Our BJ42 LX rebuild

[Theo Marx]

After all the bashing from the others I finally gave up driving her and started stripping her...  












PO seemed to have a thing for ammo boxes  





The OEM BB brackets needed some attention




With the "mask" removed







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





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














Some door rails







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







Then the front doors







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







Small hiccups







 aside the panels came off...







 and before long she was topless







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











Box removed and what did I find hidden beneath ?







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







After a quick clean-up











Perfect fit !  


 ..  and then I found







 the reason why JT hides a stash of chips in his 40  

[Theo Marx]

In spite of  :pig: ninja turtle and his tjommies last night, I managed to get a little bit done on my truck today..

[Theo Marx]

For JT   

[Theo Marx]

Update from last night's efforts..

[Theo Marx]

Removed the front fenders but first had to remove all the attachments that go with it.   






















The OEM battery holder is really robust and heavy   











And then onto the wipers and motor housing etc

















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

[Theo Marx]

Got a little bit done tonight.










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.


























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





And then another discovery   







It sure looks 25 yrs old. 




 

[Theo Marx]

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.





Then the cluster and the wiring














Was forced to cut the wiper motor wiring   






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

[Theo Marx]

Made some more progress tonight   


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.








Them pipes running into and out of the heater





and through a tight grommet in the fire wall








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





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





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.








then I removed the padded dash..





.. and found this underneath






 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..









So now she is a little naked..

[Theo Marx]

Got a little bit done last night.In order to remove the steering column I had to remove a load of other stuff

















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





... and now she looks better.

[Theo Marx]

Made some good(for me as it is iro wiring) progress today.
Starting at the pax foot area as I had done the driverside previously





All coded, tagged and bagged..

















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



Pulling the head through..



The entire snake !



That still left the OEM Heat & Sound shield





Leaving her almost bare inside !



Next will be the rest of the loom on the outside

[Theo Marx]

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 ...















Almost loose..



The entire snake



And now she looks like...



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



See the naked but oily pin? It still had the empty plug attached when I found it

[Theo Marx]

Visually I didn't get much done last night. Need some more tools first 

[Theo Marx]

Some progress....

Starting with LRT









Which left the towbar...







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



 ... even paper was used  :roll:















The complete rear-end of the snake..



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







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

[Theo Marx]

Update pics:

















Hidden beneath all the bondo...







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





Only this spot in the back 



The front floor being a mix of good and bad

[Theo Marx]

The total amount of sound and heat matting removed



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