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Old 05-21-08, 11:23 AM   #1 (permalink)
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Re Birth BT60

FJ-60 Rebirth About two years ago I found my third FJ-60 in Charleston SC at an auto dealer used car
lot. Went by for a check out and immediately realized that this bo bo knew less about a
FJ than just about anybody alive. After laughing inside at his attempts to start a cold 2F
(April 85, FJ-60) poor guy did not know to pull the choke on a cold start. I got in pumped
her three times pulled the choke and she fired. I was hooked; later that day she went home
with me. As I did not have any excess funds at the time I just used her as a daily driver
on the weekend (have an assigned vehicle when on duty) when I was not playing on my Indian
Motorcycle. I added shocks and Michelins for a better street ride. Knowing I was going to
fix her up some time, I just drove her on. About nine months later I was driving her to
work (had something personal to do after work so took my baby not the assigned POS) and heard
a strange noise. It turned out to be the fan going through the radiator. As I had already
found a great wrench to work on baby decided now was the time. Follows the description of the rebirth:

STAGE ONE
New Radiator Aftermarket unsure wrench got it.
New Fan Toyota
Pulled Engine Completely rebuild with RV cam 20 over on pistons,
All new seals gaskets etc. all Toyota Resurfaced Flywheel
New heavy duty clutch pp and bearings, New Master Cylinder and Slave Cylinder for clutch
New Valves Guides etc. (PO had not taken care of this 2F ova led cylinders two cam lobes
wore off completely, don’t know how she ran as well as she did)
Engine Performance MAF Ceramic Header, Distributor, and 38 Weber Carb Custom Exhaust 3 inch Stainless
Lift Kit OME 3 ½ Heavy ,SS break lines
Locker Detroit Rear, Auburn LS in Front 4.11 R&P
Body Lift 2 inch ,4+ (MAKING ROOM FOR THE H55 in stage three)
Pulled both Axels Locker and LS all new gaskets and seals and replaced oil drain plugs
New u joints for both drive shafts Toyota
New Warn Hubs I know I know: but I like Warn Hubs OK
New Brake Cylinders
New Break Pad’s Front and Rear
New Parking Break Pads
New Tie Rod Ends
ARB front bumper
Winch to come (stage two)

4+ Rear Bumper Awesome product
4+ Sliders
Corbeau Seats VX-2000’s Black with Red inserts, red 3 point comp seat belts Doors and back seat redone
in black and red vinyl.
SOR Overhead C Also in black and red vinyl.(only came in brown wish it had been in gray then no recover needed)
SOR Grab Bar
4+ Battery Tray plan to isolate 2nd battery with the “perfect switch”(dual battery stage two)
38 Gallon Gas Tank Still on Back order Mad a Fre(may get pushed to stage two tired of waiting on it)
Body Work Rust is being cut out and metal formed and welded back in place. Heavy duty rust primer then
Bed liner type(unsure of Brand my mechanic is trusted on this) both as undercoat and down low
side of body, ( along the line of the fenders and lower area covering both the arb and
the 4+ bumpers and sliders. ) and inside up to the headliner. Color above that will be tan/beige
with red accent line(yes read pin stripe) to match my Indian Colors. Had color photo shot to match
bike. Pulled carpet and trashed: new rubber diamond pattern from SOR on Floor and back of Rear
Seat. Roof will be bed liner also in case something falls from the future rack? New Windshield
door seals Wagonner site has however I don’t want to slow him down on other more important projects.
Fender Flares Sahara (SOR)
Tires and Wheels Boy what a can of worms, Just wait for the photos and then you all can tell me what an idiot I am.
But I think you will be surprised!!!
OK jig is up 17X10 Marsh Steel Rims with Straun double internal beadlocks and 12X 35 BFG KM@'s That’s it for now just waiting for the pieces to come together. Will drive for a while to allow differentials to seat
and engine to seat then to Stage #2
Stage #2
Winch Want a big one 12000 or so with lots of line capacity any ideas on what will fit with the arb front?
Second Battery and isolator
Roof Rack Probably Custom( I do like the arb unit however)
Stereo At least one Sub with 4 6 ½ with I pod
CB Oh yes
Cage for interior Have a unique idea on this wait and see.(However want to wait for QP from Kevin prior
to Fabrication don’t want to lose the ability to get in the hide-e hole.
Quarter Panel Storage Whenever I get to the top of the list (thanks again Kevin)
Tailgate Storage Whenever I get to the top of the list (thanks again Kevin)
Round Eyes Headlights And upgrade to electrical harness
Power tank For air mattresses and tires these little compressors just take to farking long.
Lights Yes but still looking.
Rear Disc Breaks Possibly depends on how she stops with the 35’s
H-55 and toy box Atlas???? Probably phase #16 if ever
Exoskeleton ?????
I am not new to Land Cruiser’s have owned a FJ-40, operated a FJ-45 on a cattle ranch for two years, owned a pig(FJ-55)
{put 350,000miles on the pig}. And Two other FJ-60’s over the years. It is really funny all three have been the 85 year
model one red, one blue, and now this gray one. I am new to Charleston SC and IH8Mud however.
I have been lurking and learning. If I have stepped on toes sorry. As for prior pictures just look at any and all
the stock FJ-60 in rusting steel gray and that is what she looked like. Now if the wrench will just call for pick up.
I can’t wait. Pictures as soon as Phase one is complete as I am not near the rig to take pictures at this time.

Edits in red show items completion or nearly so.

Last edited by IndianDoc; 09-24-09 at 05:42 AM.
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Old 05-21-08, 01:39 PM   #2 (permalink)
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That sounds like an awesome rig!! I can't wait to see how it looks.

You have a lot of the same plans as I do...

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1987 FJ60 - MoonShine - SROR Front Bumper, H55f, 2-low, SOA, 62+AAL fronts w/ Ironman rears, 36's, FF w/ 4.11's, Round Eyes, KMR's Tailgate Hatch, desmog + headers, Storage / Sleeping system, etc. -- DD w/242k

Waiting to be installed:
York 210 OBA, shocks, lots of little things....

1967 Stevens Mfg. Co M416 - almost RUST FREE!!!

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Old 05-21-08, 01:45 PM   #3 (permalink)
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Quote:
Originally Posted by GLTHFJ60 View Post
That sounds like an awesome rig!! I can't wait to see how it looks.

You have a lot of the same plans as I do...
Great minds similar channel!! Pic's next week of some of the stage one stuff.
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Old 05-21-08, 05:06 PM   #4 (permalink)
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Looking forward on this awesome build ..

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if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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Old 05-21-08, 09:35 PM   #5 (permalink)
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Quote:
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Looking forward on this awesome build ..
Thanks but Skinner's is the awesome build and check out that shop. I drool every time I check out his work. Mine is going to be functional the way I want it but only middle of the road built. No Diesel or big V-8 ( I just love that 6) only mild lift and tires more expedition ready than any thing. any who Thanks again
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Old 05-22-08, 09:27 AM   #6 (permalink)
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I love 6 turbo diesel engines .. ( have 2 ! )

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if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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Old 05-22-08, 09:49 AM   #7 (permalink)
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I love 6 turbo diesel engines .. ( have 2 ! )
And talk about awesome I have viewed your rigs here while lurking about and I must say WOW!!! and WOW!!! again Tencha is just about wonderful!! Keep safe will post pic of my rebirth BT60 (name for now is BT60 she's going to be black and tan an/or if I am mad at her at the moment The Bitc* hum you get the idea. )

It has been very slow going for the last 12 months my work requires extensive travel. Hopefull as I have the next two weeks off I can get pictures and get a bunch of stuff done or closer at any rate. The low country chapter of the Upland Cruisers is my local TLCA club an I hope to have her on the road (not likley unless lots of help just shows up) for the club meeting on the 31st. in Awendaw SC. My best to you and your fine two turbo rigs in Panama LOL
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Old 05-22-08, 02:21 PM   #8 (permalink)
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Quote:
Originally Posted by IndianDoc View Post
And talk about awesome I have viewed your rigs here while lurking about and I must say WOW!!! and WOW!!! again Tencha is just about wonderful!! Keep safe will post pic of my rebirth BT60 (name for now is BT60 she's going to be black and tan an/or if I am mad at her at the moment The Bitc* hum you get the idea. )

It has been very slow going for the last 12 months my work requires extensive travel. Hopefull as I have the next two weeks off I can get pictures and get a bunch of stuff done or closer at any rate. The low country chapter of the Upland Cruisers is my local TLCA club an I hope to have her on the road (not likley unless lots of help just shows up) for the club meeting on the 31st. in Awendaw SC. My best to you and your fine two turbo rigs in Panama LOL
Thank thanks thanks thanks dude ..

Close to 10 years together Tencha and me ... just snap a few pics here and get enough courage to end with your proyect .. cheer up !

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if you are achieveing the max boost then it isn't the boost that is going to kill your engine... it is your right foot.
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Old 05-24-08, 06:08 AM   #9 (permalink)
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That sounds like an awesome rig!! I can't wait to see how it looks.

You have a lot of the same plans as I do...
Any update on the overhead console you and Tapage were discussing in another thread. Haven't installed my SOR unit and did not see any install pictures on that thread. So how goes that cool overhead console story. (Might change my plans.)
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Old 05-24-08, 08:28 PM   #10 (permalink)
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Quote:
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Any update on the overhead console you and Tapage were discussing in another thread. Haven't installed my SOR unit and did not see any install pictures on that thread. So how goes that cool overhead console story. (Might change my plans.)
I believe that we're still waiting on Dirtgypsy to post up pictures and a write up. Watch this thread!!

http://forum.ih8mud.com/60-series-wa...ic-inside.html

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1987 FJ60 - MoonShine - SROR Front Bumper, H55f, 2-low, SOA, 62+AAL fronts w/ Ironman rears, 36's, FF w/ 4.11's, Round Eyes, KMR's Tailgate Hatch, desmog + headers, Storage / Sleeping system, etc. -- DD w/242k

Waiting to be installed:
York 210 OBA, shocks, lots of little things....

1967 Stevens Mfg. Co M416 - almost RUST FREE!!!

Previous Rig:
1987 FJ60 - Big Red

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Old 05-26-08, 04:36 AM   #11 (permalink)
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Quote:
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I believe that we're still waiting on Dirtgypsy to post up pictures and a write up. Watch this thread!!

http://forum.ih8mud.com/60-series-wa...ic-inside.html
Thanks for the link had forgotten exactally where it was at. Hope to see that overhead soon.
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Old 05-26-08, 11:07 PM   #12 (permalink)
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The rebuilt engine is nestled back into the frame. And the interior is approaching ready to paint stage. However she sure looks funny without any wheels and axle's.
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More to come as time goes on.
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Old 05-29-08, 07:22 AM   #13 (permalink)
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Work continues, while removing the rear bumper found evidence that BJ has been wrecked in the past. The driver side bumper bracket was riveted (stock application) and somebody had welded it to the frame across top and both vertical sides. Made for a nasty removal. Well grinder will smooth it out. Name:  DSC_0023.JPG
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Old 05-29-08, 07:26 AM   #14 (permalink)
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Off to the diff shop for the lockers and a compleate rebuild of all seals, gaskets etc.
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Old 05-29-08, 07:28 AM   #15 (permalink)
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did you have any rust under the interior wheel well covers?






Quote:
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Attachment 234200

Off to the diff shop for the lockers and a compleate rebuild of all seals, gaskets etc.
who is going to rebuild them?...

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Old 05-29-08, 07:30 AM   #16 (permalink)
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Dry Fitting the webber and adaptors to the manifold.


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Old 05-29-08, 07:31 AM   #17 (permalink)
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Dry Fitting the webber and adaptors to the manifold.


Attachment 234201
if that weber doesn't work out.. i have two extra 60 carbs.

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Old 05-29-08, 07:32 AM   #18 (permalink)
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Quote:
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did you have any rust under the interior wheel well covers?
None could not believe it. However the rust on the rear cross brace is bad but that's comming out to put the 4 +bumper on. Name:  DSC_0035.JPG
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Old 05-29-08, 07:33 AM   #19 (permalink)
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if that weber doesn't work out.. i have two extra 60 carbs.
Good to know I've still got mine too.
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Old 05-29-08, 07:35 AM   #20 (permalink)
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did you have any rust under the interior wheel well covers?







who is going to rebuild them?...
Will have to check with my mechanic and friend in sumter he's setting it up, claims the diff guy is the best in all the carolinas, we will see we will see.
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Old 05-29-08, 07:43 AM   #21 (permalink)
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rust area

Quote:
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did you have any rust under the interior wheel well covers?






who is going to rebuild them?...
One small area near the wheel well perforation into body tub. Welding in new steel today or tomorrow.Name:  DSC_0031.JPG
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And some in the rockers Name:  DSC_0027.JPG
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Old 05-29-08, 08:27 AM   #22 (permalink)
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poke at the base of the rockers with an ice pick. Mine looked great until I bumped a tree stump and they crumbled like a dry rusty cracker.

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Old 05-29-08, 08:46 AM   #23 (permalink)
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poke at the base of the rockers with an ice pick. Mine looked great until I bumped a tree stump and they crumbled like a dry rusty cracker.
Is a common site for rust but they have been poked and banged pretty good, the photo shows the new steel that has been welded in and the thin layer of fiber filler over the pinholes etc. in the rockers they were rusty but over all in pretty good shape. the one rust rear fender panel and the rear cross brace had the worst rust. I was really surprised. Name:  DSC_0026.JPG
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By the way the box the 4+ bumper and sliders arrived in was huge. Nice product will post pictures of them latter. Name:  DSC_0015.JPG
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Old 05-29-08, 04:12 PM   #24 (permalink)
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What a ....

By the way the box the 4+ bumper and sliders arrived in was huge. Nice product will post pictures of them latter. Attachment 234214 oh my back!!![/QUOTE]

What a tease.....

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Old 05-30-08, 02:46 PM   #25 (permalink)
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Always leave em wanting more!!!!

And back at ya

Thanks for the phone call and the hood decal is set up they will send me a proof via email prior to shipping. Thanks Trapper.
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Old 05-30-08, 03:05 PM   #26 (permalink)
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Sounds

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Always leave em wanting more!!!!

And back at ya

Thanks for the phone call and the hood decal is set up they will send me a proof via email prior to shipping. Thanks Trapper.
Sounds like everyones on the same page, sweet-Glad to help the cause!

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Old 06-03-08, 11:54 PM   #27 (permalink)
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Diffs in shop

Finally got the little trailer gone to the shop.

Looks like a week or two before they return. (ended up being 6 months, who knew!)

More pictures Friday or Saturday. Still plugging along.

Checked Kevins threads on the tailgate mods and the quarter pannels I'm still moving up, looks like I may get them from Kevin prior to finishing Stage one mods. Great!! (Sur nuf they are sitting and waiting on my slow butt to get the BT back together)

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Old 06-07-08, 01:34 PM
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Old 06-07-08, 02:18 PM   #28 (permalink)
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Still going

Over the last two weeks I got to work a little on the BT. Mostly removal of the headliner and the associated hardware. Then scraping off the insulation and finally sanding off the glue and most of the old paint. Not many photos too boring.

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That crappy glue clogs up wire brush, grinder wheels only thing worked was a sander and grinder grade disc.

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Old 06-07-08, 02:29 PM   #29 (permalink)
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BT60 bump stops

When my arms got exhausted from the overhead work took a break and installed the 4+ bumpstops (2 inch) a half bannana job.

Stock

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Mod complete.

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Also installed the 2nd battery tray and some other engine bay componets but was too tired to take photos , more to follow.

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Old 06-07-08, 03:47 PM   #30 (permalink)
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keep the pics coming!


Looks like you are having some fun!

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