83 FJ60 Build up thread

Project60 · 01-03-07, 07:11 PM

I have decided to start a thread on the build up of my 1983 FJ60. I have read all the great threads in the 40 & 55 section and haven't seen one in the 60 section yet.

I have never rebuilt a car from the ground up, so I am not an expert (please bear with me). I wanted to give myself a bodyshop 101 course while attempting to give back what others here have provided to me.

I bought a blue FJ60 with gray interior in July of 2006 with 233k miles on it. The clutch was out and the PO had put an electric fuel pump on when the mechanical pump went out. There is rust around the rear wheel wells, and some minor body damage. The interior is worn out, but complete.

I am not going to "restore" the truck. I am going to rebuild the 60 from the frame up but change things to suit me (paint color, seats, etc.). I will keep the original 2F and drivetrain. The end result will be a daily driven truck that I can say honestly say "I rebuilt it".

This is going to be a long project as I have two little boys and have to travel on occasion for work. I will try to update as often as I can.

Thanks all!

Project60 · 01-03-07, 07:20 PM

More Pics

Project60 · 01-03-07, 07:26 PM

Got about 3.75 hours total on the FJ60.

45 minutes on 12/26 removing the grill and headlight covers.

1 hour on 12/29 attempting to remove the front bumper and apron. The PO had ran the truck into something on the driver front side and pinched the front bumper into the apron. Ended up removing the headlights instead - Had to use easy out to get the screws out.

2 hours on 12/30 removing the apron, bumper, hood latch support, hood springs and hood. I had to drill out one of the bolts on the bumper to get the bumper off.

Dave-T · 01-03-07, 11:07 PM

Sounds cool. I'll look forward to following you.

jgordon · 01-04-07, 09:41 AM

yeah, I'm looking forward to this too. My only suggestion would be to consider keeping the color original - it looks really good.

hks3sgte · 01-04-07, 09:47 AM

Finally a build-up thread on a 60. x2 on keeping the original color.

Winston · 01-04-07, 10:16 AM

Are you going to use the same chasis/frame?
If so, what are you going to do about rust?

87 FJ60, with rust

Project60 · 01-04-07, 11:00 AM

Quote:

Originally Posted by Winston

Are you going to use the same chasis/frame?
If so, what are you going to do about rust?

Thanks all for the interest! I will definitely do my best to keep moving and try to post as many pics as I can.

Winston, I am going to keep the same frame and body. I bought a 4' x 8' sheet of 18 gauge steel to cut out the rust and weld in new metal in the body. The frame looks like surface rust only, except for the C channel in the non-boxed portion behind the rear axle (Sounds common from all the threads I have read). I will have to take a better look at the frame when I get into it - may have to remove the C Channel and box it in, or cut and splice.

Project60 · 01-04-07, 11:02 AM

Quote:

Originally Posted by hks3sgte

Finally a build-up thread on a 60. x2 on keeping the original color.

I'll keep my color options open. Is there an online reference to the stock colors so I can see what the original unfaded color looks like?

Project60 · 01-05-07, 02:37 PM

Bought a 2 Ton engine hoist and load leveler yesterday. Will get pics when I get it assembled.

Dave-T · 01-05-07, 02:48 PM

Regarding the stock colors, Cool Cruisers of Texas has a list and some photos on their website, might help. TLC in Van Nuys has a list also but no photos.

sirenmoses · 01-05-07, 03:39 PM

colors here: http://coolfj40.stores.yahoo.net/colorcodes.html.

Nepalm · 01-05-07, 03:43 PM

I will be following this closely. I have an 84 fj60 in the same color and condition. Rust in all the same places. Let me know if I can be of any help, I live in northwest Denver.

good luck!

svo_jon · 01-05-07, 03:52 PM

I too have the wheel well rust problem, I look forward to seeing your solutions

sirenmoses · 01-05-07, 03:56 PM

Quote:

Originally Posted by svo_jon

I too have the wheel well rust problem, I look forward to seeing your solutions

x3.

getting a donor tailgate to practice my rust repair techniques on...

Pathfinder · 01-06-07, 07:45 AM

I have an 84 with rust in the same areas as well. I'm going to be doing a build soon as well. Look forward to seeing your solutions so I have an idea of what I need to do during my trek down build up.

Quote:

Originally Posted by Nepalm

I will be following this closely. I have an 84 fj60 in the same color and condition. Rust in all the same places. Let me know if I can be of any help, I live in northwest Denver.

good luck!

Project60 · 01-06-07, 09:10 AM

Quote:

Originally Posted by sirenmoses

colors here: http://coolfj40.stores.yahoo.net/colorcodes.html.

Thanks for the color codes. I will leave the color up in the air until I get that far along. I was actually thinking of a gun metal gray, I didn't even know that was a stock color. I do like the darker blues too.

Nepalm I will let you know if/when I need help. I think the biggest pain will be getting the body off the frame.

Project60 · 01-06-07, 09:25 PM

2 hours on the 60 today. Because I am doing this all in a 2 car garage, I had to get the new engine hoist assembled and out of the way. I also pulled the radiator overflow tank, battery tray, side turn signal lights (rubber was cracked and shot) and carb fan.

Question: Why the need for the carb fan? Was this a 60 only thing due to the emissions crap, or something all cruisers had? I don't remember my old man's 40 having one... it was an F engine though.

Wife is out of town with the camera, I will post pics on the next update.

FinHJ60 · 01-06-07, 10:56 PM

Nice thread, keep posting pics. Just did my rear frame, used new C-profile and made totally new frame, little more than half meters, about 2 feet. And the rearmost crossmemer.

Project60 · 01-08-07, 04:05 PM

Got an hour yesterday on the 60.

I drained the radiator and removed the radiator, fan shroud, hood latch and radiator hoses. The petcock "knob" on the radiator was broken, still sealed though.

I removed the side vents on the front fendors as well. I broke one of the plastic "studs" with the metal expanding clip on each side.

jmkfj60 · 01-08-07, 04:17 PM

I think one of the reasons for the carb cooling fan was to help cool the exhaust manifold. I have been known to be wrong most of the time though. Good luck on your build.

Project60 · 01-08-07, 07:48 PM

Got about 20 minutes on the 60 tonight.

I finished removing the radiator support. I had removed all the bolts easily except the two mounts to the body. One I took off with an impact wrench last night with some PB blaster. The other one wouldn't budge. Since the little one was sleeping (< 1yr old), I had to improvise on my method of cutting the bolt off. I started off with a hacksaw and moved on to a dremel wheel.

Problem came when my 3yr old son who was helping me learned his first lesson when working in the garage. Don't pick up hot parts! All was soothed over with some ice cream.

Project60 · 01-08-07, 07:53 PM

Here is work from 1-7-07.
Radiator removed:

Work from 1-8-07.
Cut bolt:

Radiator Support Removed:

Radiator Support Bushing:

Project60 · 01-08-07, 07:55 PM

I decided to keep a log book at the start of this project. It has all of my hours, dates and receipts in it. That way I won't loose track of everything. When I am done, I will tally up all the hours and $ spent on the project for all to see.

Project60 · 01-08-07, 07:58 PM

When I pulled the bumper I realized the bumper mounts were bent up. Looks like the mounts are buck riveted to the frame. I am thinking about pulling these off as I will probably mount a new bumper right to the frame. Any thoughts on this?

Project60 · 01-08-07, 07:59 PM

Quote:

Originally Posted by jmkfj60

I think one of the reasons for the carb cooling fan was to help cool the exhaust manifold. I have been known to be wrong most of the time though. Good luck on your build.

I was thinking the same thing when I saw the intake and exhuast manifold on the same side with the carb.

Project60 · 01-13-07, 07:38 AM

Got 45 minutes on the 60 last night.

Took off the LH fender. You can see the damage to the front corner where it attaches to the apron. You can also see some rust closer to the drivers door.

Took off the washer fluid bottle. Lid is broken off.

Took off the hood hinges. Unfortunately one of the bolts broke off. I tried getting it off with a bolt extractor but no luck. I will have to work on it when I get more access to the firewall.

Project60 · 01-13-07, 02:04 PM

Got an hour on the 60 today.

Removed the LH inner fender.

Removed the Antenna and RH Fender. You can see the rust around the mud flaps and the start of the deep scratch the PO left down the passenger side.

Removed the RH front mud flap bracket. There was no mudflap left.

Removed the Ignition coil. Removed the aftermarket electronic fuel pump the PO had installed. Not sure why they didn't just put a new mechanical one on.

Removed the RH inner fender as well.

toolman · 01-13-07, 02:17 PM

Hey Project60,
Is this the cruiser that was parked on 120th by Barbers Turkey's that was for sale?

kevinmrowland · 01-13-07, 02:25 PM

Looks good, keep the momentum going and you will be there before you know it!

Carb fan is there to keep the fuel from evaporating from the carb after it is shut off with a hot engine. Also helps the seals and boots and things last a bit longer because they stay moist with fuel.

The bumper hangers are best removed, they do not do much, and get in the way of future mods. Either grind the head off and pound the stud out with a punch or just torch the head off and do the same.

Edit: Torch on the hanger side to avoid removal of frame material.