yourself!

(http://www.classiccruisers.com/media/panel.jpg)

Quote
We make this panel to be used when you remove your top to run a soft top or run with no top. It bolts in where the lower rear door hinges bolt and has holes for your license assembly.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 08, 2010, 06:56:14 PM
For Theo. Easy to make yourself!

(http://www.classiccruisers.com/media/panel.jpg)



Thanks Adolf, will look into it  :-*
Title: Re: Our BJ42 LX rebuild
Post by: Trevor Roux on January 11, 2010, 10:51:39 AM
It looks GREAT Theo,makes me wonder :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 18, 2010, 07:04:29 PM
The half-doors needed them side mirrors ...


(http://lh5.ggpht.com/_p7bewmqq6YI/S1SBc0FNapI/AAAAAAAAGjk/s9s9liuFoD4/s720/DSC_0028_2029.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S1SBu5X8OTI/AAAAAAAAGjo/w_KxeTBcz_Y/s720/DSC_0040_2041.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S1SB718kVWI/AAAAAAAAGjs/GKd4aLjQLlo/s720/DSC_0045_2046.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S1SCowuweEI/AAAAAAAAGkQ/H5O1K8W1S0o/s720/DSC_0054_2055.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S1SCPgYZcYI/AAAAAAAAGjw/EUrDNhMiJxg/s720/DSC_0052_2053.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/S1SFTJiUgpI/AAAAAAAAGkw/-mC7vEpILe8/s720/DSC_0058_2059.JPG)



We also discovered a nice "play-pit" very close to our home where my son can practice his driving skills ...


(http://lh5.ggpht.com/_p7bewmqq6YI/S1SGdZiv0OI/AAAAAAAAGlo/p4_IShyydVw/s720/DSC_0062_2063.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/S1SF6hl1XqI/AAAAAAAAGlM/rtQ6dzRrAfM/s720/DSC_0060_2061.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on January 19, 2010, 08:49:02 AM
Theo, I dont know what it is but the rear of your 40 looks like its sagging. My Smurf is level, looks the same height at the rear as yours. My front is much lower though.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 19, 2010, 10:34:02 AM
LOL , you almost sound like someone else again Pappy  :jt:

On a serious note, it must be just the angle of the pics. The rear is in fact a quite a bit higher than the front and IIRC, I am around 35 -45 mm higher than Pierre's BJ which is on the exact same tyres as mine and on the same 2.5" HC prongs as you.
 ;)


Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on January 19, 2010, 11:52:31 AM
Theo

Is it my imagination or is your 40 also draggin its arse :jt: :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on January 19, 2010, 12:05:52 PM
Picture angle corrected, arse sagging...
(http://lh5.ggpht.com/_feFahMMGRDU/S1WD0yT0L-I/AAAAAAAAArk/9-rqrwMRttc/s800/theosag.jpg)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 19, 2010, 12:20:31 PM
Theo

Is it my imagination ..

Yep it is. Next time you are in CT, you can have a look in person  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on January 19, 2010, 03:54:55 PM
Theo

What did you tap in to for the mirrors??
Did you use the old rivnuts or did you put new rivnuts on
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 19, 2010, 07:44:20 PM
Used the old ones Keith. Just had to drill out the filler and paint first. Fortunately it was only the LHS and I could still drill  pilot holes from the inside  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on January 19, 2010, 08:32:01 PM
Phew - that was a close call  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 21, 2010, 07:58:31 PM
You bet it was Keith  :D



Just some lame posing shots from yesterday ...




(http://lh5.ggpht.com/_p7bewmqq6YI/S1c9mAsFBUI/AAAAAAAAGmo/h-iF0p1Zg5c/s720/DSC_0064_2065.JPG)






(http://lh6.ggpht.com/_p7bewmqq6YI/S1c-FTwNMEI/AAAAAAAAGnE/3CXyKafFic0/s720/DSC_0066_2067.JPG)







(http://lh4.ggpht.com/_p7bewmqq6YI/S1c-gcevaKI/AAAAAAAAGnI/7eGKaTqk7BU/s720/DSC_0078_2079.JPG)







(http://lh3.ggpht.com/_p7bewmqq6YI/S1c-5t29W2I/AAAAAAAAGnk/jxQ4x3Jahh4/s720/DSC_0080_2081.JPG)







(http://lh4.ggpht.com/_p7bewmqq6YI/S1c_o-2pw1I/AAAAAAAAGoA/3d6jQjqLhE8/s720/DSC_0086_2087.JPG)







(http://lh6.ggpht.com/_p7bewmqq6YI/S1dAEl14ZYI/AAAAAAAAGoI/XmRM_nL6S4s/s720/DSC_0087_2088.JPG)







(http://lh3.ggpht.com/_p7bewmqq6YI/S1dAji9Vb2I/AAAAAAAAGoQ/limEQozT6ig/s720/DSC_0089_2090.JPG)






The new Hell Creek springs are still a bit stiff but they are getting better with each flexing session. The shackle angles are also much better. I think it is time to extend the OEM bumpstops and to then take her out for some more serious stuff ?

  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on January 22, 2010, 07:46:58 PM
Very nice Theo... ;D
Now you need to do the hard top??  :jt:
 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on January 25, 2010, 10:10:24 AM
Yes, need somewhere to mount the speakers. :) :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 25, 2010, 02:44:59 PM
Thanks Mark !

But I need a place for speakers even when she is topless  ???
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on January 25, 2010, 04:18:36 PM
In the door panels   :jt:    :jt:     :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Trevor Roux on January 29, 2010, 09:01:40 AM
Hy lyk hamma lekka 8) 8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 15, 2010, 05:08:13 PM
 :o  Sorry for the late update.



Building a 40 is one thing but getting her ready for a serious 14 day overlanding trip is proving to be something else, especially when you realise that the roof will not be ready in time. With our inaugural J4 "Legends Trip" just 3 weeks away, at least some of us have our priorities straight ....


(http://lh6.ggpht.com/_p7bewmqq6YI/S74J50Ow6-I/AAAAAAAAGs8/zqiRCbov3Kk/s720/DSC_0326_2299.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/S74L1j5bWAI/AAAAAAAAGtg/uZRUTiX7Kxk/s720/DSC_0329_2302.JPG)


I also needed some kind of packing system. The fridge was sorted with a African Outback slide that I mounted on a piece of plywood that was bolted to the tub using the multitude of OEM captive nuts intended for the rear seats of the LX model. That left me with quite a bit of space on the pax side. With the trip being 17 days away now , there is not enough time to build a drawer system and to be honest I need some more time to decide how I want my eventual drawers to be- no need to rush into something now. I decided to go with a simple solution for 4 ammo boxes ,largely because I happened to have some old angle-iron lying around ...


(http://lh4.ggpht.com/_p7bewmqq6YI/S8TUlq8t29I/AAAAAAAAG9I/MEfMPiLSWCo/s720/DSC_0436_2409.JPG)


(http://lh6.ggpht.com/_p7bewmqq6YI/S8TVSUlQnFI/AAAAAAAAG9I/dxj7EhZjhBU/s800/DSC_0442_2415.JPG)


I had to switch the removable cross brace around in order to fit the stacked ammo boxes ..



(http://lh5.ggpht.com/_p7bewmqq6YI/S8TVAJl0TFI/AAAAAAAAG9I/DwdOt3st7NI/s800/DSC_0438_2411.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S8TVoJ770KI/AAAAAAAAG9I/Z8MQPMk69QE/s800/DSC_0445_2418.JPG)



(http://lh3.ggpht.com/_p7bewmqq6YI/S8TWTZm5iRI/AAAAAAAAG9I/3w3xPO7jGCQ/s800/DSC_0450_2423.JPG)


(http://lh4.ggpht.com/_p7bewmqq6YI/S8TWuK6_lrI/AAAAAAAAG9I/KtjRHXlOPnU/s720/DSC_0453_2426.JPG)


A bit  :D  it may be but it will work fine while I figure out exactly what I want   ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 15, 2010, 05:11:25 PM
Going to a very wet Kalahari and back in less than 34 hrs was tough and demanding ...

(http://lh4.ggpht.com/_p7bewmqq6YI/S8tMO3FB1BI/AAAAAAAAG9k/5yTgLSlOXD8/s720/DSC_0486_2459.JPG)


.. but very much enjoyable and definately worth it ...


his dad

(http://lh6.ggpht.com/_p7bewmqq6YI/S8tMqRo1OvI/AAAAAAAAG9o/DijWAUmjXg0/s720/DSC_0459_2432.JPG)


 and now please say hello to Boris


(http://lh3.ggpht.com/_p7bewmqq6YI/S8tM6EDbRAI/AAAAAAAAG9s/LghkUwTodbg/s720/DSC_0483_2456.JPG)


I am sure that our beloved Max would have approved, as Boris was already helping out in the garage today and thus we got  quite a bit done....




Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 15, 2010, 05:12:19 PM
Update pics ...

(http://lh3.ggpht.com/_p7bewmqq6YI/S8yzqrKQpoI/AAAAAAAAHI8/h8gQxT2Ji9g/s720/DSC_0024_2509.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/S84L6GmD6nI/AAAAAAAAHI8/US3inO0DWTY/s720/DSC_0065_2550.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/S83x0Qh6LKI/AAAAAAAAHI8/MPcpyraB6gY/s720/DSC_0066_2551.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/S8y12kNJqRI/AAAAAAAAHI8/1nuywAwqxCA/s720/DSC_0057_2542.JPG)





(http://lh4.ggpht.com/_p7bewmqq6YI/S84IaXO8d5I/AAAAAAAAHI8/N1LeyKTxg3Y/s720/DSC_0064_2549.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/S84LLLnCFMI/AAAAAAAAHI8/mX-smnth5PI/s720/DSC_0063_2548.JPG)




(Note to self: Get some smaller fender washers)  :roll:

(http://lh4.ggpht.com/_p7bewmqq6YI/S83xkmUgGoI/AAAAAAAAHI8/SX1NbzhDrm8/s720/DSC_0067_2552.JPG)




(http://lh4.ggpht.com/_p7bewmqq6YI/S8y0rs6toaI/AAAAAAAAHI8/8TsBSnKW0gQ/s720/DSC_0058_2543.JPG)




(http://lh6.ggpht.com/_p7bewmqq6YI/S84GmwPAuCI/AAAAAAAAHI8/EMq4NaJV7sk/s720/DSC_0075_2560.JPG)



The reason why I went for a dual gate setup  :wink:


(http://lh3.ggpht.com/_p7bewmqq6YI/S84G90P1QNI/AAAAAAAAHI8/i9VE79t-cV4/s720/DSC_0077_2562.JPG)




(http://lh3.ggpht.com/_p7bewmqq6YI/S84HXcATpeI/AAAAAAAAHI8/RFGvTn6C5OA/s720/DSC_0078_2563.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S8y1kWQuyaI/AAAAAAAAHI8/UcqCRbSgYh0/s720/DSC_0060_2545.JPG)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 15, 2010, 05:14:11 PM
When I told some friends that I was planning a Rollbar/cage cum bikini top type setup, I was immediatelly ragged for building an overweight scaffolding piece of junk. Well  most of you have seen the result of the cage and now that I have my G-string top, those  sourcrouts can just  kiss my "parson's nose"  sitting pretty ontop of the predicted scaffolding....  :jt:

(http://lh6.ggpht.com/_p7bewmqq6YI/S9HZZy6BM1I/AAAAAAAAHKo/GR2PVX5nNUM/s720/DSC_0126_2611.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/S9HbRx9Q9GI/AAAAAAAAHLY/0Q_RThS0TNc/s720/DSC_0086_2571.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/S9HZBpXpIbI/AAAAAAAAHKM/6_s1Mq1EmrE/s720/DSC_0125_2610.JPG)



(http://lh4.ggpht.com/_p7bewmqq6YI/S9HbqJTi8zI/AAAAAAAAHLc/jbrlkp6iH9c/s720/DSC_0092_2577.JPG)


I also fitted the "fmpie"


(http://lh4.ggpht.com/_p7bewmqq6YI/S9HZ1wJH_FI/AAAAAAAAHK0/zNJ1g7AVGgQ/s720/DSC_0109_2594.JPG)



(http://lh5.ggpht.com/_p7bewmqq6YI/S9HaMQ2KFsI/AAAAAAAAHLQ/bjOSYE6qvPk/s720/DSC_0097_2582.JPG)




(http://lh5.ggpht.com/_p7bewmqq6YI/S9HYqVHCurI/AAAAAAAAHJw/6k_L8jyXNcg/s720/DSC_0114_2599.JPG)


Almost ready ....   :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 05, 2010, 09:12:44 PM
On our recent Legends trip I realised that I had cut my Haystee shackles to short & to soon- I should have waited longer. With the extra weight and the flexing in the tough conditions, the rear springs started to bang and she was also a little "arse down" for my liking. I had gone from 120mm (centre of pin to  centre of pin) back to the stock lenth of 75mm(cop to cop). With next weekend's trip around the corner it was time to fix it. I put the OEM shackles back on and used the shortened Haystee shackles as samples for the new plates. It was a close call but eventually I went with 110mm in the rear and 95mm in the front.


(http://lh6.ggpht.com/_p7bewmqq6YI/TFrgpzS0YAI/AAAAAAAAHhc/mpQ9LHZexjc/s720/DSC_0075_2897.JPG)


Before
(http://lh5.ggpht.com/_p7bewmqq6YI/TFrhFeipe-I/AAAAAAAAHhg/LGDe_aI7XXE/s720/DSC_0077_2899.JPG)


After
(http://lh6.ggpht.com/_p7bewmqq6YI/TFrh0iK1uCI/AAAAAAAAHho/2W_4uK069Aw/s720/DSC_0079_2901.JPG)

(http://lh5.ggpht.com/_p7bewmqq6YI/TFrhdBzCFuI/AAAAAAAAHhk/d9TzDmQLMZI/s720/DSC_0078_2900.JPG)


(http://lh5.ggpht.com/_p7bewmqq6YI/TFriQwxneMI/AAAAAAAAHhw/iBicXomxSf0/s720/DSC_0080_2902.JPG)

She still drives great and I can still get her in and out of my garage  :D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 06, 2010, 07:15:56 AM
Looks great theo, no more banging for you then  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 06, 2010, 08:08:29 AM
Don't confuse me with my sprongs  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 06, 2010, 11:22:15 AM
 :-X
Looks good Theo..  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 07, 2010, 05:57:32 PM
At Last - well done

BUT ~ will it still fit in the garage with the roof on

BTW - when is the roof going on ???
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 07, 2010, 11:45:30 PM
Hey Oom, net omdat jy ouer as ons is: Watchit Tjomma !! ;D
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 08, 2010, 02:14:02 PM
Summer coming in the Cape.. no rain!!! At least 6 months topless still  :jt:
 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Dane Read on August 12, 2010, 11:07:22 PM
Hi theo

Probably been covered long time ago In earlier posts. But had know idea how to search for it. Was there any particular reason why your exhasust is coming out the side instead of the back? 

We need a complete new exhaust and was think stainless steel. 8) the shorter the cheaper though hence my question.   
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 13, 2010, 08:38:25 AM
Yeah, cos it looks & sounds(even ask a petrolhead like JT) absolutely badass !  ;D

Mine also came like that from Aussie and I could find no reason to change it. In general terms diesel engines don't want/need much back pressure, so the shorter the better. When I turbo her, I will stay with an exhaust that short(with bigger diam) but I will then dump the muffler altogether in order to further reduce EGTs ...  :drinks:

Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 13, 2010, 11:49:27 AM
Dane
If you fit a long range tank you have to reroute the exhaust out of the side as the LRT takes up the space where the rear silencer would normally fit
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 13, 2010, 12:32:57 PM
May have more space in a 44  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on August 24, 2010, 12:21:30 PM
Theo

My half doors are presently being painted.

do your half doors have door handles on the inside, as the normal position for the interior handle gets cut off

If you have interior handles send pics

If not I'll have to make a plan and decide wher to mount the interior door handles
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 24, 2010, 12:36:12 PM
Sorry Keith, no interior handles - the line I chose,cuts them in half and IMHO any line higher than that, looks decidedly crap !  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on October 05, 2010, 11:16:46 AM
Please spare a thought for

(http://lh3.ggpht.com/_pytUuTtTgaE/TJUO7GFZ9cI/AAAAAAAAAG8/Ttp5bUD_d58/s512/DSC_0149_3089.JPG)

He has just gone under the knife to try and correct a wrong diagnosis that was made two months ago   :'(
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 14, 2011, 10:35:47 AM
It has been a long time since I have had some spare time to spend working on Olive. In prepping for the upcoming Turbo conversion I got an EGT guage. The one in my 105 is almost 5 years old so I decided to go with another MGL Avionics unit, for obvious reasons. Due to the fact that space is a premium in the 40 I went with the smaller TC1 unit. The kit included the K-type probe with wire.

(http://lh3.ggpht.com/_pytUuTtTgaE/TS__qu1ZQfI/AAAAAAAAAIQ/mY6sBrRUBF0/s720/DSC_0014.JPG)

In order to obtain accurate before and after figures, I decided to install the guage before even fitting the turbo.

(http://lh4.ggpht.com/_pytUuTtTgaE/TTAAm8Ns5HI/AAAAAAAAAIg/Zpgkp8kIi6A/s720/DSC_0005.JPG)

Having drilled and tapped the stock manifold I routed the probe wire in such a way that I didn't need the extention piece that came in the kit. I also added some extra protection in the form of Plymouth tape etc ...

(http://lh6.ggpht.com/_pytUuTtTgaE/TTAA3NN1s5I/AAAAAAAAAIk/d-GjRtVP-Ko/s720/DSC_0013.JPG)


I made a new bracket for and relocated the VHF mic in order to fit the guage in the most visible& practical location while still being aestetically pleasing ...

(http://lh4.ggpht.com/_pytUuTtTgaE/TTABRD_L0jI/AAAAAAAAAI0/L2sV0-zqJw8/s720/DSC_0028.JPG)


The view from my normal driving position

(http://lh5.ggpht.com/_pytUuTtTgaE/TTABk2MRwlI/AAAAAAAAAJE/NVjh7BQ73B0/s720/DSC_0033.JPG)

I also decided that it was time to fit that EL wire instrument cluster upgrade

(http://lh4.ggpht.com/_pytUuTtTgaE/TTAB8X72bWI/AAAAAAAAAJc/sGybdLz9TYw/s720/DSC_0019.JPG)


(http://lh6.ggpht.com/_pytUuTtTgaE/TTACxDvdrRI/AAAAAAAAAJk/KUarpDsz8Hc/s720/DSC_0027.JPG)

What an awesome improvement indeed !
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on January 14, 2011, 11:13:21 AM
Nice slippers  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 14, 2011, 11:54:40 AM
 :-[
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on January 14, 2011, 06:28:34 PM
Nice slippers  >:D

Indeed.. Stokkies I think they called  :P
Where the before and after pics of EL wire lighting effect?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 15, 2011, 02:27:22 PM
Where the before and after pics of EL wire lighting effect?  :jt:

Here http://www.gotbezel.com/index.php?action=post;quote=2308;topic=143.0;num_replies=31;sesc=f6baf3f97780dbd2c9ce14c3ac8814b4 (http://www.gotbezel.com/index.php?action=post;quote=2308;topic=143.0;num_replies=31;sesc=f6baf3f97780dbd2c9ce14c3ac8814b4)

  :-*
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on January 15, 2011, 07:17:59 PM
LOL  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2011, 05:49:23 PM
Putting a racing sadle on a Jackass ....

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TU64xOFjM8I/AAAAAAAAALQ/e-KilqsydbY/s720/DSC_0036.JPG)


The candy


(https://lh4.googleusercontent.com/_pytUuTtTgaE/TU63Gn8jOrI/AAAAAAAAAKo/ij2Yngz-00Q/s720/DSC_0040.JPG)


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TU632O6TCbI/AAAAAAAAAK4/yH4AZCDJwUM/s720/DSC_0039.JPG)


Taking it slowly but boy it feels good to be working on her  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on February 06, 2011, 06:59:54 PM
For Coleen's Birthday??  ???  Turbo Hairdreyer!  8)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 06, 2011, 07:03:52 PM
You need to still paint the word "TURBO" red, it will make it even faster  :D
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on February 06, 2011, 10:16:15 PM
Man thats looks great, Hi tech engineering at it's best. Where does the oil feed from?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 07, 2011, 08:17:37 AM
Thanks, I think. :jt:

Pappy,  I will feed it from either the low oil pressure cut off or the oil pressure switch via that T piece that you can just about see in the last pic.

JT, do you have some of that red paint ?  :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 27, 2011, 08:50:46 PM
I had limited time lately but I got some stuff done ...  :whew:

I was not happy with the way the original adapter spaced the turbo towards the firewall etc

(https://lh4.googleusercontent.com/_pytUuTtTgaE/TVIRk4fKUsI/AAAAAAAAAMg/A3NEpBjbsDo/s720/DSC_0055.JPG)

I wanted some height but not that much


(https://lh5.googleusercontent.com/_pytUuTtTgaE/TVITQossNgI/AAAAAAAAAMk/vFI3wvVXqq4/s720/DSC_0059.JPG)


(https://lh3.googleusercontent.com/_pytUuTtTgaE/TVIX9L_cgEI/AAAAAAAAANM/umUGM2Z-bwY/s720/DSC_0057.JPG)

So it got trimmed


(https://lh3.googleusercontent.com/_pytUuTtTgaE/TWp6b_yly5I/AAAAAAAAAUA/JCm9nck4hmg/s720/DSC_0090.JPG)

I also did not like the angle of the oil drain. I clocked it towards the rear as the wastegate actuator arm was in the way but the angle was still wrong. Eventually the only solution was to drill and tap the actuator housing and to relocate it. This freed some space but I am not entirely sure that it is perfect yet ...


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp78pjFNwI/AAAAAAAAAUo/01m9Ez1ub_E/s720/DSC_0103.JPG)

At least the oil pan was still good ...


(https://lh4.googleusercontent.com/_pytUuTtTgaE/TWqBUzROzrI/AAAAAAAAAW8/4Spgkb-k4vM/s720/DSC_0062.JPG)

Fortunately I had a new OEM gasket ...


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp3qORPk8I/AAAAAAAAATE/ZLgtsCp7s2g/s720/DSC_0065.JPG)

I used a T on the Low pressure switch for the feed. The size was very clo0se but I had to put a die to it in order to get it into the block. Size is 1/8 BSP 28.

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp4IWdySMI/AAAAAAAAATI/qMjgsyEht2M/s720/DSC_0070.JPG)

The OEM PS hose was in the way and definately too close to the 13BT manifold for my liking so I had a longer one made up while using the OEM ends.


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp4sdLyeVI/AAAAAAAAATY/o5v4MoTfseo/s720/DSC_0073.JPG)


The new route freed up some more space and I will be able to use the stock airfilter housing


(https://lh3.googleusercontent.com/_pytUuTtTgaE/TWp5OfMrFII/AAAAAAAAATc/uT8denuz8mE/s720/DSC_0074.JPG)

The oil filter & housing scenario I temporarily solved with a shorter filter

(https://lh4.googleusercontent.com/_pytUuTtTgaE/TWp5fId1xSI/AAAAAAAAAT0/HjCprqkUafY/s720/DSC_0082.JPG)


(https://lh4.googleusercontent.com/_pytUuTtTgaE/TWp5x3gqPlI/AAAAAAAAAT4/q8GGOjSdWjQ/s720/DSC_0085.JPG)


My first attempt at gasket making

(https://lh5.googleusercontent.com/_pytUuTtTgaE/TWp6Dv_kpRI/AAAAAAAAAT8/rcwn7OKLEfs/s720/DSC_0089.JPG)


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp6-qMtJSI/AAAAAAAAAUI/lzZVU1ByKjk/s720/DSC_0095.JPG)


At least some parts are still Toyota

(https://lh4.googleusercontent.com/_pytUuTtTgaE/TWp7SsYzV5I/AAAAAAAAAUQ/3PnZNwrmQ7s/s720/DSC_0098.JPG)


(https://lh5.googleusercontent.com/_pytUuTtTgaE/TWp7kQZlkCI/AAAAAAAAAUk/MKWpZndKncs/s720/DSC_0099.JPG)

Relocated the heater pipe bracket to the slightly forward position on the 13BT manifold

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp78pjFNwI/AAAAAAAAAUo/01m9Ez1ub_E/s720/DSC_0103.JPG)


The new angle was much better

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp8T0AMaGI/AAAAAAAAAU4/qp_EoFd76Fo/s720/DSC_0105.JPG)


Still measuring and cutting ....

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp81qDhIxI/AAAAAAAAAVI/2TDUJOuWt_M/s720/DSC_0106.JPG)


From the onset I wanted to use the OEM air filter housing and
I tried selecting the correct silicon hose fittings for the air intake but without the car at hand it was impossible. I therefore decided to use one of those  boyricer type cone filters just to get the car to the exhaust shop and the silicone hose shop.


(https://lh3.googleusercontent.com/_pytUuTtTgaE/TWp9TzudM_I/AAAAAAAAAVU/DMJrw3Cn__o/s720/DSC_0110.JPG)


Andd then it was time to prep and start her. I disconnected the FCM with the arm in the stop position and then swung her for a while to build some pressure(not sure if it worked). I also primed the turbo with some oil using a ....

(https://lh5.googleusercontent.com/_pytUuTtTgaE/TWp9r8fLoDI/AAAAAAAAAVY/xN1e-DZpsN0/s720/DSC_0112.JPG)


And then it was time ....


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TWp-GOWXmuI/AAAAAAAAAVs/ukAktuBethE/s720/DSC_0113.JPG)


(https://lh3.googleusercontent.com/_pytUuTtTgaE/TWp-iBLMz-I/AAAAAAAAAV8/ZVxKexXW2wg/s720/DSC_0114.JPG)


She started first time, doesn't leak at all and makes the most awesome whistling sound. Tomorrow I will take her to the exhaust shop as that short down pipe leaves the engine bay very hot. I have not touched the fueling but sofar she definately pulls stronger ...

  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 27, 2011, 09:02:23 PM
 :o Shweet  :drinks:

BTW thanks for the red paint  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Andre Bosch on February 28, 2011, 02:05:18 PM
baie mooi Theo
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on February 28, 2011, 02:49:12 PM
Theo

Nice work

But that Turbo looks HUGE ! ! is it not too big (too big = too much lag)

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 28, 2011, 03:38:45 PM
Actually it is quite small by normal standards Keith. It is the Mitsu TD04H and was matched to the 3L Hilux Diesel range by Alpine. OEM it comes off of the 2.3L gassers. It seems to spool up right from the bottom as I expected from my research  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on February 28, 2011, 04:26:22 PM
Very nice - well done!
Title: Re: Our BJ42 LX rebuild
Post by: Rob Wright on March 01, 2011, 10:58:11 AM
 Looking Good Theo .
 Might be an idea to Cerramic coat that down pipe ,or wrap with Heat Wrap Cloth ,That Exhaust gets vely Hot ,And maybe make up some heat shields around the Turbo .
 What are you going to set boost pressure to .i think no more than 0,7 bar ,
 Well done on your mod . :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 01, 2011, 02:01:54 PM
Thanks  :drinks:

Wastegate is set at 7.5 Psi. I have a few ideas on some heat shields already but need to finish the other loose ends first. Just got her back from the zaurst shop  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 01, 2011, 02:08:14 PM
Post a video of sound  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on March 01, 2011, 03:21:01 PM
Awesome turbo conversion.  :drinks: Great workmanship.  8)

Title: Re: Our BJ42 LX rebuild
Post by: Philipp Becker on March 01, 2011, 10:38:29 PM
Baie lekker werk, Richter  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 02, 2011, 08:31:22 AM
Thanks guys  :drinks:

Post a video of sound  >:D

She is a tad loud at the moment but I have to finish the airbox and snorkle. Planning a shakedown/evaluation trip next weekend and will thereafter decide whether to fit a silencer box and flexi- knuckle ...  :-\ 

Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 02, 2011, 11:03:23 AM
Where are we going?  :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 02, 2011, 01:01:37 PM
Don't know yet but thinking Cederberg  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 05, 2011, 04:10:02 PM
That short downpipe was noisy but most of all it dumped all the hot air in the engine bay causing. I wanted her to be as freeflow as possible  so we fitted a longer pipe only, that ended just above the chassis ...

(https://lh5.googleusercontent.com/_pytUuTtTgaE/TXI8cvyo8OI/AAAAAAAAAZ4/AUM6-iXE07U/s720/DSC_0123.JPG)


(https://lh4.googleusercontent.com/_pytUuTtTgaE/TXI82GaJQkI/AAAAAAAAAaA/Dh6ZG7Id5HI/s720/DSC_0119.JPG)

This did improve the underbonnet temps but she was louder than before  so ....

(https://lh3.googleusercontent.com/_pytUuTtTgaE/TXI6lGIUANI/AAAAAAAAAZQ/Uky9fxIIsWs/s720/DSC_0152.JPG)


(https://lh5.googleusercontent.com/_pytUuTtTgaE/TXI64xwH7bI/AAAAAAAAAZk/BP2RkcmOCnE/s720/DSC_0153.JPG)

This did away with the tractor noise (unfortunately including also my new favourite whistling sound) but and against conventunal teachings improved performanc ?? The performance increase could however be due to the doing away with that cone filter inside the hot bay ...

I wanted a stockish look but it meant that I had to cut the box. The wastegate actuator also interferred with the one clip ...

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXDfeODph1I/AAAAAAAAAXk/UOhO4QWfcAg/s720/DSC_0129.JPG)


(https://lh5.googleusercontent.com/_pytUuTtTgaE/TXDf0jB21pI/AAAAAAAAAXs/24sOB4tXegE/s720/DSC_0130.JPG)

Drilled the spotwelds

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXDgLp_f0tI/AAAAAAAAAX0/SRzF7WrVv98/s720/DSC_0132.JPG)


and chopped the rest but utilising the chopped bit ...

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXDgsjDL00I/AAAAAAAAAYI/IVC5CKJYAWM/s800/DSC_0134.JPG)


The result after paint etc ...

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXI5xPKfXnI/AAAAAAAAAZE/XZjk7zO2hDA/s720/DSC_0145.JPG)


(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXI5WEfvqQI/AAAAAAAAAY8/1QSfEd5g6lw/s720/DSC_0147.JPG)

This made a significant difference to EGTs and idledown times! Connecting the snorkle also improved things to the extext that I have now increased fueling by just less than 1/8 turn and I am still below pre turbo conversion EGTs   :o  

(https://lh6.googleusercontent.com/_pytUuTtTgaE/TXI6M8BQwFI/AAAAAAAAAZM/HdzsyGN_OB4/s720/DSC_0141.JPG)

For now I will leave the fuel alone as I have achieved what I wanted to achieve   :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on March 05, 2011, 08:55:37 PM
Well very surprised you eventually did it.  :drinks:
Hope you are more than satisfied. Pitted the snorkel is on the left making that inlet pipe so long.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 06, 2011, 08:04:57 AM
Well very surprised you eventually did it.  :drinks:
Hope you are more than satisfied. Pitted the snorkel is on the left making that inlet pipe so long.

 :drunk:  ?
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on March 06, 2011, 12:16:35 PM
But

You havent told us how it goes

Is it strong....

Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on March 06, 2011, 03:15:57 PM
What I meant Theo, is that it seemed like so much of a shlep and required a lot of research etc, that if it was me I would have given up. So well done to you, and I hope we can go for a drive with you and my Smurf and see how it compare's as to the last time when we were on LT2. It would be interesting to see if it reduced your fuel consumption although a BJ is light anyway.

Can you give us any comparative stats, like going over Bellville hill, or Sir Lowrey's Pass, before and after, gears that you had to use as against now as an example. We are all wanting to know - How it goes, not just "Lekker" - "Noisey" etc.  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 06, 2011, 05:45:00 PM
..Is it strong....



She has gone from being a donkey to a mule in running gear  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 06, 2011, 10:09:29 PM
Looking  8), well done, look forward to driving some day soon
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 07, 2011, 08:21:03 AM
Any time  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 14, 2011, 10:52:18 AM
Turbo feedback

I fitted the EGT gauge prior to the conversion as I wanted to compare pre and post figures. I was used to the figures on my 105 and did not expect the NA 3B figures – it was much higher than expected.- eg going up N1 Plattekloof  in 3rd I had to tap off at a still climbing 625 degC. After the conversion the temps were noticeably down, even after I turned the fueling up. This weekend I drove up Piekenierskloof pass (which is much steeper and longer that N1 Plattekloof) and at 60 – 70 km/h in 3rd gear the EGTs maxed out at 565 degC ! Having fitted the 33” tyres I had basically lost the use of my 5th gear but post the conversion I can cruise in 5th @ 2500 rpm with the EGTs at 490 degC. I was being overtaken less and actually found myself doing some overtaking of my own. I am more than happy with the results and I will be investigating an intercooler …

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 17, 2012, 01:02:39 PM
Time for an update  :wink:

 I fitted some custom bushes(to replace the old OEM ones) from the onset but the right rear one I over-tightened during the tub installation causing some small cracks/splits. It bothered me so I kept an eye on it for the last 18 months but after a recent excursion it had collapsed completely.I decided to replace both sides in the rear and removal turned out to be a pita as I had to loosen the entire cage etc .. 

(https://lh4.googleusercontent.com/-kA6hT2tiChs/Tw0rUsac_yI/AAAAAAAAAs0/S3Ns9eIlFuc/s720/DSCN0064.JPG)

(https://lh5.googleusercontent.com/-0iGGSkkGFhA/Tw0rLxRodKI/AAAAAAAAAss/m5p3xsBBiXc/s720/DSCN0062.JPG)

The new ones

(https://lh3.googleusercontent.com/-wukij3jCCfY/Tw0qJXWgiaI/AAAAAAAAAsU/8KoqtQyIIAY/s720/DSC_0265.JPG)

I also wasn't happy with the aussie AM bonnet hinges and at the first signs of rust I replaced them with OEM

(https://lh6.googleusercontent.com/-HSgcti_5Tow/Tw0p7EdwPxI/AAAAAAAAAsE/BEWHPpd_KxA/s720/DSC_0010.JPG)

(https://lh4.googleusercontent.com/-6xcn9ZlBDF8/Tw0p__tT3xI/AAAAAAAAAsM/HYlTnkoIlLQ/s720/DSC_0007.JPG)



My initial turbo oil return banjo was a bit of a hacked job and it caused my initial hose to be burt/chaffed badly. I modified a new hose with some spring but eventually a buddy sourced me a propper fitting- it goes straight down initially and then turns out making for a much better routing.

(https://lh5.googleusercontent.com/-aXdaDf3ilc0/Tw0qql6lRQI/AAAAAAAAAsk/KRA5bN4_gUk/s720/DSC_0266.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on January 17, 2012, 01:19:37 PM
Thanks for the update  8)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on January 17, 2012, 03:49:12 PM
Theo,
I need bonnet clips for the 45. Give me a price for the AM ones.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 18, 2012, 08:17:53 AM
 :-*

I was going to treat the tiny bits of surface rust and keep them in case I ever needed them for a future project(prolly unlikely) but you are welcome to have them mahala on condition that you replace them with suitable ones, if I ever did need them ?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2012, 10:09:01 AM
Discovered a coolant leak from the right rear of the block somewhere -It was significant enough that I parked her again and had to take the barbie to wek  :(  ???
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on February 06, 2012, 10:25:35 AM
Maybe that was also your coolant leak long ago, just not so prominent!  :(

Hope it will be just heater pipes etc.  :whew:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2012, 10:39:19 AM
It is not the same as last time OD(JB  did a complete coolant pressure test back then and since I filled the coolant reservoir to the more correct level all has been fine) but I also hope it is just the heater pipes although early indications are that it is not - at least not visibly.Motor doesn't run hot or show any strange symptoms  ???

 Maybe Mark Watson will have some more work on his plate soon  >:D 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 06, 2012, 11:02:09 AM
Sorry to hear Theo  :'(
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2012, 11:30:00 AM
Thanks but lets not write the old donk off, just yet. I will attempt to do a decent search & trace investigation this afternoon - Maybe I need to borrow JB's Snapon telescopicctopuscamera mathingy  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Rob Wright on February 06, 2012, 12:27:16 PM
 Theo,s theres a small welsh plug on the 3B on the head at the rear ,check that but unfortunatly to change it ,its either eng out or head off .Also look on yr oil cooler ,theres 4
nuts (12mm ) spanner that hold the cooler inside the housing ,these sometimes start to leak
 after time .
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2012, 02:09:56 PM
Will do thanks. From the rebuild I remember all the plugs were new - even those hidden under the bellhousing which was further confirmation that the PO had probably rebuilt the motor as they claimed post the sale.

I also remember a fred on mud about even smaller hidden plugs on the side of the head just above the ventpipe cover but they could have been oil galleys - I am searching for it now. If I had to pull the head I would probably have to decide between replacing and ceramic coating just about all VS a conversion  ... ???
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on February 06, 2012, 05:29:10 PM
So Sorry to hear Theo. I hope its something simple to sort out.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 06, 2012, 07:30:53 PM
It is not the 2 welch plugs in the head but instead seems to be the one large one in the block itself. I was unable to visually confirm it but touching it provided enough proof.None of the womanfolk in my house have handmirrors :o so I will have to make another plan to do a visual evaluation. Strangely TOYDIY gives the OD for the front plug as 51mm and the rear as 35mm but on my truck the rear infadel is definitely closer 51mm ! ??? I wonder if there is a SST in existence somewhere  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on February 08, 2012, 11:15:38 AM
Strangely TOYDIY gives the OD for the front plug as 51mm and the rear as 35mm but on my truck the rear infadel is definitely closer 51mm ! ??? I wonder if there is a SST in existence somewhere  :-\

Maybe engine was fitted wrong way into engine bay!?  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 08, 2012, 11:18:40 AM
Why don't you go check out Egberts motor to compare, rather ?  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 13, 2012, 08:53:30 AM
So this morning I drive her to JB to sort out that leaky welch plug and guess what  |(  No more leak  :(  Jb will investigate and fix it.

Good news regarding radiator though as JB reckons the weeping/sweating is so small that it is not even worth sending it in for repairs.  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 13, 2012, 02:38:28 PM
Bad news !!!  

Snake mirror camera thing revealed it is in fact a blown/leaking HG  :'(
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 13, 2012, 02:39:58 PM
 :o  :'( to hear that Theo, time to break out the spare gasket set.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 13, 2012, 02:45:19 PM
Yeah but I need 18 headbolts also and I am not sure that they are still obtainable
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on February 13, 2012, 02:56:23 PM
Nooooooo. :'(
Question from a doffie: Why would that happen Theo?
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 13, 2012, 02:58:37 PM
a doffie or adolfie?  >:D

Many reasons Pierre, but remember we have no idea of life of engine, I guess turbo may have been the last straw. Please note I am not saying the turbo caused it.

Damn are they stretch bolts Theo?
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on February 13, 2012, 08:12:43 PM
Sorry to hear Theo. Maybe you weren't watching your EGT's  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 14, 2012, 08:34:09 AM
Headbolts are still obtainable cos they are the same as found in the 2.8 and 2.4 motor.

JT, we have confirmed that they are not stretchbolts so will prolly reuse.

Pierre, doffie is just trying to stir. We suspect that when they rebuilt the motor the PO didn't take it back to retorque those headbolts after the 1st 1000kms. The extra pressure from the turbo prolly exelerated the leak though, but we will only be able to confirm once the head is off so watch this space ..
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on February 14, 2012, 08:43:09 AM
No stirring. Concern. Remeber, I drive one as well!!!!!!!
At least the news is getting/looking better.
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 14, 2012, 08:57:31 AM
good news about the headbolts :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 14, 2012, 10:58:14 AM
No stirring. Concern. Remeber, I drive one as well!!!!!!!
.

Jus kidden Pierre. I think you should be ok being NA and still on your original HG, IIRC ?  >:D

Now to try and find som pre-cups in ZA as I am very tempted to ceramic coat the head and cups while it is off.  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 14, 2012, 11:13:52 AM
 :o Sheize !! After discount but incl R1 649.00 EACH !! 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 14, 2012, 12:30:43 PM
The D-cups?   :o
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 14, 2012, 01:23:10 PM
In this case A cups would be a more accurate classification, but yes them pre combustion chambers AKA pre cups. The weakness of IDI diesels ... 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 26, 2012, 08:21:36 PM
Bump  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 27, 2012, 11:05:34 AM
 :o :o  Shock and horror ! This morning JB removes the rocker cover and the rocker-shaft to get to the 2 hidden bolts and .......

All the headbolts are completely loose !! Some as much as 30 - 60 and the 0ne where it sprung a leak 180 degrees turning circle !!! So the engine is actually fine as it is clear that those bolts were never retorqued after the rebuild - Is this good or bad news for me ?  :'( :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on February 27, 2012, 11:26:10 AM
Its bad news  :P
But I am sure you will find a way to feel better uz'ed  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 27, 2012, 11:42:42 AM
Good news  :jt: :P

Maybe they vibrated loose
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 27, 2012, 12:29:29 PM
Maybe they vibrated loose

Yeah, let's sommer take theoretical potshots at the rollcage mountings again ?  |( 

Seriously though, what do I now do with a perfect 3B that was rebuilt 18K kms ago  ???



Title: Re: Our BJ42 LX rebuild
Post by: Johann Meyer on February 27, 2012, 01:39:07 PM
Keep it as is, original  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 27, 2012, 01:56:22 PM
With oversized wheels, 4" lift etc I think it is a tad late for that JB.

Either way, I am crying & smiling at the same time ...

Have you checked/tested her again ? 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 27, 2012, 09:47:24 PM
Pity you too late to sell it to Egbert.
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on February 28, 2012, 10:18:39 AM
Yeah, let's sommer take theoretical potshots at the rollcage mountings again ?  |( 

Seriously though, what do I now do with a perfect 3B that was rebuilt 18K kms ago  ???

Take out and put in storage for Pierre Bester. Then fit Lexus V8. :jt: :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 28, 2012, 11:44:08 AM
You just made his day  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on February 28, 2012, 03:03:23 PM
Why didn't you just buy a Heep or Defecator and mod that? Much more available and much cheaper.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 28, 2012, 03:13:29 PM
 ???  Cos I love driving and enjoying Olive not some other piece of cr@p. I "rebuilt" Olive to enjoy her not to put her in a glass box and only to look at her or drive her on the tar only or to sell her for a profit ! WTF, I thought you understood that ! None of our vehicles are or will be originals - so why not transform it to the best it can be for your own enjoyment?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Johann Meyer on February 28, 2012, 03:18:56 PM
Its like taking a 45 bakkie, chop it off and call it a 40 shorty  :jt: ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 28, 2012, 03:49:36 PM
Oh shus, MR ICANNOTBECLAMPEDCOSMYWHEELSARETOLARGE  !  :P
Title: Re: Our BJ42 LX rebuild
Post by: Johann Meyer on February 28, 2012, 04:02:37 PM
You going to roll that shorty with V8 lexus engine in the front  :'(
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on February 28, 2012, 10:27:17 PM
Go for it Theo  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on February 29, 2012, 08:40:50 AM
Time to start a new thread Theo.  ??? (It will be like starting over) as the song goes.  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on February 29, 2012, 09:01:34 AM
Quote
None of our vehicles are or will be originals

Within the boundaries accepted by restorers? Who says?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 29, 2012, 09:44:18 AM
Which "restorers" Shaun and what "boundaries"? Internet PC restorers ? Genuine restorers will never accept any of our vehicles Shaun. The moment you change anything from being OEM or add anything non OEM and non standard for a particular model/year, the originality is lost !  If you start playing with boundaries and semantics you are fooling yourself.
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on February 29, 2012, 10:43:50 AM
These are recommended - they obviously work well:

(http://www.barlowstackle.com/Assets/ProductImages/Hooks/428365.jpg)

Theo, I have a serious restorer in the office next to me. He has done an Austin Healy which he sold for R300K seven years ago (the GP oke who bought it took it back to GP on a trailer so it wouldn't get dirty) and has just completed a 5 year resto on a Jag. He has changed wheels, tyres, gearbox components, paintwork etc and the vehicles are still considered concourse original collectables.

So my BJ42 will be original even if it doesn't have OEM sprongs and shocks, rims and other bits and bobs where the Toy part is unavailable. And it's spec will still match its original VIN plate which, to me, is important.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 29, 2012, 12:22:58 PM
 ;D

So by your friend's definition, a 1983 FJ 40 that still has a 2F but is converted SOA with twin shocks on 37" super swampers with twin stick ultra low TC and twin ARB lockers will be "considered concourse original collectables" because the engine, Gbox, axles and paint code are as per Vinplate ?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: milton slabber on February 29, 2012, 01:29:21 PM
Its like taking a 45 bakkie, chop it off and call it a 40 shorty  :jt: ;D

Jy moet nou nie kom stirr hier nie, JB!! :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on February 29, 2012, 02:01:31 PM
Quote
1983 FJ 40 that still has a 2F but is converted SOA with twin shocks on 37" super swampers with twin stick ultra low TC and twin ARB lockers

Now you are arguing like someone who would take a fine BJ42 and bastardize it into a pipe car. Don't be ridiculous!

 :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 01, 2012, 01:35:17 PM
Is that all ? I was expecting more  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on March 01, 2012, 02:29:06 PM
I was too gobsmacked  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 02, 2012, 01:40:14 PM
Bump  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 04, 2012, 06:07:37 PM
 ;D
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on March 07, 2012, 10:49:14 AM
Theo,

This is what my mods are going to look like:

Non-standard but period sport wheels

(https://lh4.googleusercontent.com/-eYmrh4anVy8/T1ceIdg_agI/AAAAAAAAEEs/bc6NKLKjzyo/s640/DSC01241.JPG?gl=ZA)

Non-standard but period steering wheel, non-standard gear knob, seats (ex XJ40 [not BJ40!]) and upholstery.

(https://lh3.googleusercontent.com/-7NLp-6Zc5NM/T1ceGxr0Z_I/AAAAAAAAEEo/eHfdtxE06ys/s640/DSC01240.JPG?gl=ZA)

Non-standard indicator lenses and air vent/grille

(https://lh5.googleusercontent.com/-daZ1ZpdXYao/T1ceFModcAI/AAAAAAAAEEc/fIAWnCjttec/s640/DSC01239.JPG?gl=ZA)

Non-standard resevoir, carbs and air filter.

(https://lh5.googleusercontent.com/-FLQOmG6M25c/T1ceDBYtkUI/AAAAAAAAEEU/5I0stZJ12qI/s640/DSC01238.JPG?gl=ZA)

That's 4,000 hours work on a 1967 3.8l MKII Jag and it is still a Jag! Not some pimped up wannabe.



Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 07, 2012, 10:52:17 AM
I am sure we could fit a Lexus in there for you shaun  >:D

Lovely work BTW
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on March 07, 2012, 11:02:02 AM
How many oil leaks?  :jt: 

Would rather prefer a Derelict  :-*!
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on March 07, 2012, 11:48:03 AM
Nice motor, better than 2F  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 07, 2012, 01:03:00 PM
Nicely pimped Jag  8)

Is it a K&N filter setup? 
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on March 17, 2012, 10:24:55 AM
I have a BJ in my stable!  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 17, 2012, 01:32:21 PM
I always knew you truly desired to own one  :jt: ... now go find your own BJ and deliver mine to Mark with no detours, please !  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on April 23, 2012, 08:17:37 PM
bump  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on April 23, 2012, 08:36:53 PM
Here you go JT (http://www.gotbezel.com/Themes/kani_119/images/post/xx.gif)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on April 30, 2012, 06:01:26 PM
so no updates??  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 01, 2012, 07:52:18 PM
Will do when there is a bit more substance to it Mark ! At the moment we are are still stubbornly plodding along trying to figure stuff out  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 13, 2012, 04:10:22 PM
bump  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 13, 2012, 07:15:30 PM
Ok ok ...  The pics tell the story ..

(https://lh6.googleusercontent.com/--paGhi_RSpE/T4gSJc0gqXI/AAAAAAAAAxo/xX4AcVUW2ww/s720/eng%25205.JPG)


(https://lh6.googleusercontent.com/-pJaMLBqOYwI/T4gPylkL29I/AAAAAAAAAxE/9-DkDzckBRA/s720/eng2.JPG)
The long fine spline input shaft due to the short old four banger turned out to be a blessing ...

(https://lh5.googleusercontent.com/-4q1JGrLTiOA/T6_pkTT8EWI/AAAAAAAAA2w/9d_HdJT7B3A/s720/s6301336.jpg)

Adapter plate for the bell housing..


(https://lh4.googleusercontent.com/-51OaleU_cAE/T6_pqxi1QiI/AAAAAAAAA24/5yiCJhSBhmY/s720/s6301335.jpg)

Custom flywheel but we have since sold this one as it was for the 260mm clutch and we have decided to go with a 275mm clutch

(https://lh6.googleusercontent.com/-aoyIU85SiTo/T5OgG1KT-AI/AAAAAAAAAzc/SIRy-hULC8U/s720/IMG_0720.JPG)
Test fitting the dummy motor

(https://lh4.googleusercontent.com/-KyByC5eio24/T5OgB2lBE8I/AAAAAAAAAzU/jafFs7q2SrU/s720/IMG_0719.JPG)

Too close to the firewall - we scored 25mm by moving the gearbox forward while the cross member remained in place

(https://lh6.googleusercontent.com/-BJ0MCDQEBJs/T67I9KvbuMI/AAAAAAAAA1k/J-cuq3o3YZ4/s720/s6301343.jpg)

Drilled the rivets out in order to bolt in the new lookalike mounts but first some Galv spray to stay with the rest of the frame's theme  ;)

(https://lh6.googleusercontent.com/-S91hM6DzsdE/T67ISfIWdzI/AAAAAAAAA1E/lAuw5k5ubVU/s720/s6301353.jpg)


(https://lh3.googleusercontent.com/-vnkSmXXoqgA/T67IRUYbtvI/AAAAAAAAA08/dc1AzxJBdIE/s720/s6301371.jpg)

The new heart  8)

(https://lh6.googleusercontent.com/-It71IFYYq2c/T67IGzKUNbI/AAAAAAAAA0s/2CU0R2u7VXo/s720/s6301375.jpg)

(https://lh5.googleusercontent.com/-g0W3ixThOAk/T67IMdOtLVI/AAAAAAAAA00/bSeH3lrcyKM/s720/s6301377.jpg)

In it's soon to be, permanent nesting place

(https://lh5.googleusercontent.com/-oiUC8Bs0Rk4/T6---hhPD2I/AAAAAAAAA2Y/ogDOdSzmHWA/s720/s6301379.jpg)


(https://lh5.googleusercontent.com/-rNe8n4rdr2o/T6--9ZZMeUI/AAAAAAAAA2Q/fmyOMJHTu_Y/s720/s6301378.jpg)

Cover on anyone ?

(https://lh6.googleusercontent.com/-WORbwNI2n-E/T6--_0A3hII/AAAAAAAAA2g/ePjTb1m4Jsc/s720/s6301382.jpg)

 :drinks:














Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 13, 2012, 09:18:42 PM
That's quite an update, looks  8) so far, looking forward to the end result.
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on May 15, 2012, 07:30:23 AM
 :o :o :o :o
Bliksem!!!!!!!!!!!!!!!!
I will have to leave 3 days before you for the Legends trip.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 15, 2012, 11:39:19 AM
Nahh .... I have a strong towstrap that we can use   :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on May 18, 2012, 10:54:04 AM
Time for a new update!  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 18, 2012, 12:17:04 PM
When there is more than just boring old test fitting and checking clearance, results  |(
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 18, 2012, 12:59:36 PM
but that is interesting to some  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 18, 2012, 04:12:58 PM
ok ok ...

And the test fitting, checking clearances and planning ahead continues but we are moving ahead ..

(https://lh4.googleusercontent.com/-nK0jDCKQoJw/T7U77YdtggI/AAAAAAAAA5A/PHDWNfs25gs/s720/IMG_0810.JPG)


(https://lh5.googleusercontent.com/-cv8p-dXqO7U/T7U8BcVC9UI/AAAAAAAAA5I/t0mJUSxFrJY/s720/IMG_0816.JPG)

The viscous is slightly offset just like the old 3b was....


(https://lh6.googleusercontent.com/-kUEUeiweuII/T7U7nTzHP-I/AAAAAAAAA4o/dsDx9om8IwA/s720/IMG_0804.JPG)


(https://lh5.googleusercontent.com/-QK0wXtvBZIk/T7U7wFLH9FI/AAAAAAAAA4w/bp8kxMgUxxE/s720/IMG_0802.JPG)

The radiator will go in on Monday for the bottom tank to be flipped around and a general recon.


(https://lh5.googleusercontent.com/-w_66mCt7gxs/T7U714u4cnI/AAAAAAAAA44/_t-5231gGHI/s720/IMG_0803.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 18, 2012, 04:15:14 PM
Looks @home in there  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 27, 2012, 06:41:03 PM
Time to get going on the last chapter of normal work on Olive. Unpacked the bits and pieces ...

(https://lh5.googleusercontent.com/-7xgN45zvcu4/T38VgUB8jOI/AAAAAAAAAwo/lNUDFEsbjOg/s720/DSC_0019.JPG)


(https://lh6.googleusercontent.com/-Pnd0-H3srto/T38VoFaCFpI/AAAAAAAAAww/_f2kBAVHpkc/s720/DSC_0020.JPG)

(https://lh4.googleusercontent.com/-iU61UORVPZQ/T38VXBOYABI/AAAAAAAAAwg/NQujdrELw2Y/s720/DSC_0018.JPG)


Testing fitment after all the layers of paint and the manner of removal  :oops: .

(https://lh6.googleusercontent.com/-jDfJkzJruNY/T7J_VXIyJMI/AAAAAAAAA3I/gD486IqDlGg/s720/DSC_0305.JPG)


Some of my old rubbers were new and just needed a clean

(https://lh6.googleusercontent.com/-MPGumV5hsWw/T7J_fZqaCoI/AAAAAAAAA3Q/S9WOPDXhFzI/s720/DSC_0315.JPG)

still fits perfect ...

(https://lh4.googleusercontent.com/-DOSG1QbAGFk/T7J_oNIpFUI/AAAAAAAAA3Y/7arxQPLOPBc/s720/DSC_0317.JPG)


But the twin channeling was shot and I wanted to get to the insides of the frame ...

(https://lh6.googleusercontent.com/-LAv13-70yX4/T7J_3KsjpvI/AAAAAAAAA3g/QVhfIHfDe1I/s720/DSC_0326.JPG)


(https://lh4.googleusercontent.com/-CJBgqY2i3vo/T7J_-4hidnI/AAAAAAAAA3o/uu4XLoA-qJ8/s720/DSC_0328.JPG)


The left overs ...

(https://lh4.googleusercontent.com/-w14mqhga28o/T7KANT7sA7I/AAAAAAAAA3w/pVxvUz47m2w/s720/DSC_0329.JPG)


The one door was missing the upper rubber and felt with the result ...

(https://lh3.googleusercontent.com/-TkbbhWzi_sw/T7KAoNKcotI/AAAAAAAAA4A/0obgPQVtNoY/s720/DSC_0343.JPG)


The quarter vent windows also need new rubbers and a refurbish ..

(https://lh6.googleusercontent.com/-cCTd2Ec6KbE/T8IaiYji9BI/AAAAAAAAA6c/qy-zVDtpDVo/s720/DSC_0366.JPG)


(https://lh6.googleusercontent.com/-ZqUBwE5W4o4/T8Iau6qI34I/AAAAAAAAA6k/6RRWFSTbAsc/s720/DSC_0374.JPG)


Rust Bullet no longer has an SA agent due to some fallout over a Guarantee with  head-office. I couldn't do another direct import from the USA and so found the Belgium version of RB. It is identical i.r.o looks , smell, texture, preparation, application, dilution, removal and also sticks to your hands like sh!te. Today the weather was just right so I could start shooting all the cleaned up bits and pieces with the required 2 coats ...

(https://lh5.googleusercontent.com/-DeVAmRiEu-4/T8IbhO3ezcI/AAAAAAAAA68/YAbgr5tYbjQ/s720/DSC_0442.JPG)


(https://lh5.googleusercontent.com/-9HgX1TAH4Wc/T8IbFUO9GnI/AAAAAAAAA6s/W-qi1NOT2qI/s720/DSC_0444.JPG)

(https://lh5.googleusercontent.com/-8xyDonDk00U/T8IbOn0YtII/AAAAAAAAA60/kMqugEVBXRM/s720/DSC_0443.JPG)

If all goes to plan I will start shooting some color after work tomorrow
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 27, 2012, 06:44:37 PM
Well done, but if it the same as RB then it needs 2 weeks to cure before top-coat.  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 27, 2012, 07:04:04 PM
Nope within 24 - 48 hrs you don't need to sand but after 72hrs then you have to
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on May 28, 2012, 08:46:50 AM
It was time to move on the top half of Olive. Glad you started.  :drinks:

Your motor looks superb.  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 28, 2012, 12:20:41 PM
Your motor looks superb.  8)

Much appreciated Pappy  :drinks:

I just wish I could have been closer to the action ..
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 30, 2012, 07:18:00 PM
Received a long awaited parcel in the post today

(https://lh5.googleusercontent.com/-yfHE1lMSc1A/T8ZTACH-VAI/AAAAAAAAA7k/F97yAABkjtw/s720/DSC_0450.JPG)


Will get on with it as soon as Olive is home


(https://lh4.googleusercontent.com/--E6zybVEDlY/T8ZTa-q6-rI/AAAAAAAAA74/DeOcRxopT8Y/s720/DSC_0451.JPG)


In the mean time I got going on the Aussie LRT that she came with.That red desert dust becomes a very tough caked muck when mixed with diesel   :o

(https://lh6.googleusercontent.com/-RjfDQ96Vrgg/T8ZR5AljBkI/AAAAAAAAA7c/rW5FRRS3Hng/s720/DSC_0446.JPG)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 30, 2012, 07:44:10 PM
But you don't have a winch  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 30, 2012, 09:43:46 PM
You need to visit more  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 10, 2012, 06:45:57 PM
Some update pics. The original headers couldn't give us the exit for the routing that we needed

(https://lh5.googleusercontent.com/-8P6JaxEuZVc/T9S_9P1AobI/AAAAAAAABBo/aZklHJJGntI/s720/S6301443.JPG)

so they got chopped, trimmed and tigged..


(https://lh6.googleusercontent.com/-jfO-LgQL8hI/T9S_z2naBEI/AAAAAAAABBQ/tP_dab5kAMs/s720/S6301447.JPG)

Only the best is used


(https://lh6.googleusercontent.com/-Eyw_jmM-Nj8/T9IA2W9WCMI/AAAAAAAAA-g/uH72-xr2TPA/s720/S6301429.JPG)


(https://lh6.googleusercontent.com/-jP4i2h3lsY4/T9S_6S7kw-I/AAAAAAAABBg/-lW2BgdJYmI/s720/S6301444.JPG)

The routing we want

(https://lh5.googleusercontent.com/-ZcOQ93Ft-ac/T9S_vp86IdI/AAAAAAAABBI/Vn7MLd7GvAA/s720/S6301450.JPG)


(https://lh5.googleusercontent.com/-ZtfCSYGEf_I/T9S_4nG2_0I/AAAAAAAABBY/lOeknY7tZqI/s720/S6301446.JPG)


(https://lh4.googleusercontent.com/-Xe53sQTnf4s/T9S_rhUNkjI/AAAAAAAABBA/PVuGRBm0d7Y/s720/S6301455.JPG)


(https://lh4.googleusercontent.com/-LelBqrSvaQE/T9S_cVSai_I/AAAAAAAABA4/Pj7Rq31icik/s720/S6301457k.JPG)

I want the tip to point slightly downwards as opposed to completely level ..more like she was ..

(https://lh5.googleusercontent.com/-gh50MyTiVJE/TXI64xwH7bI/AAAAAAAAAZk/vLoafWWE_TE/s720/DSC_0153.JPG)


For the rest the test-fitting and measuring continues. Re-cored radiator with flipped bottom tank is back

(https://lh3.googleusercontent.com/-L1iTKe_Z10Q/T9D_M7E_F5I/AAAAAAAAA94/ccy_fh8tyN0/s720/S6301434.JPG)

New spot for the P/S Reservoir - neatly tucked away ...


(https://lh3.googleusercontent.com/-2JdwrfhZC-4/T9D_HD4-olI/AAAAAAAAA9w/UbyEQhk907I/s720/S6301435.JPG)

Aux battery bracket needs to be shortened ...

(https://lh3.googleusercontent.com/-unSQNV1a7lI/T84ntzrlnZI/AAAAAAAAA9I/jl8YC0fGJkg/s720/IMG_0869.JPG)


(https://lh3.googleusercontent.com/-brRb0g93NBU/T84n0_M1QrI/AAAAAAAAA9Q/pmRypk83qG8/s720/IMG_0866.JPG)

(https://lh3.googleusercontent.com/-Rw7w0N11k_k/T9D_cS55EkI/AAAAAAAAA-I/ltn2QoV3BF8/s720/S6301437.JPG)

(https://lh4.googleusercontent.com/-lkCURIdbRmQ/T9D_kJQnGBI/AAAAAAAAA-Q/hgFWC-fpICg/s720/S6301438.JPG)


But other areas are good. We are going to replace the 3B rubber engine mounts with those found on the 79/80/105/100 ser which will not only be stronger but will hopefully give us the additional 10 mm of lift that we still need

(https://lh5.googleusercontent.com/-02vMDdIb7LU/T9D_VcMHvaI/AAAAAAAAA-A/zN959oiTGo8/s720/S6301436.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on June 10, 2012, 09:09:14 PM
So much work goes into this conversion, its mind boggeling, but look great.  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on June 10, 2012, 10:40:55 PM
 8)
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on June 11, 2012, 10:18:40 AM
Well done Theo. Great work!
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on June 11, 2012, 11:57:02 AM
Looking good Feo!
How long till Drive time?
 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 11, 2012, 12:08:04 PM
Thanks guys, much appreciated !

Mark I reckon at least a month but prolly longer  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 11, 2012, 07:29:14 PM
I like newly painted parts ...

(https://lh6.googleusercontent.com/-4-DiuOJXLTk/T9STWSc8a3I/AAAAAAAAA-4/_3uuEN7m98E/s720/DSC_0468.JPG)


It deserves new OEM rubber ...


(https://lh6.googleusercontent.com/-mxLge_ahioA/T9STjpvTM8I/AAAAAAAAA_A/8sMOAq2vWQA/s720/DSC_0470.JPG)

(https://lh3.googleusercontent.com/-Bdp_H9nRHNM/T9ST-4hTjzI/AAAAAAAAA_U/obHnuM68x7s/s720/DSC_0474.JPG)

Do not clean the "beeswax"- like substance before fitment, as it aids in giving you a proper grip to install it

(https://lh5.googleusercontent.com/-Cn9ohQ-AqJU/T9ST0W77Y-I/AAAAAAAAA_I/oeHyvmHdqXY/s720/DSC_0472.JPG)

(https://lh4.googleusercontent.com/-HCOV7SV4A0M/T9SUaX16zdI/AAAAAAAAA_c/0e6WlUoTFls/s720/DSC_0476.JPG)

next the glass using new hardware

(https://lh4.googleusercontent.com/-z-gmA5BER7I/T9SUvDp_H5I/AAAAAAAAA_s/caKATqDWIZ0/s720/DSC_0477.JPG)

The end result

(https://lh4.googleusercontent.com/-YY0PiV222iY/T9SU8EHrPbI/AAAAAAAAA_0/r-IMTMy7HGo/s720/DSC_0480.JPG)

With a short break in the torrential rain that we have had I managed to get some "Rust Bullet" brushed into all those hard to reach areas and seams on the inside bottom half of the doors ..

(https://lh6.googleusercontent.com/-sRd7HMPHUmk/T9SVELRlPWI/AAAAAAAAA_8/Avbb0ImCaoA/s720/DSC_0460.JPG)


Then it was on to those sliding window frames.Toyota doesn't stock the OEM twin-felt rubbers for the 40 ser.I was advised to use the Toyota minibus rubbers but were not a perfect fit and I was loathed to cut something that expensive.Instead I found a perfect match and the stuff was sold by the meter !

Doesn't look like much

(https://lh3.googleusercontent.com/--t3yVjIwnUw/T9S3DUnx3II/AAAAAAAABAY/yq-7QYlaphI/s720/DSC_0485.JPG)

but with a bit of pressure

(https://lh5.googleusercontent.com/-2tsumdwBQA0/T9S3Q7MZyYI/AAAAAAAABAo/qA6hAyydyic/s720/DSC_0483.JPG)

and it becomes a perfect fit ito height, width and depth.

(https://lh5.googleusercontent.com/-TPsv57ApRPw/T9S3MwK50aI/AAAAAAAABAg/aWTCiayHbKU/s720/DSC_0488.JPG)

Now I just need to figure out what the magic trick is to get the glass in before I resort to the usual violence   |(


Also found time to dig out the old A/C system that will be going back to Aussie as part of the engine sale.

(https://lh4.googleusercontent.com/-yXZ2zqqswHw/T9S28kIRQCI/AAAAAAAABAQ/nOYtK5j5Ge8/s720/DSC_0482.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on June 12, 2012, 10:41:27 AM
Geez  :o , that aircon must be able to freeze a cold room !  :jt:

Nice going there Theo.  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 16, 2012, 04:21:29 PM
We have been fighting some clearance issues issues on various fronts for a while. Basically the 1UZ is not as tall and slim as the old 3b so we needed some height.Initially I wanted to stay with the old 3B rubber engine mounts for various reasons but then I found some info that the HDJ 80 series mounts are actually beefier and stronger. It did not take much to convince Mark and after swapping them out the results are amazing  ...

Before

(https://lh4.googleusercontent.com/-lkCURIdbRmQ/T9D_kJQnGBI/AAAAAAAAA-Q/hgFWC-fpICg/s720/S6301438.JPG)


After

(https://lh6.googleusercontent.com/-FhYMxiY5aIg/T9tkP1RzaYI/AAAAAAAABDQ/vz_9HZo4E-k/s720/S6301467.JPG)


Before

(https://lh3.googleusercontent.com/-Rw7w0N11k_k/T9D_cS55EkI/AAAAAAAAA-I/ltn2QoV3BF8/s720/S6301437.JPG)


After

(https://lh3.googleusercontent.com/-BS5ETHvzSwg/T9tkSIL7OOI/AAAAAAAABDY/NaG6s8i0Bco/s720/S6301468.JPG)


Before

(https://lh4.googleusercontent.com/-JszMWRYPZ54/T9yTk_9ghgI/AAAAAAAABEw/6X1TNlpGb6c/s720/IMG_0812.JPG)

After

(https://lh3.googleusercontent.com/-X8x0boyMNuM/T9tkNuZVvHI/AAAAAAAABDI/sBcrUeWjsC0/s720/S6301466.JPG)


Before

(https://lh4.googleusercontent.com/-0FprtmwAWyw/T9yPB_SUwXI/AAAAAAAABEg/lC-BG8WTJZA/s720/IMG_0809.JPG)

After

(https://lh6.googleusercontent.com/-l6OpQt2za-E/T9tkVUWZZLI/AAAAAAAABDg/J7OgE-_20rQ/s720/S6301469.JPG)


This also meant we could finish the zaursts which we were also experimenting with   8-)

(https://lh5.googleusercontent.com/-zr8t8F9Wx7I/T9x4FZ3bBpI/AAAAAAAABEA/4XpFNt8gSJc/s720/S6301470.JPG)

I really like the new look and feel  8)


(https://lh4.googleusercontent.com/-clyichdFQZ0/T9x4Hfju2zI/AAAAAAAABEI/o2O9WMCKRtQ/s720/S6301471.JPG)

(https://lh5.googleusercontent.com/-nQ8Nd25SF_M/T9x4JdSnbJI/AAAAAAAABEQ/Pyut94GCmbA/s720/S6301472.JPG)

Now for the heat shields, main batt tray and the daunting task of fabbing an OEM like viscous fan shroud ...

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on June 18, 2012, 07:14:57 AM
Looking good but man, this is a lot of work!!!!
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 04, 2012, 09:44:50 PM
Visually we have not made much progress but it is to be expected when you custom design stuff and then change your mind. I do not like the exhaust slapping sound caused by most V configuration engines when running a true dual zaurst- setup, so we decided to do a X pipe but as soon as we realized we could actually run a balance pipe at 90 deg with the header pipe, we reverted back to the original plan. This meant further delays as our freshly made headers had to be cut ...

(https://lh3.googleusercontent.com/-yxhUYNdMw7w/T_CN70pjEcI/AAAAAAAABG4/7GvonHw52aE/s720/S6301493.JPG)

To find the correctly sized flex joint also proved a mission as conventional teachings are that the balance pipe should be 75% diam of the main pipe and enter as close as possible to the headers themselves  ...

Testing

(https://lh5.googleusercontent.com/-ettTZMNQnbA/T-yPC9JVSKI/AAAAAAAABGY/fm_xClzlaBE/s720/S6301482.JPG)


Space is at a premium as all sorts of issues complicate the matter eg the new rearsump and groundclearance vs additional heat  but eventually we got there ...

(https://lh4.googleusercontent.com/-0EeuqFTsXhI/T_SS2_-QD6I/AAAAAAAABHg/X6K2SeTKv4U/s720/S6301499.JPG)

The normal frontsump has been removed as the back of the new custom rearsump is being further modified to clear the balance pipe.


(https://lh4.googleusercontent.com/-b30IE40SkMY/T_SS811IymI/AAAAAAAABHo/5xnPHrW-Cqg/s720/S6301500.JPG)

But she did put up a fight and drew some blood during the welding - sorry Mark   ;D

(https://lh5.googleusercontent.com/-C9nS0qoZXwM/T_SSd6XdO5I/AAAAAAAABHI/9kDUyyZ8QCA/s720/S6301504.JPG)

How good does that still look ?    8)

(https://lh6.googleusercontent.com/-KcnjpwMrMc8/T_SS-SC8R3I/AAAAAAAABHw/-wdmHQSceNo/s720/S6301501.JPG)
 
On these VVTi motors the oil filterhousing is located under the A/C compressor on the bottom left front of the motor so we needed to see which of the different OEM 1UZ housings would work best as space was once again tight and I did not want a filter hanging in a vulnerable spot underneath. Eventually we decided to use the 3UZ's oilfilter housing    :whew:


(https://lh3.googleusercontent.com/-Yby6U20wMB4/T_SSx1Pz3EI/AAAAAAAABHQ/eQTNXPJq0Mc/s720/S6301495.JPG)


(https://lh5.googleusercontent.com/-MR9BKQ-iUVA/T_SS1OmoSkI/AAAAAAAABHY/H8JSFzr6gPE/s720/S6301498.JPG)

Behind the scenes there has also been alot of work done on wiring and we have decided to opt for Spitronics management instead of the OEM.From now on things should start speeding up visually and there should be more regular updates  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on July 05, 2012, 11:43:50 AM
 :drinks:
 :meeting:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 09, 2012, 04:56:45 PM
The newly made custom, larger and very strong sump being welded while on the dummie motor to combat any warping.After sorting the pickup and dipstick, it will have been cleaned & sent for powder coating today.  8)

(https://lh5.googleusercontent.com/-lLFkdD5YbTs/T_nQMHarv2I/AAAAAAAABII/DBIkQ-dSHZU/s720/S6301505.JPG)


(https://lh5.googleusercontent.com/-CsEX95QuMik/T_nQPeCqEqI/AAAAAAAABIQ/V6bhFGeZuSc/s720/S6301506.JPG)


the new 4mm custom alu heat shields using only OEM chassis holes, new bracketry and Toyota bolts & nuts.

(http://)(https://lh5.googleusercontent.com/-NOdbZrySkCo/T_nQRKaP5DI/AAAAAAAABIY/zGpfxem4RK0/s720/S6301508.JPG)

(https://lh6.googleusercontent.com/-93cUVx_G4es/T_nQTF3UqfI/AAAAAAAABIg/ygtBPPcTfmo/s720/S6301510.JPG)

Both sides a mirror image save for the bracketry ....

(https://lh6.googleusercontent.com/-CCcs4wupYKc/T_nQVDoY_vI/AAAAAAAABIo/73V_uFz9pzU/s720/S6301511.JPG)


The new S/S Surge tank fitted completely out of harms way     8)


(https://lh5.googleusercontent.com/-k9AL09rZEm0/T_nQY-nMzpI/AAAAAAAABIw/pfJKg0uQHjo/s720/S6301507.JPG)


The new external pump will be in an even more protected spot yet easily reachable for a quick bush-replacement

(https://lh4.googleusercontent.com/-9EiXvztREyQ/T_nRC9rrLEI/AAAAAAAABI4/xpzv2BDhbvc/s720/S6301509.JPG)

Not quite in the home stretch yet,  but if all goes to plan this week then we might be able to at least start her by the end of the weekend



 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 09, 2012, 07:14:53 PM
 :drinks: progress, thanks for sharing
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on July 10, 2012, 08:34:12 AM
That sump must be heavy !  :o

Otherwise  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on July 10, 2012, 11:00:52 AM
Now for the sprint to the finish line...you must be breathless already  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 10, 2012, 11:16:14 AM
That sump must be heavy !  :o


You 2F donk drivers are beginning to sound like the diesel okes  :jt:

Seriously though, an extra 10 - 15 kg doesn't even begin to account for the lighter V8 vs that heavier 3B and if it did, it would just further improve the already better COG  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on July 10, 2012, 06:18:20 PM
Bliksem..
I remember the days..
all the mock ups we had to do ..
PDM
XDM
takes me back to my "hard core Engineering"...  :-[

btw.. not much OEM here me finks  ;D

but looking good Theo, can't wait for start up report.. and you had better spend a weekend testing in GP before taking it for soak test in the Cape  :drinks:

Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 10, 2012, 06:57:31 PM
Ok she is off the lift and this afternoon the motor was going to be pulled so the new clutch and custom flywheel can be sent for dynamic balancing.At the same time the headers go for ceramic coating and the infamous sump for powder coating. While waiting for that the wiring will start in earnest with a few other surprises.

The new S/S(- it has not been cleaned or polished) feed pipe for the snorkel . New mounting brackets will be made using the existing OEM holes where the now obsolete vacuum pipes used the be attached.

(https://lh6.googleusercontent.com/-oA1fOnT4MkE/T_vmc5I3AlI/AAAAAAAABJQ/3CKnkSp6JRg/s720/S6301512.JPG)



(https://lh6.googleusercontent.com/-ByP5HUpRWy4/T_vmc-tHWuI/AAAAAAAABJM/I6N6oqUKzio/s720/S6301514.JPG)

That 3" snorkel is now worth it's weight in gold   ;)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 10, 2012, 08:45:20 PM
Nice pipework there Theo  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 10, 2012, 09:16:47 PM
Thanks  8)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on July 11, 2012, 10:17:10 AM
What pypkar is this  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 12, 2012, 08:14:07 PM
Engine is out and flywheel with new clutch & pressure plate has been sent for dynamic balancing. Meanwhile old "ugly bash-plate" has been coated and fitted onto it's new home.    ;D

(https://lh6.googleusercontent.com/-iNWY4D8mrc4/T_8EUFGWUmI/AAAAAAAABJ0/AajxVamnVYM/s720/S6301516.JPG)


(https://lh3.googleusercontent.com/-ueZ9mYXWU_o/T_8EXiQ5V1I/AAAAAAAABJ8/-YGApc4dfK8/s720/S6301518.JPG)


The wiring has also started in earnest. Instead of making up a complete new loom we decided to use the original OEM Lexus loom as this will give it that "factory" look but also give you peace of mind regarding reliability.The standard 1UZ VVTI engine loom is however quite a monster in own right.

(https://lh5.googleusercontent.com/-bClEO70Fx14/T_8ESJ4ZJ7I/AAAAAAAABJs/d3WsZKR-KTI/s720/S6301515.JPG)



I didn't want any enlarging or cutting of new holes in the firewall so we decided to discard as much of the obsolete wiring as possible and to use the 1UZ loom grommet that is seemingly a perfect fit   

(https://lh6.googleusercontent.com/-jf9uAaq2bMs/T_8EZRINWYI/AAAAAAAABKE/9ojkiSayuYw/s720/S6301520.JPG)


The remaining Lexus loom after a bit of a diet ...

(https://lh6.googleusercontent.com/-36WL-QkTWps/T_8E679vx-I/AAAAAAAABKQ/4mESpif29g0/s720/S6301521.JPG)



The same will be done with Olive's loom and the two will then be joined up for a real OEM look & feel. All the existing OEM gauges and sensors will be used plus a few obsolete warning & glow lights will be used as warning lights  8)

Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 12, 2012, 10:55:44 PM
ooh spagetti  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 16, 2012, 02:22:49 PM
(https://lh6.googleusercontent.com/-iNWY4D8mrc4/T_8EUFGWUmI/AAAAAAAABJ0/AajxVamnVYM/s720/S6301516.JPG)

:o I am so glad I waited for your pics, I was about to mount my engine the other way up  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 16, 2012, 02:44:16 PM
 ;D




Just don't allow it to slow down your progress  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 18, 2012, 05:18:25 PM
I got some new pics today and must admit that I was almost blown away by how good the motor is looking   8)

Olive in a state of readiness to receive the motor for the last time. Most of the OEM 3B engine bay wiring has been prepped ...

(https://lh4.googleusercontent.com/-rabTwDpEX7o/UAbHx9hSOCI/AAAAAAAABK0/F_lGc2Lwzxg/s720/IMG_1002.JPG)


The wiring on the motor itself is also basically done and all the tails are marked and ready to be routed through the firewall where it will be wired to the Spitronics ECU in a novel location(Watch this space!).The new oil filter already mounted on the new 3UZ housing   8)


(https://lh4.googleusercontent.com/-sg294bmBce8/UAbGKV3IMfI/AAAAAAAABKs/TIqHm9nxLUY/s720/IMG_1003%255B1%255D.JPG)

We were being kept up by the ceramic coating of our custom headers and balance pipe but the result was worth the wait and the additional expense.

(https://lh6.googleusercontent.com/-dO88ylaCxd0/UAbH-YXm1uI/AAAAAAAABLE/_C517FSK_So/s720/S6301524.JPG)

The HD viscous fan and clutch also now fitted and just about visible

(https://lh6.googleusercontent.com/-s__mg_Zwshg/UAbH8QhqsCI/AAAAAAAABK8/EYkPWWlf7G8/s720/S6301523.JPG)


The whole balance pipe came out great and I cannot wait to hear the noise it will cause but also feel it's effect on low and mid range torque seeing that we already went with 2.5" zaursts. Lotsa homework wen into that one ...   8)


(https://lh6.googleusercontent.com/-_Obz0MB6tgY/UAbIDHMDWbI/AAAAAAAABLM/hR_QwP8gM0Q/s720/S6301525.JPG)


Who says bling can't be purdy ?


(https://lh4.googleusercontent.com/-RduW69r5J_A/UAbIFXX0qUI/AAAAAAAABLU/V179-ONQJv8/s720/S6301526.JPG)


If all goes to plan and we get the flywheel and clutch assembly back from dynamic balancing this afternoon still, then the motor will be back into Olive tonight. The basic idea is to have her started during the weekend and hopefully have her mobile by this time next week ..  :drinks: 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 18, 2012, 07:58:31 PM
Franken-olive  >:D  8)
Title: Re: Our BJ42 LX rebuild
Post by: milton slabber on July 18, 2012, 09:21:07 PM
Looking windgat Theo. By now I am almost sure you think I am a pain in die gat, but there shorts a bit of Olive on that intake..
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on July 19, 2012, 11:25:59 AM
 8)
 :drinks:
 :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 22, 2012, 04:41:35 PM


The new Spitronics engine management

(https://lh3.googleusercontent.com/-GdPwL6AEjNc/UAwEjCSagHI/AAAAAAAABMM/dv4qDBUyuwE/s720/S6301531.JPG)

The old 3B rubber grommet VS the new Lexus grommet with the now integrated loom.

(https://lh3.googleusercontent.com/-Jrz3HAjUaDg/UAwFDT6xRiI/AAAAAAAABMw/Paokur5Obtc/s640/S7201540.JPG)


Does that look OEM or what ?

(https://lh6.googleusercontent.com/-s5hewdUmvYs/UAwFdv9DlrI/AAAAAAAABNg/lG1auopeO6Q/s720/S6301538.JPG)


Even the OEM fusable links were retained during the integration.

(https://lh6.googleusercontent.com/-iA7Y0HM65CE/UAwFaeP4NUI/AAAAAAAABNY/41yQ3f9dj0Q/s720/S6301541.JPG)


The custom spacer to relocate the spigot/pilot bearing.It allows us the use the standard input shaft with the new custom flywheel and adapter ...

(https://lh6.googleusercontent.com/-PEuU7_6QWBk/UAwEdBs99pI/AAAAAAAABME/VhIKZ_Z2XLU/s720/S6301528.JPG)

It is a press fit item   

(https://lh5.googleusercontent.com/-3fQJsUZmECQ/UAwF0YNXCII/AAAAAAAABN0/DGGVJiHllNY/s720/S6301529.JPG)


The new Exedy HD 275mm 21 spline cruiser clutch assy with custom flywheel all dynamically balanced and ready to go on

(https://lh4.googleusercontent.com/-5Rwp8MFtW1U/UAwEqbViAXI/AAAAAAAABMU/X9eeLaWmUUs/s720/S6301532.JPG)


Spigot bearing visible through the clutch disc splines

(https://lh4.googleusercontent.com/-_delzPwjhNY/UAwEy1UcF5I/AAAAAAAABMk/ttiPRgHDmQE/s720/S6301537.JPG)


All bolted& torqued up  .. just needs a place to sit ...

(https://lh6.googleusercontent.com/-7aJEDHEhwo8/UAwExLcVpGI/AAAAAAAABMc/hg4nl95kvvY/s720/S6301536.JPG)


In she goes ...

(https://lh4.googleusercontent.com/-7kYqUWCpCbI/UAwFM03QNFI/AAAAAAAABNI/fIeXfAMN0nI/s720/S6301544.JPG)


(https://lh4.googleusercontent.com/-1490Tdl1xuE/UAwFJ7GolYI/AAAAAAAABNA/cfl1VPNYyaU/s720/S6301543.JPG)


New belt and check out that huge HD viscous clutch.Also note the nice clearance for the oil filter and then see if you can spot the reason why we can use the OEM oil pressure gauge.We are doing the same with the OEM heat guage   8)

(https://lh5.googleusercontent.com/-zdgMd45mECk/UAwFPHLkuFI/AAAAAAAABNQ/NctH2FlMG00/s720/S6301545.JPG)


We are getting closer    :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on July 23, 2012, 10:04:21 AM
 ;)
Just need a bouncing smiley now  :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 23, 2012, 12:28:15 PM
In my case more like two of them !  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 25, 2012, 07:51:00 PM
Ok the fuel tank is not in yet (will be tomorrow) but a few things did get done during the last 3 days ..

Inside wiring is about 90 % done

(https://lh4.googleusercontent.com/-gaX6w9QYzSw/UBAq0ptdkSI/AAAAAAAABO0/naAk7geU5U8/s800/S6301556.JPG)


Sump clearance is good and high

(https://lh3.googleusercontent.com/-z6V_jV6Wt20/UBAqJjCAZlI/AAAAAAAABOM/sAy_SDOxEsY/s800/S6301552.JPG)


Air intake and oversize snorkel feed is done


(https://lh4.googleusercontent.com/-dWz9FRzVX6k/UBAqSItfi-I/AAAAAAAABOU/j76kUD5yMWA/s800/S6301553.JPG)


Fabrication of the new viscous fan shroud is underway.Will be sent for powder coating asap

(https://lh3.googleusercontent.com/-zyrNNenwd3k/UBAqYWhV2WI/AAAAAAAABOc/JIHRMCNiRy8/s800/S6301557.JPG)


The brand new 2UZ-FE viscous fan blades have been trimmed by 25mm and dynamically balanced   8)

(https://lh5.googleusercontent.com/-_4VNYvi7Z0Q/UBAqGpTmzhI/AAAAAAAABOE/VBJR-Cu-eiw/s800/S6301550.JPG)


1st Start-up has been rescheduled for Saturday but we will see    :-\
  
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on July 26, 2012, 09:35:00 AM
Well done Mark. Exciting times now  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Johann Meyer on July 26, 2012, 03:20:52 PM
Wow, well done. Looking good  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 27, 2012, 09:13:28 AM
Thanks guys, much appreciated !  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 28, 2012, 09:01:13 PM
(https://lh5.googleusercontent.com/-e_LgJjE7uUQ/UBQwFLAAoBI/AAAAAAAABPM/29dax6L9xLQ/s800/S6301558.JPG)


The new nesting place of all the ECU's way out of dust and water  8-)

(https://lh6.googleusercontent.com/-aYrJfTbnWV8/UBQwGicT7kI/AAAAAAAABPU/vSXzuZo6VwA/s800/S6301559.JPG)


(https://lh4.googleusercontent.com/-fO-ndPc_Qlo/UBQwJLtXtwI/AAAAAAAABPk/f7M9gUAVrn0/s800/S6301561.JPG)


(https://lh6.googleusercontent.com/-6odxxaUi-cw/UBQwUXc81CI/AAAAAAAABP0/4_WolfsK3s8/s800/S6301563.JPG)

And he even fixed that old fan that nobody can ever repair

(https://lh3.googleusercontent.com/-ayQi_ZrqsYo/UBQwXknYuzI/AAAAAAAABP8/Mjvo0PSaoSQ/s640/S8001564.JPG)


Keith, there is your solution


...  :wink:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 29, 2012, 05:24:58 PM
looks good, now go and fetch it, so  I can have a look for ideas to mount my ECU  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 29, 2012, 07:51:26 PM
Did I mention that after connecting the ECU Mark put some fire to the wire yesterday ? The idea was just to swing the motor over and to see if it would turn and check for potential wiring faults. Well after priming the fuel pump twice he turned the key and she barked right into life on the very first swing.Mark was so impressed with her that he promptly phoned me and had me listen over the phone.Even more impressive was the very good & immediate oil pressure even on the OEM BJ gauge - just over halfway on the gauge at cold idle !! Obviously we couldn't idle her much as the radiator was still missing due to the work on the new shroud. I did not get much sleep last night  8) 
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 29, 2012, 08:34:43 PM
Today I finished the 2 front doors to the point that the upholsterer can now do his thing. Honestly it was a PITA job probably made worse by the fact that I waited too long before I tackled them and had a bit of a struggle to piece the bits together ..   |(


Made some new plastic and rubber gaskets ..

(https://lh4.googleusercontent.com/-FE-6AO9bu6A/UBVy3JbakiI/AAAAAAAABQY/ZNtcA6AfTxI/s800/DSC_0489.JPG)


(https://lh5.googleusercontent.com/-UCvk_fHQ8gE/UBVy7R-i5QI/AAAAAAAABQg/NzTMGQzKI50/s800/DSC_0490.JPG)


(https://lh3.googleusercontent.com/-9HbDJyVPMco/UBVzjZ5wi5I/AAAAAAAABQo/kPkFAme1iVc/s800/DSC_0498.JPG)

Some new parts ....

(https://lh4.googleusercontent.com/-ZIZvWWCA2ww/UBVzqV4t79I/AAAAAAAABQw/PCG4dtIK0r8/s800/DSC_0500.JPG)

(https://lh3.googleusercontent.com/-C_8TsACndoQ/UBV1bRF0JjI/AAAAAAAABRg/VjAL2tzPVRY/s800/DSC_0505.JPG)


(https://lh3.googleusercontent.com/-cz6yiK4UZJo/UBV0Jsj77rI/AAAAAAAABQ4/1BkEu1SbdXw/s800/DSC_0503.JPG)

The 2nd one was not easier ...


(https://lh6.googleusercontent.com/-lvXa-fdBb_8/UBV0RDhIMNI/AAAAAAAABRA/VL0C4zoafKs/s800/DSC_0504.JPG)


Can you see the problem ? On the pax door there were factory holes to allow for those clips to clip into but on this door there were only those tiny round holes like on the opposite side.Suddenly it made sense why the truck was missing that piece when I bought her Darn PO never bothered to make a plan to fit that piece.

(https://lh6.googleusercontent.com/-MEH5FDI8Af8/UBV0gnVaQII/AAAAAAAABRI/cyFIFp9eslc/s800/DSC_0511.JPG)

I removed those square metal clips and after trying out those "spring loaded pinch clips" , I ended up using some removable glue ..


All done


(https://lh6.googleusercontent.com/-ghKB6lMQ19Y/UBV01--dSMI/AAAAAAAABRQ/rU64OUkAS_g/s800/DSC_0513.JPG)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 29, 2012, 08:41:31 PM
Looking good  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 29, 2012, 09:21:52 PM
Thanks ! Here are the fresh pics ...

The new viscous fan-shroud needed to be bigger and centered downwards & to the left. This meant some cutting and plenty of welding. Tomorrow it will be grinded down smooth and sent for powder coating ..


(https://lh5.googleusercontent.com/-b51z-_Fivk0/UBWFU_tQJXI/AAAAAAAABR8/Ps-IZtLFcp8/s800/S6301566.JPG)



(https://lh5.googleusercontent.com/-RDnGQx3p8N0/UBWFcaN-8hI/AAAAAAAABSE/fS8kDxY1oUA/s800/S6301565.JPG)



The new shroud "allowed " the use of some more SS for new water lines ..



(https://lh4.googleusercontent.com/-zsi-xWugnI4/UBWFrxm7V6I/AAAAAAAABSU/HVqTlg0PxKI/s800/S6301568.JPG)



(https://lh3.googleusercontent.com/-rHLvQoeTYaE/UBWFnDSdFWI/AAAAAAAABSM/zuTLnyZQuDc/s800/S6301567.JPG)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 01, 2012, 05:48:18 PM
 :drinks: :drinks: looking good
 8)

cant wait to hear that she is running.. and all done!!

been one hellava process!! Thanks for sharing
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 04, 2012, 04:07:09 PM
Thanks Mark ! She is running at the moment and will prolly go to the dyno on Tuesday.Mark will drive her home for the first time today  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 05, 2012, 02:08:12 PM
Finally we are in the home straight   :whew:


(https://lh6.googleusercontent.com/-zvJxjPYgst0/UB5dTK8rDfI/AAAAAAAABS0/jCjTe8yKOBw/s800/20120804_141428.jpg)


(https://lh5.googleusercontent.com/-mHphi8ipymM/UB5c-9WvWtI/AAAAAAAABSs/9o6Xo2ZdDA8/s800/20120804_154138.jpg)


Does this look OEM or what ?  8)


(https://lh5.googleusercontent.com/-fcx5ThvlpFg/UB5c6QgluSI/AAAAAAAABSk/iS6uDBXaEDE/s800/20120804_115505.jpg)


On her own steam again   ;)


(https://lh4.googleusercontent.com/-QwQzvw7imO8/UB5drbOACMI/AAAAAAAABS8/BFGss1BVVoc/s800/20120804_152454.jpg)


(https://lh4.googleusercontent.com/-3BWgho8yikw/UB5dxG-9JHI/AAAAAAAABTE/XquOnr8k4R4/s800/20120804_152514.jpg)


Now for the Dyno results on Tuesday !

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on August 05, 2012, 05:11:20 PM
 :drinks:

Looking very  8)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 05, 2012, 09:02:44 PM
 :whew: looking  8)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 06, 2012, 01:05:10 PM
 8)
and that DIESEL badge on the front  :jt:

 :jt:

I hope she lives up to all your expectations and more!!

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 10, 2012, 04:23:24 PM
No news  :-\ I thought today was Dyno day  :'(
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 10, 2012, 05:40:31 PM
Ok guys, here goes:

On the wheels: 143 Kw  and 268  Nm torque with 80% of the latter available from about 1000 Rpm. When converted to sea level and flywheel figures it becomes very impressive.  8)

What impressed me the most is the fact that we seemed to have absolutely nailed the cooling system.During the entire dyno run the water temp never went above 85 deg C and the usual 1/3rd up on the OEM gauge.Even more impressive was the fact that they initially had to switch the blower fans from the front off in order to get the motor out of the OEM cold start settings ie 60 deg C. So combination of the 3 core radiator, 2 UZ viscous fan & coupling together with the slightly larger sump should be able to handle any off road situation that we will throw at her 

 :drinks: 
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 10, 2012, 05:44:59 PM
Congrats Theo, now you have a whole week to wait before you can drive her  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 11, 2012, 03:50:33 PM
Got a bit done ....

The square Ambi glass rubbers are no longer available from Toyota but after a loong search I found the 1980 Datsun/Nissan windscreen rubber to be an almost exact match   8)

(https://lh6.googleusercontent.com/-WdOkj96U75U/UCZY3w-s3hI/AAAAAAAABTk/FF9dQglkHV0/s800/DSC_0541.JPG)


(https://lh3.googleusercontent.com/-5OgPGpg5dIE/UCZY-WHXXLI/AAAAAAAABTs/rUvFG8fTOM8/s800/DSC_0540.JPG)


Insides doused with Rust Bullet & Tectyle spray ...


(https://lh5.googleusercontent.com/--coMG_v18xc/UCZZuQNVoHI/AAAAAAAABT0/BCUMu2LbvOg/s800/DSC_0516.JPG)


New hardware as always ...


(https://lh3.googleusercontent.com/-1LcpUNnrLMc/UCZZ-39diQI/AAAAAAAABT8/kQRrp1__6xM/s800/DSC_0530.JPG)

Did I mention that I love Rust Bullet ?

(https://lh5.googleusercontent.com/-1X1XJEvJ7M4/UCZaLXUNX0I/AAAAAAAABUQ/P6iC0L5Axq8/s800/DSC_0536.JPG)


Ready for the upholsterers ..

(https://lh5.googleusercontent.com/-5J562CS7AKA/UCZaGHrCa7I/AAAAAAAABUE/hBdjpy3f8E0/s800/DSC_0535.JPG)


(https://lh6.googleusercontent.com/-TyrG3lZtWN4/UCZbFmp5nbI/AAAAAAAABUY/WAbQYtXJj3A/s800/DSC_0521.JPG)


(https://lh5.googleusercontent.com/--b1A51bQipY/UCZcF9Wf0cI/AAAAAAAABUg/AIx6JMIRvko/s800/DSC_0523.JPG)


If you Toyota parts guy claims that the Lisence plate light assy for the 40 ser is no longer available then tell him to search under the Gen/European 60 ser bumper light - exact same part !

(https://lh5.googleusercontent.com/-goIYLpO6M4M/UCZcTL2mCUI/AAAAAAAABUo/dhLJ0MbcPIg/s800/DSC_0545.JPG)

I am a rookie spray-gun holder but did try to play around to create a "hammered" finish ....

(https://lh5.googleusercontent.com/-ixERRRGrZdA/UCZcdTitUCI/AAAAAAAABUw/EReJuX-8nNE/s800/DSC_0552.JPG)


(https://lh6.googleusercontent.com/-ONUBZnG8CaA/UCZclNHLriI/AAAAAAAABU4/Agxbd8QshSU/s800/DSC_0555.JPG)


(https://lh4.googleusercontent.com/-moyjqjsx_SQ/UCZcvPs1jNI/AAAAAAAABVA/l136z6bN4KA/s800/DSC_0559.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on August 13, 2012, 09:26:16 AM
Congrats Theo - stunning! And leave the diesel sign there because it could cause some uber confusion at the robots in Bellville  ;)

Where did you source the door window rubbers? Part numbers?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 13, 2012, 04:31:24 PM
Thanks, badge will stay as a tribute to encapsulate the old motor's spirit into the new one. 8)   


All part numbers are in the pics oom  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 14, 2012, 01:49:29 PM
 8)
so when you fetching?

or you need someone to spin around the block here a few times to make sure all tight and good?  :P
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 14, 2012, 05:00:48 PM
Yes he does, but it certainly wont be a v8hater purist like yourself, wouldn't want to spoil you  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 14, 2012, 05:53:30 PM
Landing Thu and collecting Friday morn, Mr Fish.   8)  Then a 3 day road trip  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 16, 2012, 06:46:07 PM
D-day bump  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on August 17, 2012, 11:55:56 AM
Smiling...  :drinks:

(https://lh6.googleusercontent.com/-9759XenEnV8/UC4BYutdkhI/AAAAAAAAFnI/V0aqnN_Uo_w/s640/IMG_1064.JPG)

.. still smiling!  :meeting:
(https://lh5.googleusercontent.com/-Dltsmwvg6LI/UC4BiECqYDI/AAAAAAAAFng/syVcZ8H-6l0/s640/IMG_1067.JPG)

Ready to Rock and Roll at about 08:30 !  ;D

(https://lh3.googleusercontent.com/-Q4O8qISjCLc/UC4BkD0kWXI/AAAAAAAAFno/FN1aUrJ0uC8/s640/IMG_1068.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on August 17, 2012, 11:58:33 AM
Time for the Hardtop!  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 17, 2012, 12:21:45 PM
 :drinks: thanks for the update Adolf
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 17, 2012, 08:40:58 PM
Thanks for all the phone calls and SMSs guys. :drinks:

 Having an absolute blast -  JT you are going to love that truck when you are done, trust me  8)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 18, 2012, 10:36:24 AM
 :drinks:
enjoy..
drive safely and hope you dont freeze to death!!
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 19, 2012, 02:34:11 PM
Just got back  :drinks:

The weather only turned foul from Mosselbay onwards  :whew:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 19, 2012, 03:30:52 PM
Bump...

...pics and video  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 19, 2012, 04:38:05 PM
Why don't you impersonate ?  :P
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 19, 2012, 05:51:27 PM
sounded something like this  >:D

Spitfire under bridge (http://www.youtube.com/watch?feature=endscreen&NR=1&v=Xf3UtmHLKUU#)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 19, 2012, 09:38:38 PM
It sure does  ;D :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on August 20, 2012, 11:28:32 AM
Quote
All part numbers are in the pics oom

Okay Mr Happy Chappie, show me in which pic the Nissan lubber part numbers are shown
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 20, 2012, 12:18:23 PM
Eish oom, I didn't buy them from Nissan.It was from Pro Auto Rubber and it was the 1980 generic Datsun W/S rubbers.I suggest you take your old ones and head to your local PAR store and buy a roll.If you can't I will buy you some down here but be aware that your trokkie will then also no longer be OEM,original etc etc ... BUT be aware, some folk might also start reporting you to the "powers that be" for any little nitpicking straw  :P :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on August 21, 2012, 09:00:41 AM
Theo:
Quote
The square Ambi glass rubbers are no longer available from Toyota but after a loong search I found the 1980 Datsun/Nissan windscreen rubber to be an almost exact match

Shaun:
Quote
Where did you source the door window rubbers? Part numbers?

Theo:
Quote
All part numbers are in the pics oom

Shaun in exasperation:
Quote
Okay Mr Happy Chappie, show me in which pic the Nissan lubber part numbers are shown

Theo:
Quote
Eish oom, I didn't buy them from Nissan.It was from Pro Auto

So why didn't you say so in the beginning? And it is not necessary to resort to demeaning sarcasm like
Quote
but be aware that your trokkie will then also no longer be OEM,original etc etc ... BUT be aware, some folk might also start reporting you to the "powers that be" for any little nitpicking straw

 >:D  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 21, 2012, 11:33:25 AM
With seemingly so much time on your frail hands, to type such longwinded drivel, I assume that the LT 2012 trip planning has been completed ?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on August 21, 2012, 03:33:13 PM
Been too busy trying to source ambo door window rubbers from Nissan  :P
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 21, 2012, 08:06:09 PM
 |( They will not have - go to PAR and ask for the 80's E20 W/S rubber by the running meter.Glassfitt will shape and install them for ya at a smallish fee  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 22, 2012, 07:36:35 PM
Thanks for the ride  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 22, 2012, 09:44:19 PM
Looked and sounded as if you enjoyed it  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on August 23, 2012, 08:41:37 AM
Both of you will never ever enjoy a classic 2F anymore!  :'( Not to even mention the mighty 4500EFI or a Turbo Diesel!  :jt: >:D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 23, 2012, 09:36:35 AM
If need a dose of nostalgia, I can loan one of your's  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 23, 2012, 11:03:56 AM
I can loan one of your's  >:D

or just rent a thirsty mule somewhere  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Seele on August 24, 2012, 03:49:49 PM
so what was the consumption on the way down?  :-\
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 24, 2012, 09:29:31 PM
Overall @ 6km/l but .....  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on August 30, 2012, 07:11:10 PM
Whenever the weather "allows" I continue to work on getting the roof back on ..

Empty hard top panels back on after all these years

(https://lh6.googleusercontent.com/-qtePJrIK1CY/UD-MYloYzSI/AAAAAAAABX0/frxtez2Rxcw/s800/DSC_0052.JPG)

New hardware and the bottom rubber strip/cushioning I made from quality rubber

(https://lh5.googleusercontent.com/-kLJi0uwNvEY/UD-MfQ6gZGI/AAAAAAAABX8/AcEsmGGksyo/s800/DSC_0054.JPG)

I used the same rubber to make some pads to fill the gaps at the top sill(the PO used seem sealer) but I want this top to be easily removable when needed

(https://lh4.googleusercontent.com/-UawpnOZdnvw/UD-MRhwGMNI/AAAAAAAABXo/EDarttyqoi0/s800/DSC_0057.JPG)


(https://lh4.googleusercontent.com/-cvDbd4e-USs/UD-MF8O9OKI/AAAAAAAABXY/Hrs_fyrVNck/s800/DSC_0063.JPG)


(https://lh3.googleusercontent.com/-R-fz_drIawo/UD-MAqe1MQI/AAAAAAAABXQ/Mwhm_JDcyIM/s800/DSC_0065.JPG)


New leather upholstery for the door panels - I am undecided on the lighter colour and the stitching pattern.At least I used new OEM door rubbers - they were a much better fit than the ambi door rubbers ..

(https://lh6.googleusercontent.com/-kh6mGLOHtho/UD-Mp2PPToI/AAAAAAAABYE/Z_GbYycURbw/s800/DSC_0076.JPG)


(https://lh3.googleusercontent.com/-8St-2yliVug/UD-MxiydVZI/AAAAAAAABYM/a1HXjbmeTro/s800/DSC_0080.JPG)
 

New ambi door rubbers

(https://lh4.googleusercontent.com/-VHYspDhmM5Q/UD-L58K1PEI/AAAAAAAABXI/oIR6-Uy4Da4/s800/DSC_0066.JPG)


With all doors and glass fitted as of this afternoon ..


(https://lh4.googleusercontent.com/-HkjKJn0Byfg/UD-M5_gdREI/AAAAAAAABYU/doaanI3-314/s800/DSC_0083.JPG)


(https://lh5.googleusercontent.com/-dL0PKfr79XM/UD-Nbzd-5JI/AAAAAAAABYg/rak9BBSyfGM/s800/DSC_0082.JPG)


Now for the new rain-gutter and the roof nightmare ...

 :D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on August 30, 2012, 07:47:33 PM
 ;D
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on August 31, 2012, 08:53:20 AM
Now that looks the business!  :drinks:  8)

Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on September 03, 2012, 07:37:40 AM
 8)
Now Olive is starting to look the part!!!!
Very nice Theo!!
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 03, 2012, 10:06:02 PM
Thanks guys, much appreciated  :drinks:

With less than 3 weeks before our next trip the pressure is on to try and finish the roof.This afternoon the rain-gutter kit that I bought from SouthbostonFJ got welded together. Fitment was good ..

(https://lh5.googleusercontent.com/-VKGA_4f_7Do/UEUFGygcftI/AAAAAAAABY0/tUNtbTgi-tU/s800/DSC_0087.JPG)


Trimming and drilling the new holes


(https://lh6.googleusercontent.com/-xZcrUULyVqk/UEUFQTOXHOI/AAAAAAAABY8/OyRafOuvuMg/s800/DSC_0089.JPG)


All done and ready for the next step

(https://lh6.googleusercontent.com/-CXwbgZ1_qDQ/UEUFZbLvfLI/AAAAAAAABZI/RJRVOQdfTGU/s800/DSC_0092.JPG)


 :whew:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on September 04, 2012, 09:14:30 AM
Lokking excellent!  8)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on September 04, 2012, 11:14:00 AM
Next step - Rust Bullet >:D
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 04, 2012, 11:35:14 AM
 ;D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 04, 2012, 11:54:52 AM
Nope, first need to drill new poprivet holes before RB  :-*
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 04, 2012, 09:36:43 PM
Add then the wheels fell off...

(https://lh3.googleusercontent.com/-7Ht1ct2Nn1M/UEZYEFt8u2I/AAAAAAAABhQ/tv2SxF5o8IA/s800/theows.JPG)

8) bumperettes...
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on September 05, 2012, 08:55:24 AM
Very  8) bumperettes !  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 05, 2012, 10:36:55 AM
I thought you would like em OD  :drinks:

I have come to also like them  :-[ 8)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on September 05, 2012, 10:37:57 AM
Soooooo cool!!! :D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on September 05, 2012, 02:04:48 PM
Wow Theo - I dont believe it - you are finally attempting your roof install

well done ! ! !
Title: Re: Our BJ42 LX rebuild
Post by: Shaun Cullen on September 05, 2012, 07:57:56 PM
Goferit Theo - fantastic!

Like the new lounge  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 05, 2012, 08:18:29 PM
Thanks guys  :drinks:

Today I started on the dreaded roof itself ..

(https://lh5.googleusercontent.com/-GjYdr9n9Ftw/UEeSlhlvbvI/AAAAAAAABZY/oL_DI1idy0Q/s800/DSC_0093.JPG)


I lost count how many pop rivets I had to remove but found the best way of doing it, was to grind the heads off and then punching them with a center punch before drilling them out. I also found traces of bondo on the underside of the old gutter   |(


(https://lh4.googleusercontent.com/-BDB95wJfe_s/UEeSwNpEyuI/AAAAAAAABZg/in8sNyyqiuk/s800/DSC_0102.JPG)


I thought removing the rivets would be a PITA but it was nothing compared to the seam sealer ...


(https://lh6.googleusercontent.com/-rzvTS_0z7Rs/UEeS6PLOr0I/AAAAAAAABZo/-Br-_AlJjis/s800/DSC_0105.JPG)


All done bar the W/S piece  that will only be done later

(https://lh4.googleusercontent.com/-YNXyNCBmAf8/UEeTFz1BznI/AAAAAAAABZw/0BUM7c83-Iw/s800/DSC_0110.JPG)


The old bits


(https://lh6.googleusercontent.com/-iUBBsl4AROA/UEeTPfMBhtI/AAAAAAAABZ4/Nge_57tYN7o/s800/DSC_0111.JPG)

 :whew:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 05, 2012, 09:11:34 PM
Job well done  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on September 06, 2012, 08:57:35 AM

Today I started on the dreaded roof itself ...

What medicine did you take?!  >:D  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 06, 2012, 09:17:36 AM
JontiBiotics   :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on September 06, 2012, 02:30:51 PM
I guess this means you will not be in Yzerfontein this weekend...
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 06, 2012, 02:31:58 PM
Nope, too much wek on Olive  :whew:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 06, 2012, 07:55:54 PM
Today I removed the last of the old seam sealer all around the edge of the fiberglass roof cap.Then it was time to see if it would fit into the gutter frame - I was a bit concerned as I have had to cut and reweld the front of the frame 3 times already  :oops:

Moment of truth

(https://lh5.googleusercontent.com/-3sq9s7yzKCo/UEjgfqwWK_I/AAAAAAAABaI/T88gD45929g/s800/DSC_0119.JPG)


The problem frontal area now sorted

(https://lh5.googleusercontent.com/-VagtoF3yqbc/UEjgoyEp4tI/AAAAAAAABaU/8ku1DXtjAtE/s800/DSC_0120.JPG)


(https://lh6.googleusercontent.com/-IB29Qn7bRcw/UEjg1JLJyXI/AAAAAAAABac/eEqgIqV0T5o/s800/DSC_0122.JPG)


Then I removed the W/S channeling


(https://lh4.googleusercontent.com/-BgjHXcPppic/UEjhBB57L9I/AAAAAAAABak/Si5k-LnY9Xs/s800/DSC_0127.JPG)

Questions: Would Sikaflex without rivets be strong enough to hold the F/G cap to the gutter and the W/S channeling ?

Do I fit that W/S channel piece first or can I fit it after attaching the gutter to the F/G cap ?
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 06, 2012, 08:09:30 PM
Q1: use the rivets too.

Q2: fit loosely between the windscreen frame and roof cap, with roof mounted to vehicle, then you can make any adjustment before you permanently mount it.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 09, 2012, 01:59:49 PM
Although the gutter was covered in good quality primer(no signs of corrosion after 2 years storage) my addiction to "Rust Bullet" won again ...

Make shift spray booth

(https://lh5.googleusercontent.com/-01L7YA0_xe8/UEudCPcxhlI/AAAAAAAABa0/_REDGV7FAuw/s800/DSC_0129.JPG)


(https://lh6.googleusercontent.com/-kVIdkiWo7hg/UEudSiTgG_I/AAAAAAAABa8/5jI42Hlw3DM/s800/DSC_0131.JPG)


I eventually decided to attach the FG cap using a combination of sealant and blind/sealed poprivets.However instead of using Sikaflex I opted for the Wurth corresponding product as it is also MCU and Xylene based, making it ideally compatible with the Rust Bullet.  8)

(https://lh5.googleusercontent.com/-LPsDw-Xzs9Y/UExw70BFzCI/AAAAAAAABbM/PdPCLFdnxTg/s800/DSC_0137.JPG)

All sealed and back into the frame ready for the rivet holes to be drilled - first 3mm and then 4 mm

(https://lh4.googleusercontent.com/-ovlsvn2BieU/UExxIS6WplI/AAAAAAAABbU/FLgAiU-teLc/s800/DSC_0144.JPG)


For the riveting I had managed to secure a pneumatic riveter from a buddy who owns a well known shop.Unfortunately someone seemingly forgot to inform the staff, so when I arrived it was safely locked away and the keys MIA! >:D I can confirm that there are exactly 127 of those little buggers in total ...

(https://lh6.googleusercontent.com/-JL8PV5eT_B0/UExxN-CyXhI/AAAAAAAABbc/bwHuXA3xzBs/s800/DSC_0149.JPG)

And suddenly none of my buddies answered their phones !  |(

(https://lh5.googleusercontent.com/-uEw_r-VyqBU/UExxZMnM89I/AAAAAAAABbs/RAi18lP9srw/s800/DSC_0150.JPG)


Finished at last

(https://lh5.googleusercontent.com/-5Ft0ic7Glu4/UExxeye1u0I/AAAAAAAABb4/lTu8fGNR2xY/s800/DSC_0153.JPG)


(https://lh5.googleusercontent.com/-ERqR9yd1pyM/UExxkqjaWiI/AAAAAAAABcA/MZDGVKmL7zY/s800/DSC_0154.JPG)

I will do the self leveling seamsealer that SouthbostonFJ supplied in the next day or two but I doubt if there will be enough time to paint the roof before our trip next week but who cares - the worst is done !    8)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on September 09, 2012, 04:39:21 PM
Always good to have a good, solid brick foundation.
 ;)
Looking good Theo!
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 09, 2012, 08:11:26 PM
I see the foundations, and I see the roof... but I think you forgot the walls  :-\

BTW mah phone did not ring, guess I am not a buddy, or maybe your fingers were too tired to press the dial button  >:D

Well done  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 10, 2012, 08:22:37 AM
BTW mah phone did not ring, ..

Chuck that fruity phone away  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on September 10, 2012, 08:37:23 AM
BTW mah phone did not ring, guess I am not a buddy, or maybe your fingers were too tired to press the dial button  >:D

(http://factoryjoe.s3.amazonaws.com/emoticons/emoticon-0140-rofl.gif)

Btw, me neither ... :jt:

Welldone!  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 10, 2012, 12:12:22 PM
Thanks guys !  :D

So what is the code/name for the white roof paint, please ?
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 10, 2012, 01:14:00 PM
W-Hit-e
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 10, 2012, 02:28:34 PM
Try Cygnus T012 !
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 12, 2012, 09:04:03 PM
A small update in between  the roof resto ...

License plate lights are now working

(https://lh3.googleusercontent.com/-E0j1v_ftJLk/UFDTxfbVLYI/AAAAAAAABck/TJM7xGLuNMI/s800/DSC_0155.JPG)


Speakers for the newly upholstered full doors


(https://lh5.googleusercontent.com/-6A84hoeH-gs/UFDT9ze1mBI/AAAAAAAABcs/OVBzbIU6q8w/s800/DSC_0166.JPG)


And finally ...

 To: Dad




(https://lh3.googleusercontent.com/-JgVM9HVonBU/UFDUGE-ugLI/AAAAAAAABc0/l8frdHZmC5g/s800/DSC_0159.JPG)




 From : Dad     :D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 16, 2012, 01:47:49 AM
For JT and Mark  :wink:

 (https://lh6.googleusercontent.com/-rvyVnhuLuQo/UFUNH9vVOVI/AAAAAAAABdE/KQxGNv6xrW4/s800/DSC_0167.JPG)

So what type of oil do I use in the blanked-off A/C and how much do I put in ?


Now for the good part ...

(https://lh4.googleusercontent.com/-dl7D3otbkTY/UFUNN5E3wuI/AAAAAAAABdM/yUVcFFd-B0M/s800/DSC_0169.JPG)


(https://lh6.googleusercontent.com/-FViy4c43fBc/UFUNW3bhcfI/AAAAAAAABdU/6LKt-9Rx3sU/s800/DSC_0173.JPG)

The top is nice but the sides of the gutter is still crap from the seam sealer - I just simply ran out of time and willl redo it after our trip this week.

(https://lh4.googleusercontent.com/-NMMEH8Oxxv0/UFUNdCaew3I/AAAAAAAABdc/C-MAvB_X7ew/s800/DSC_0176.JPG)

New hardware as usual ..

(https://lh4.googleusercontent.com/-sA9U3TkDRAk/UFUNk4WHDBI/AAAAAAAABdk/balEOzo0VVk/s800/DSC_0179.JPG)


BUT after a long 4.5  years ...  

(https://lh6.googleusercontent.com/-5sGjYCodktA/UFUNq_BZ-SI/AAAAAAAABds/96DdTVvEsAk/s800/DSC_0180.JPG)


(https://lh5.googleusercontent.com/-Fwg-lL9-WkU/UFUN3uhtczI/AAAAAAAABd4/5mz0eKwVO-8/s800/DSC_0187.JPG)


(https://lh3.googleusercontent.com/-b6faXuD8oKc/UFUOFXLMEZI/AAAAAAAABeA/BsOdxPvG9jg/s800/DSC_0183.JPG)


(https://lh6.googleusercontent.com/-EpOBNUdMOFM/UFUOlti2LaI/AAAAAAAABeQ/5NQvTkIdx9k/s800/DSC_0182.JPG)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on September 16, 2012, 08:40:08 AM
Well done  :drinks:  8)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on September 16, 2012, 04:24:36 PM
Very, Very, Very nice!!!!!!! :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Grahame Burchell on September 17, 2012, 08:06:57 AM
Well done!! Now you have a "Full Cruiser". No more freezing your Butt off.  ;D
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on September 17, 2012, 09:10:50 AM
Eventually  >:D , the work has been completed!  :drinks:

Looking very  8) .
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on September 17, 2012, 09:46:09 AM
Thanks guys, much appreciated !  :drinks:

, the work has been completed!  :drinks:


Actually there is still quite a bit to be done but it can wait till after our Legends Trip  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on September 17, 2012, 03:25:43 PM
At Last  ! ! ! !

Well done Theo
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 17, 2013, 10:56:40 AM
Mr Yoda sent me some goods as part of our ongoing maintenance/upgrade plan  ;)

(https://lh5.googleusercontent.com/-pKvVyi2natA/UZXqs-9cxkI/AAAAAAAABvk/rfru_iqBuM4/s720/DSC_0002.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 17, 2013, 01:40:33 PM
Glad to see you have the gas cap - would be interested to see if that gearbox mount is the same PN as mine - I will check when I get home, but I think mine is now under the gearbox so may not be that easy  ???
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 17, 2013, 03:06:28 PM
Toyodiy only lists it for all the B,2B and 3B models 40/42/43/45/47/60/62 interestingly enough irrespective whether it is 4 or 5 speed !  :o
Title: Re: Our BJ42 LX rebuild
Post by: Allan Rice on May 26, 2013, 11:28:39 AM
then I removed the padded dash..


(http://lh4.ggpht.com/coleenmarx/SAUI2u3YDcI/AAAAAAAAArg/3RG5cX59vFM/P1020567.JPG?imgmax=512)


.. and found this underneath


(http://lh4.ggpht.com/coleenmarx/SAZiYe3YDnI/AAAAAAAAAts/uwrk8CJXAaQ/P1020636.JPG?imgmax=512)



 8O Any ideas what it is? I just labelled the wires and continued onto the speedo cluster. With most of the other gauges and switches etc done it came out with little fight..
It is the light to illuminate your gauges, think it is a 10w festoon bulb
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 26, 2013, 05:20:11 PM
It is supposed to illuminate all the control knobs on the dashboard Allan  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 02, 2014, 08:52:03 AM
My new 4 core Aluminum radiator from Champion Radiators finally arrived from the US. It is a thing of beauty !

(https://lh5.googleusercontent.com/-hpboD-AnYs4/U2KEzXf5EoI/AAAAAAAACLo/ZCeCYIB3O4o/s800/DSC_0605.JPG)

And the quality is every bit as good as what was claimed

(https://lh3.googleusercontent.com/-81J_JxN3iSw/U2KE8un6dWI/AAAAAAAACLw/Ak-CLxkPBv4/s800/DSC_0607.JPG)


I had read that the 4 core might not be a complete simple "bolt in and go job" like the 3 core is but it was easy enough.In total I had to drill only 2 holes in the radiator's mounting flange on the LHS and I had to trim the radiator support at the bottom on all 4 corners by about 3 mm.I also enlarged the oem access hole to the radiator drain and that was all that was required.

(https://lh5.googleusercontent.com/-jM1b3OyEBf0/U2KFDZVJ-zI/AAAAAAAACL4/dITIJh9GhTY/s800/DSC_0610.JPG)


(https://lh4.googleusercontent.com/-vKiS9lDS9ZM/U2KFK5VeZMI/AAAAAAAACMA/yf8rB5Dbd-s/s800/DSC_0613.JPG)


(https://lh4.googleusercontent.com/-FNuplTsG8_M/U2KFYXQAmmI/AAAAAAAACMI/p9hIZhSe6oY/s800/DSC_0615.JPG)


I had to strip the entire front end away in order to fit it back.In this regard it gave  me an opportunity to view some of Mark's "hidden" work that was done during the conversion.It is here where the attention to detail came out - well done Mark ! These are the custom things that take so much time to do right and usually end up never being seen by anybody else !   8)

(https://lh6.googleusercontent.com/-BMleAXRLPUY/U2KFtcTCWMI/AAAAAAAACMY/er7uYRsFSZc/s800/DSC_0625.JPG)


(https://lh4.googleusercontent.com/-LRJ5xPAXXuU/U2KFe-lC4mI/AAAAAAAACMQ/imrAqPrDw9c/s800/DSC_0617.JPG)


All back together ...


(https://lh4.googleusercontent.com/-RZFXrsKeMiY/U2KF5AAt2YI/AAAAAAAACMg/0E8P53K3w6M/s800/DSC_0628.JPG)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 02, 2014, 09:43:15 AM
Nice  8)  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Rob Wright on May 03, 2014, 01:19:10 PM
Looks Like a Quality Radiator ,See on the bottom tank you got 2 plastic blanking plugs
confirm this an Option to fit a trans cooler if you were running Auto box .
Olive really looking  8) now that its all  completed . :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 03, 2014, 07:07:44 PM
Thanks and yep Rob,I really thought you would be the one to spot it.Mostly needed for the beloved auto boxes in the US, although I have to be honest and admit that I stood there rather temptingly looking at it and those OEM P/S lines shaking my head ... so who knows what will happen tomorrow ...
Title: Re: Our BJ42 LX rebuild
Post by: Rudi Hinze on May 04, 2014, 09:03:53 PM
Theo, you can also use it as an oil cooler for the engine oil...
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 05, 2014, 08:56:11 AM
You sure can Rudi  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on May 05, 2014, 11:49:46 AM
you have to wonder how much cooler the oil would be - i think it would make the PS oil hotter and debatable whether it would make much difference to the engine oil temp, as the block is water cooled already.

But I did notice the bungs and wondered why they were not pink  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 05, 2014, 12:12:28 PM

At the moment the PS lines are only air-cooled so the radiator should be an improvement but I am not convinced that the OEM setup needs to be improved.Same goes for the oil as at the moment the oil is only cooled indirectly while if a oil cooler is utilized then the oil is also directly cooled ?
 
..but did notice the bungs and wondered why they were not pink  >:D

Only you would notice such things  >:D
Title: Re: Our BJ42 LX rebuild
Post by: Rudi Hinze on May 07, 2014, 07:23:45 AM
you have to wonder how much cooler the oil would be - i think it would make the PS oil hotter and debatable whether it would make much difference to the engine oil temp, as the block is water cooled already.

But I did notice the bungs and wondered why they were not pink  >:D

An (engine) oil cooler situated in a radiator can actually serve two functions. Firstly, it can heat the cold oil quicker and then, it keeps the oil temperature stable. Merely relying on oil volume to keep the oil temperatures down is dangerous. Water in an engine block does not invariably serve to cool the oil. It cools the block. A block which is cooler than the engine oil will invariably draw heat from the oil but this is an inefficient process.

Engine oil temperature ideally needs to be near water's boiling point. However, after that it quickly reaches a point where the oil starts to break down.

Even power steering oil can quickly become too hot when slow driving occurs with the power steering system working hard (off road driving). Nothing cools the power steering oil and it can then also boil. So, to cool it (or rather, to keep the temperature stable) cannot be a bad thing.

If I am wrong, then all racing cars and even the mighty Bugatti Veyron with its 10 radiators have it all wrong.

Nothing precludes Theo from not using the ports on the bottom of the radiator.
Title: Re: Our BJ42 LX rebuild
Post by: Rob Wright on May 07, 2014, 08:42:57 AM
 Agree with Rudi .
  My 100 series had a pipe arrangement to assist with cooling power steering oil ,
  and after driving for an hour or so ,pipes were too hot to hold with very minimal diff
  at start and end of pipe .Since fitting bigger intercooler and having to modify steering
 cooler to an Air type ,after a few hrs driving ,outlet on cooler I can hold the pipes without
 getting burnt ,High oil temps causes all sorts of issues with seals etc .Will be interested to
 see how long my pump and steering rack lasts on my 100 as per norm 200K seems to be
 when they start giving problems .Same should apply to the 40 .
 Theo might be an idea to measure yr steering oil temp and see if its worth converting to
 using the Rad cooler bearing in mind that temps of coolant in that bottom tank going to be
 on average around 60' C .
 Maybe sometimes things better left alone if not giving a hasstle . ;D
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on May 07, 2014, 09:04:32 AM
Theo, please post details of Champion Radiators. Would like to get same!
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 07, 2014, 07:47:33 PM
Adolf it is from www.championradiators.com (http://www.championradiators.com) - I went for the more heavy duty 4 core/row MC 180 model rather than the stock CC 180 3 core/row. MC 180 is rated to cool a 600 hp motor so foir our ZA temps it is perfect.I bought and shiped it via Leadfootracing which has a very good reputation on EBAY.Champion is also the only supplier that I could find who offers a lifetime guarentee ..
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on May 08, 2014, 08:46:53 AM
Thank You!  8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on January 30, 2015, 09:43:45 AM
Time for an update.My old packing system was functional


(http://lh4.ggpht.com/_p7bewmqq6YI/S8TVoJ770KI/AAAAAAAAG9I/Z8MQPMk69QE/s800/DSC_0445_2418.JPG)

but eventually I got gatvol of schlepping those ammo boxes around so it was time for a change.The only requirement was that it had to be completely (bolt in and out) removable.I eventually settles for teflon slides as opposed to the conventional bearing type drawers.

(https://lh6.googleusercontent.com/-TS16hz2eRw8/U94-SF9MF4I/AAAAAAAACTc/Xc0q1VNg9-s/w983-h653-no/DSC_0874.JPG)

Aluminum drawers

(https://lh5.googleusercontent.com/-Ef1YETx139Q/U94-LhkxubI/AAAAAAAACTU/jwcJmdIfvAg/w983-h653-no/DSC_0873.JPG)

At the same time I built a box for the water container and moved the Fini to a semi-permanent spot which was otherwise wasted space

(https://lh5.googleusercontent.com/-n9yv7GQwDsQ/U94-awWYA0I/AAAAAAAACTk/opeQemz-zXI/w983-h653-no/DSC_0876.JPG)

Easy in and out and only OEM boltholes used !


(https://lh3.googleusercontent.com/-G6XJCB40Fh8/U-enGgGe5CI/AAAAAAAACYI/DeRNTNkpu6Y/w983-h653-no/DSC_0001.JPG)

I has some OEM tie downs left over from our previous 105 and 120 series so ...

(https://lh3.googleusercontent.com/-SuEg3XwBsro/U-enMFdIoJI/AAAAAAAACYQ/eAOCfqWf7Lo/w983-h653-no/DSC_0003.JPG)

All done

(https://lh5.googleusercontent.com/-L_WAGNhPw34/U-eoImREBFI/AAAAAAAACZA/1aASjnBP50s/w983-h653-no/DSC_0016.JPG)

Then I remembered swambo always complaining about the lack of storage space for keys, cell phones etc ...

(https://lh4.googleusercontent.com/-_gZ8NA6UwIk/U-enY8RitWI/AAAAAAAACYg/8Am74tHhpnc/w983-h653-no/DSC_0005.JPG)

Those OEM humpcover bolts came in real handy

(https://lh3.googleusercontent.com/-P8gWo-suGYc/U-en6cdPStI/AAAAAAAACYw/JhLef32-roQ/w983-h653-no/DSC_0008.JPG)

(https://lh5.googleusercontent.com/-XC8v5ZYplvI/U-en0iNMFKI/AAAAAAAACYo/6dPdHaxnuAk/w983-h653-no/DSC_0014.JPG)

And last but not least something for dad ...

(https://lh5.googleusercontent.com/-qZT4NlpHkVE/U-eoBycjfxI/AAAAAAAACY4/uNyEeKC4M78/w983-h653-no/DSC_0015.JPG)

I also fitted some wheel spacers ...

(https://lh6.googleusercontent.com/-ZPoO_-DEJWc/U3exGWJuLYI/AAAAAAAACOw/iur45OaZb6Y/w983-h653-no/DSC_0641.JPG)

Which has changed Olive's look a tad but definitely improved her cornering etc

(https://lh3.googleusercontent.com/-E58k4gQ2syI/U3erjrEWwvI/AAAAAAAACOY/USwdfBITZFY/w983-h653-no/DSC_0665.JPG)


With our upcoming trip just around the corner, I decided to relocate the aux batt electrics to the rear and to build a proper 3 way distribution box ...

(https://lh5.googleusercontent.com/--Hd44nGau7A/VAMTOc8VViI/AAAAAAAACgE/Ly2Hv9dqiKs/w983-h653-no/DSC_0035.JPG)

(https://lh3.googleusercontent.com/-gVQhasqOD9A/VAMTEHGEnVI/AAAAAAAACf8/DzGi1_Fe3ic/w983-h653-no/DSC_0024.JPG)

I also attempted to tidy the loose wiring a bit in order to open up some more valuable space ..

(https://lh3.googleusercontent.com/-tSveS3eixU4/VAMTb4_JVpI/AAAAAAAACgU/Il7hOFNyP5o/w983-h653-no/DSC_0033.JPG)


(https://lh6.googleusercontent.com/-Fs1VU4YBbtY/VAMTTjXJEEI/AAAAAAAACgM/0U04vSPVlco/w983-h653-no/DSC_0032.JPG)

  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Rob Wright on February 04, 2015, 02:34:21 PM
Congrats Theo .Looks Nice and neat and Drawers more Practical than those Ammo boxes .
.Looks better with those spacers fitted .just be careful that tyres don't catch on rear wheel arches like Smurfs did now that its a bit wider ..
 Looks like only a few of us posting on Bezel . :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 05, 2015, 01:17:11 PM
Thanks Rob. Yeah I have flexed them already and fortunately they do not touch - I suspect it is the combo of the Hellcreek springs and the 10.5" tyre width(12.5 would have touched).

The others are probably too busy driving their 40's  ;)
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on February 16, 2015, 05:11:35 PM
Quote
With our upcoming trip just around the corner

When? Where?

Looking good BTW! :)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on February 20, 2015, 08:08:15 AM
That was just before LT 2014  :P
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on April 04, 2015, 11:34:29 AM
Didn't you do some work recently?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on April 07, 2015, 11:48:37 AM
We should ask you that !  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on April 07, 2015, 01:03:23 PM
But why when you know I didn't  ???
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on April 08, 2015, 02:38:29 PM
To try and force you to pull finger off course !  ???
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 28, 2015, 08:36:07 AM
Did a quick trip this weekend to the Tankwa and this happened


(https://lh3.googleusercontent.com/-GArJ1hQfWhE/Vbcg4MXw07I/AAAAAAAACqk/OS3h8yA-lwE/s912-Ic42/IMG-20150724-WA0009.jpg)

Recently enlarged the air intake and power & consumption showed a significant improvement. Best consumption this weekend was 7.8 km/l and the worst was 7.3 km/l  8-)
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on July 29, 2015, 08:30:30 AM
Pics of process of enlarged intake and end product please, or are you talking about your intake and not the vehicles
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on July 29, 2015, 09:43:43 AM
 ;D

Where da pics, Oom Theo!?  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on July 30, 2015, 01:18:54 PM
Now if you were attending the Legends meet in Slaapies this weekend(like all should) you would not need any pics oupa Dolfie !  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on November 09, 2015, 03:29:57 PM
Time for an update - I fitted some wheel spacers which actually improved stability and cornering on gravel roads quite significantly. However with the flexy Hell Creek springs it did not take me long to damage the rear fenders. So I imported some Bushwacker Fender Flares.

It was not easy to take a grinder and drill to her fenders ... :'(
(https://lh3.googleusercontent.com/-wFJFOp2qGvc/VkCZemDBi0I/AAAAAAAACsg/d3vyh2Ea91c/s912-Ic42/Olive1.jpg)


But I decided to simultaneously refresh all of the old paint which was beginning to show the battle scars from the last 6 years so the result ...

(https://lh3.googleusercontent.com/-PPxltIxbGeU/VkCZmXtJRkI/AAAAAAAACsM/3MPFpWssRbw/s912-Ic42/Olive%2525202.jpg)



(https://lh3.googleusercontent.com/-IR8uc6IqDtc/VkCZ4I4B8eI/AAAAAAAACsE/vS5C7Zui55s/s912-Ic42/Olive3.jpg)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on November 09, 2015, 03:49:41 PM
 :-X  :-X
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on December 08, 2015, 06:28:18 PM
 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Keith Richardson on December 22, 2015, 03:11:05 PM
looks good  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 28, 2015, 09:50:20 PM
Thanks Keith, her flexing will be severely tested on this trip  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on January 22, 2016, 12:44:26 PM
AND  :jt:
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on March 13, 2016, 07:38:06 PM
I eventually settles for teflon slides as opposed to the conventional bearing type drawers.

Theo, why did you decide on Teflon instead of runners?
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 14, 2016, 01:11:25 PM
Cos I go places where there is dust  :P

In addition the Teflon slides are much stronger, quieter,  take up less available space i.e. the drawers can be a bit wider and as you know in a 40 ser space is a premium,plus they are cheaper to start with (or even to replace) and are basically maintenance free ...
Title: Re: Our BJ42 LX rebuild
Post by: Jonathan Tee on March 14, 2016, 01:16:00 PM
A concise and informative response from the learned gentleman
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 14, 2016, 01:18:19 PM
 :o ??? :-\  What have you done/ do you want ?
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on March 15, 2016, 08:06:22 AM
How deep (front to back) are your drawers? I am just worried that holding a 800mm loaded drawer with one hand while trying to get something out the back with the other hand might be problematic.
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on March 15, 2016, 08:21:09 AM
If you build, then please make two!  :-* I have NL 50L FF.

Thank You.  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on March 24, 2016, 11:01:34 AM
How deep (front to back) are your drawers? I am just worried that holding a 800mm loaded drawer with one hand while trying to get something out the back with the other hand might be problematic.

Sorry Pierre, only saw this now. I cannot remember offhand and Olive is not with me as I am still putting the roof back after the new lining was done.What I can tell you is that you do not need to support the drawer when it is out, provided that you do not slide it past the "point of no return' which is short enough, that you will practically never ever NEED to slide it out that far.
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on April 14, 2016, 11:50:13 AM
When my son and go on trips with Olive, we always sleep in our swags but for our upcoming trip to Mabua, his mother decided that our usual arrangements would be completely inadequate. I have learnt when to pick my battles and on this occasion I decided to just get on with finding a solid way to fit our Impi from the trailer onto Olive. Enter Heinrich Siepker at Hannibal: I did not want a complete rack and after patiently listening to what I wanted, we came up with this.


 (https://lh3.googleusercontent.com/-2pBVQEx5xb0/Vw9gPmcZV1I/AAAAAAAAC-s/_4eQsAn3PxY-ze9ytb_GhySCqQYZKpnkQCCo/s900-Ic42/RR%2B5.jpg)


(https://lh3.googleusercontent.com/-RvkajBGxjxU/Vw9gPedVQ6I/AAAAAAAAC_A/0Q_WvnByF7UK_QOVLnnoLxtTSdqGn52nwCCo/s900-Ic42/RR%2B4.jpg)


(https://lh3.googleusercontent.com/-Y2604uzBGvs/Vw9gKQmIudI/AAAAAAAAC_A/37XddotkYaU2zvJNPvaJkamDpunXUrsKQCCo/s900-Ic42/RR%2B2.jpg)


(https://lh3.googleusercontent.com/-VJS3qoo1IMk/Vw9gMvGMzmI/AAAAAAAAC_A/FPKOxeFts3QOIMTRuhPcXrgj1-3cBEy5QCCo/s900-Ic42/RR%2B1.jpg)


(https://lh3.googleusercontent.com/-FsT4usdb6lQ/Vw9gLR3h1wI/AAAAAAAAC_A/g4Tq7fHwT4EW2BUQztGOhZ0uXQqucZ-gQCCo/s900-Ic42/RR%2B3.jpg)


The slats to which the 6 feet are connected run all along the full length of the gutter so the load is nicely distributed along the whole gutter. Superb service from Hannibal and I am stoked with the result.   8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on April 20, 2016, 08:48:14 AM
I like the OEM steering wheel but always felt it lacked something so ...

(https://lh3.googleusercontent.com/-oVMBZfqmUls/VxchyMrV-iI/AAAAAAAAC_g/L5sF1BIGWAY2DUR71--gHwV4xM9gbHl_wCCo/s920-Ic42/steering%2Bwheel%2B1.jpg)


and the stitched leather made a huge difference to the overall feel. I should have done it along time ago.


(https://lh3.googleusercontent.com/-VJTTZBnjLH8/Vxchwj7YFhI/AAAAAAAAC_g/A8bdJrzlc1kOyr8b2xJ2jCY8Htk3n6bkwCCo/s920-Ic42/Steering%2Bwheel%2B2.jpg)


 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Adolf Hüster on April 20, 2016, 08:51:59 AM
I am chuffed. Looks very good.   8)
Title: Re: Our BJ42 LX rebuild
Post by: Mark Auer on April 28, 2016, 04:25:00 PM
 8) 8) 8)
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on May 27, 2016, 08:47:02 AM
Impi fitted for Mabua !

(https://lh3.googleusercontent.com/-vt3rDKFNV5c/V0foe1E1WmI/AAAAAAAADBM/aW2EfFouzpwNuK5Zf6ytA9ojrS_y34Q-wCCo/s900/Impi.jpg)

 :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 01, 2016, 09:37:36 AM
Replaced the old worn struts inside the Impi and changed the point of entry to the side.


(https://lh3.googleusercontent.com/-cOEgO87RQpE/V06M1YMyG6I/AAAAAAAADBk/YkYI46YxAjUMuw3NGj4INWQuF8VNFUgZwCCo/s900/Impi%2Bfinal%2Bmount.jpg)
Title: Re: Our BJ42 LX rebuild
Post by: Eric Guldemond on June 01, 2016, 10:15:21 AM
 8)
that must be one of the nicest CRUISERS is SA!
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on June 01, 2016, 10:24:44 AM
Thank you kindly sir !  :drinks:
Title: Re: Our BJ42 LX rebuild
Post by: Theo Marx on December 05, 2016, 09:07:08 AM
I always new that one day I would part with Olive but I did not know when. Well after 9 years exactly, it is with a touch sadness that I announce that Olive was collected yesterday by her new proud farther. This vehicle was way more than just a vehicle and literally changed the lives of my family and I on so many levels. Although sad, we have no regrets as we know that the new owner is probably an even bigger cruiserfreak than myself, so we have peace in our hearts that she will be treasured like before.


Go well dear Olive, we will be watching you from the side lines and continue to treasure our fond memories of you....     
Title: Re: Our BJ42 LX rebuild
Post by: Pierre Bester on December 06, 2016, 02:45:39 PM
 :-X  :'( Very sad indeed. I don't think I would be brave enough to do that.