FJ40 Nut: Chemical mismatch and plastic plugs

Chemistry 101

So, if you learn nothing else from your introductory chem class you will recall hearing about chemical bonding. Some atoms and molecules can share electrons and form new molecules and basically "become" a new substance. Other times, features of the molecules make them incompatible with other atoms and molecules and a new substance cannot be formed. Think of oil and water. No new substance. But what about scotch and soda? A new, somewhat yummy, new substance is born! Well, that depends upon the scotch, of course.

Well clearly this phenomena was involved in a bad way today when the paint I applied on a few parts simply PEELED OFF the primer!

You see, I've become very fond of a particular paint manufacturer, SEM. I've actually spoken with their technical support, and continue to have great results sticking with only their products. So, when I ran out of my favorite SEM self-etch primer, I should have stopped right there. But NO, I have several other primers, don't I?

(At this point, you already know where this is going, so I'll spare you the gory details...)

Luckily the only parts affected were the pulley and fan on the alternator. I grabbed and wicked buy on ebay last year, purchasing an alternator (looks new but surely it's rebuilt) for about 50% savings. The fan and pulley needed to be pulled off my old unit, and this is why I was painting.

Yes, my unit needed the original fan and pulley

Old Unit (No, I wasn't going to crack it open)

Interesting: This is a Nippondenso unit rebadged by Bosch.

New Unit, pretty!

Cold Galvanizing Primer (I'll come to regret the next 2 hours)
Note the cooling lines also primed awaiting topcoat (shit!)

SEM Black "Chip-Guard" Paint

Bathing in ACETONE to remove all layers
and start over with the painting!!! (later)

Plastic plugs!

There are access holes all over the body that get covered in 'very' custom plugs that are not longer available. I mean even the most reliable sources of parts do not have them. And since they are prone to damage (floor pans!) used ones are likewise rare. I tried some inch-and-a-quarter I found on Ebay but they don't fit. I need four and I have (I think) 1 or 2 of my old ones that I can pretty up. Bumming.

Then, while rifling through one of the dozens of boxes of parts looking for the 5" mounting bolt for the alternator, I came upon a box of miscellaneous relays and switches that were included as "extras" when I purchased one particular part I needed a while back. I never thought to commit to memory (or write down) the contents of the box. But, don't you know, right there in this little box of relays are a few of those plugs! Bonus! They weren't pretty, but cleaning made them acceptable. (Note to self - Keep an inventory the next time you do something as stupid as restoring a car!)

Five large is one more than I need to cover the
access holes for the body mounts. Pretty good condition!

Two smaller rubber plugs for the rocker panels

Running Boards and Heat Shield

I was tinkering with the heat shield today and decided to go ahead and install it. The heat shield is there to protect the cabin from heat from the catalytic converter. Now I no longer have a catalytic converter, but this is an original part that belongs. Furthermore, I had spent quality time restoring the bugger. It would be a shame to let that restoration go to waste. So, under I went, and after some further bending and shaping (and cussing) I finally got it to fit... that is, until I realized that I couldn't get to the mounting bolts for the running boards, which were not yet installed. Drats again!

So, I installed the running boards! Mind you this was a distraction from the main goal of installing the distributor and wiring harness which is needed to get the old girl running. But it was good to get the first body part installed!

Install the support brackets

Teflon tape. I've had this for 20+ years and will miss it
when it's gone. Only a few feet left!

Apply some Teflon tape to the surface that mates with the body.
This is a notoriously bad place for corrosion because grit gets
between the parts and grinds the paint off.