New Member!

[clivehorridge]

This is my starting point. I will cast my mold from this original part. It is in good condition with the exception of the crazing of the plastic.

Won't the crazing reflect through to the mold?

You sound like you know what to do, but I'm interested to know too...

 

[jlpurcell]

Won't the crazing reflect through to the mold?

You sound like you know what to do, but I'm interested to know too...

The crazing can only be felt with your finger nail in a couple of places. The fix will be to cast one part then polish any imperfections then make a new mold. This will end up being a defect free mold for future casting and the first part will also be usable once polished.

 

[jlpurcell]

First test part cast!

I have cast the first test part. The mold is great and the part is great with all of the fine detail. I will have to buff the reproductions out or buff one out and make a new mold due to some slight transfer of the crazing. The next step is to build a vacuum chamber that creates a minimum of 29" of vacuum.This will make the part crystal clear with no air bubbles.
This is the original and then the test cast.

 

[clivehorridge]

Wow, that's impressive, to say the least![emoji15]

 

[jlpurcell]

Frame back from powder coat!

I just picked up the frame and parts from powder coat. I am as giddy as a 16 year old seeing their first car! I will post photos soon.

 

[jlpurcell]

Photos of the powder coated frame!

Here are a few photos of the frame back from powder coat. I just finished blasting and painting the rear differential and springs (soaked on the black gloss paint). Will start assembly tomorrow, back to a roller!

 

[tonytoyota]

Hi that is looking so good thanks for the pics A big Up Tony.

 

[Gav Peter]

Wow... Just wow...

 

[jlpurcell]

It's a roller again!

Good day today, had the day off and was able to get the springs and axles back under the frame today. All new bushings and new shackles and pins with grease zerts. Engine in by end of week???



As you can see in the pics I have not restored the tie rod yet. I did not want the front end flopping around. I will order the ends and new tie rod and pitman arm once the engine is in the frame down on the suspension.

 

[clivehorridge]

This is going to be a truly impressive build, really top work so far

 

[jlpurcell]

Rebuild of front axle knuckles and locking hubs.

Now that the axles are back on the frame I disassembled the right front axle knuckle and locking hubs. Ordered rebuild kits for both the hubs and knuckles. Ordered all of the brake rebuild kits, brake lines, stainless hard lines and stainless hoses for brakes and clutch. Ordered all new grommets for the fire wall.

 

[jlpurcell]

Zinc Plating!

Started the long and time consuming process of wire brushing all of the nuts, bolts, brackets, etc... for zinc plating. This will take at least a week if not two. Then off to the plating company. Here are some of the parts readied today!

 

[jlpurcell]

It will all come together!

I have not posted in the last few days on the progress. I have a good steering wheel center cast will continue to cast looking for the perfect combination of mixture, degassing, and casting. I have media blasted and wire brushed approximately 30% of all of the nuts, bolts, washers, brackets etc.. for zinc plating and am scheduled to drop off all of the zinc plating by the end of next week. I will then focus on the remaining parts for powder coat. I should be able to get the chassis ready for the body by the end of November.

 

[jlpurcell]

Progress?

Have completed about half or a little more of the bracket, nuts, bolts, washers, spacers, bits and pieces for yellow zinc plating. Will post picture prior to taking to plating company. I dropped off the items for chrome plating last night at the metal finish shop.Mainly the rear lift struts, door handles, ash tray, nuts and bolts etc... They will be ready in 6 to 8 weeks. I have to keep telling myself that it will all come together.

 

[jlpurcell]

Progress on the Horn Button reproduction!

Not the final product but this is my first example after using the degassing chamber. Still a few air bubbles but I went ahead and painted it to give a good idea of the progress to date on this project. You can see casting by casting the improvement.

 

[jlpurcell]

Nuts, bolts, washers, fuel lines, and brackets!

Here are 90%+ of all nuts, bolts, brackets, fuel lines etc... media blasted, wire brushed and ready for zinc plating. I am glad to almost be done with this chore but well worth the effort. All small parts daisy chained with wire to keep them from getting lost in the platting process.

 

[clivehorridge]

Jeeeeez us!

 

[jlpurcell]

Back from plating, now sorting time.

The plating company completed the job in just one day! Now it is time to cut the daisy chains and sort all of the brackets and fasteners. I picked up a can of plasti-dip for the frame rail fuel line, wiring, and brake line brackets. Great look to have the fresh yellow zinc with black plasti-dip on the tube end of the bracket. I will post some photos tomorrow. But for now here are the parts just back from plating.

 

[jlpurcell]

Car Porn! Do not look if you are not 18 years of age!

Near perfect day. Hunting in the morning, work on FJ40, more hunting in the evening, come home to dinner and work on the FJ. I finished assembly of the LF drive line today will be working on the RF tomorrow.

 

[tonytoyota]

Looking good from Tony