[ElliottB]

I thought I would add all of my pictures and ask all of my questions in one thread to keep from clogging up the forums. I've been working on cars for quite a while. My first truck was an 88 Isuzu Trooper, 5 speed, 4-cyl, just a tank. I was only 16 but I started messing with it here and there.

I then got my ZJ (jeep grand cherokee for you non-jeepers ) and became addicted to offroading, building it up, axle swaps, 4-links, making things for it, etc. My 18 page build thread for the jeep is here.

Urban Assault Vehicle - MallCrawlin.com Forums

And some pics for good measure.







Of course, wheeling a daily driver is such a risk. Everytime I went out I was too afraid to really beat on it because it always had to get me home. I couldn't have ANY down time with the rig to fix things or fab stuff. Thus I bought my daily driver. Audi A4, turbo, good gas mileage, etc. All I've done to this car is suspension, wheels/tires, intake, timing belt, lots of little maintenance things, and 20% tint.







I have since acquired a new project. This particular FJ60 comes from the western front of Colorado. I got it from a guy in Greeley a couple of weeks ago and have only gotten a few hours to really tear into it. This build won't be anything like the jeep, it will be mostly just a semi-restoration. I want everything on it to work like it did from the showroom floor. I am dividing it up into separate builds... interior, motor, suspension/drivetrain, and exterior. Right now I am just starting phase 1.

Here she is in my very limited space garage.







First things first, get all of the junk out. The interior was very trashed so everything is either getting super cleaned or replaced.

[ElliottB]

I spent part of today dealing with the previous owner's shady alarm system. It was a super hack job and a complete rats nest. I am tearing apart the dash for the heater core, along with checking out all the wiring, and cleaning things up. Here are some pics of the progression.





Ridiculous. Wires tied into the stereo, lights, EVERYWHERE.



In all 4 doors there were OLD SCHOOL crossover components that stemmed from the 20 year old Kenwood tape deck and separate equailizer. None of this junk worked when I got the truck... so they are trash.







Blower motor/assembly removed. All of the wiring cleaned up and labeled. Things are starting to look a little more sane.





Made a pretty big trash pile today.



And found the leak from my heater core.

[boombapslappy]

Great progress! Good luck and have fun!

[ElliottB]

I got a full set of seats for $50. Out of an 04 Camry, brown cloth. Shouldn't take too much to adapt them to the Cruiser.

[ElliottB]

So I've got a couple of questions. The previous owner had a real crapfest of an alarm system. There is a wire running from the battery to 2 heavy-duty looking fuse things and then into the wiring harness going toward the alternator. Is this anything important?



Also, there is a wire that goes into some of the ignition coil wiring and into a relay. Is this OEM? I can't quite figure out what it does or where it goes... Still waiting on the FSM to come in so thanks for any input!

[Spike Strip]

If you're talking about the red wire off the POS terminal, it goes to a fusible link, it's OEM. You need it. Keeps the car from burning up, I think.

Thing in the other pic I've never seen... (You're referring to the thing the black wire with yellow crimp goes to?)

Lucky your coolant leak looks like it's just an O ring.

[ElliottB]

Thanks for the advice. I will probably put a new fuse on that pos terminal as the current one looks like death.

Are you saying I probably don't need a new heater core? That would be great news because I don't really want to spend 300 bucks on one.

One last question... how can I remove the heater box without discharging the A/C? I really don't want to remove the A/C box. How do the lines to the heater core disconnect?

[Spike Strip]

Sorry, I'm too lazy to go back and read the earlier posts, but if you've not ordered the FSM, do so. It's invaluable for working on the cruiser.

Yes, from the picture, it looks like the heater core may be leaking at the O-ring. There is a brass clip that holds the slip-fit pipes together. When you remove the box, you'll have to remove some of the hold-down clamps and remove the pipes and replace the O-rings in both upper and lower pipe. Just take the old ones to NAPA. But I'd still get the core checked. If that's all it is, you're lucky. O-rings are .50 cents

The hoses to the heater are connected to an L-shaped valve high on the firewall, on the passenger side of the wall. You can't miss it, just follow where the heater control cable comes out of the firewall. The hoses are going to be very hard to get off, just 'cuz of where they are -- BE CAREFUL NOT TO DEFORM THE SOFT BRASS VALVE when removing the hoses. You might want to just get replacement hoses and cut off the old with a razor knife.

I believe the Air Cond evaporator is separate from heater box, so you will not have to disconnect it, and lose all that precious R12, if you still have it.

[ElliottB]

Spikestrip,

Thanks alot. That was a huge help! I will definitely get the core pressure tested at a radiator shop. I ordered a Haynes manual from Advance, but I'm thinking I will probably be needing the real FSM. I'll post up the progress. Thanks again!

-E

[NLXTACY]

Originally Posted by ElliottB

Spikestrip,

Thanks alot. That was a huge help! I will definitely get the core pressure tested at a radiator shop. I ordered a Haynes manual from Advance, but I'm thinking I will probably be needing the real FSM. I'll post up the progress. Thanks again!

-E

Forget the Haynes manual. The FSM is what you need. Heck the FSM is what I need after a visit to see Spike's ride.

Thanks again Spike!

[mel lowe]

You are off to a great start..

keep the pics coming

[Spike Strip]

Yup, Joey (NLXTACY) is right. Haynes, though better than nothing, (usually) is Courtney Love to the Pam Anderson FSM Maybe that's two Pam Andersons...

Thanks, Joey. I've got my eyes open looking for one for you and parts to get your idle-up working! It's so cold today, I can't even thread bolts my fingers are numb... I know, I know, I'm a So. Cal. weenie-boy when it comes to real cold.

Alf

And just so you know what the FSM looks like:

[ElliottB]

SpikeStrip... I don't quite understand the Pam Anderson reference. Maybe some more pics would help.

I got the heater core out today with the above advice. I really think they designed the rest of the car around the friggin heater core. So I'm going to get both of them pressure tested at a radiator shop (the PO included a spare core), throw some new O-rings on the pipes and then start reassembling the dash.



Dirty mofo.





All cleaned up.



Blower motor/assembly cleaned up.



And I also got around to tearing apart the guage cluster. I think my tach should start working now, along with the LED's that weren't working.







I'm picking up new stuff tomorrow. Thankfully these holidays have given me some hours to work on the rig... I assure you I am not typically this productive. Thanks for looking!

[Spike Strip]

Geeezus! You did all that today ? All I did was get my new Urban Land Cruisers Battery cable installed and I bit*ched about that!

Good work!

That foam crap around the core, if it's falling apart, you can use some self-adhesive stuff from Vato-zone as a replacement.

Only one Pam Anderson picture for you! More than one and you wouldn't get any work done... ( Well, at least for 5 mins or so... )

[GLTHFJ60]

That is a ton of progress for one day. Good work!

[ElliottB]

So I got the heater core pressure tested and it was good to go. Threw a couple of new o-rings on the pipes, and started reassembling everything. I REALLY hope this thing doesn't leak, I NEVER want to mess with the heater core again.

I also threw down a couple layers of insulation in the back. I used similar stuff in the ZJ and really liked it. I got a new roll of carpet pad too, its much denser than the stock stuff so it will be nice and quiet inside.

All cleaned up



Thrown down.



It's starting to look like a truck again!

[johnkappus]

Wow!

You work FAST

Great job...

[Tinker]

You picked the right color! I never had a brown vehicle before my (wife's) '83 FJ60, & now we have 2 (my 60's an '84).

BTW is that the stock FMIC on the 1.8T? Looks bigger than the one on my '93 S4 with the 2.2 I5.

[ElliottB]

Are you talking about my condensor? You can see the intercooler peeking out on my lower drivers side. Its just the stock unit but it works fine.

[ElliottB]

It's been a few weeks since I've updated this. I've been really busy with a new job and shoving in a 70 day snowboarding season but I finally got to mess with the 60 again today.

I've cut the rust out of the wheel wells. They are going to be patched up (probably with rivets) along with some rust bullet. I'm not too worried about its aesthetics as it will be covered up by carpet anyway.

A couple pics of the rust.





And no more... that I can see.







Then I finished laying down some insulation. I know its no dynamat but I used it on my jeep and got really good results for a fraction of the price. I used 3 rolls to cover the entire floor twice. When I get to fixing the headliner I will probably insulate the roof as well.





I ran all new speaker wires to the doors and will probably end up making a new harness to accomodate a CD player that was made sometime in my lifetime. So now the duct work for the HVAC, all the miscellaneous interior pieces, and everything is starting to come back together. Quite a tedious process.





I'll post more as progress is made. Thanks for reading!

[kling-on]

got any pics of that stuff on the roll ... whats on the back side ... is it a home depot deal ???

trucks lookin good BTW

[ElliottB]

It's All-Purpose Window Flashing. Comes in many different sizes and is self-adhesive and molds to all kinds of contours. Under the reflective side is a black rubber membrane, probably 2mm thick. Works great for the price!

[AKcruiserfreak]

Looks good! That heater core looks like a PITA to get to!

TK

[ElliottB]

So I've gotten my choke cable replaced with a new one. It works really well. I've also cut out some carpet padding (jute-like) and am in the process of putting my carpet and seats back in. I am making some rear interior cargo panels later tonight and will post pics as progress is made.

I need some new covers for the interior rear wheel wells. Does anyone know where to get these? Or is there an easy way to cover them with vinyl or carpet? Any advice would be appreciated.

[ElliottB]

I got a few hours today to work on the rig. The rear interior panels had gotten wet (from the rusted out hole in the rear quarter panel) and were completely trashed. So I made some new ones out of 1/4" oak. I am going to cover them with something, or maybe just paint them, I don't know yet.

I am going to cut little doors out in them (already got the hinges and latches) so that I can store stuff behind the panels. There is actually a good amount of room behind them.





I also started laying some of the new carpet. I got this stuff for FREE because it was left over from where our IT office was recarpeting. So this stuff is brand new, and way stiff. I know office carpet was not meant for automobiles but I really didn't want to spend $700 on a new carpet kit.

It has different shades of tan and brown, which go perfectly with the rest of the truck.





Took some massaging to make it fit. My hands are wicked sore.







And with the panels in place...





I know I've got some work to do on the tranny tunnel. I ran out of carpet so I need to get another 6' section or so. It will be relatively seamless over the tranny tunnel. Especially when I get the center console and shifter boots back on it.

[BG_TX]

You are going to town on that thing! I am enjoying following the progress. Are you going to put some insulation on the body panels as well?

[ElliottB]

I probably will end up insulating the body panels. I won't do that until after I do all the prep work before painting though. That's why I'm not working with the interior door panels yet, its all going to have to come out to paint anyway.

[cody c]

great work, i think this going to be a great cruiser when your done.

[ElliottB]

So I'm having a seat dilemma. I backed out on placing my order for the IPOR tan, vinyl, adjustable seats. But to get the rear seats to match would have been a $700 job at the upholstery place. A little pricey for me. So I'm thinking of restuffing the stock seats and throwing on some wet okole seat covers. This is still up in the air though.

Anyway, I got a couple hours today to finish up the majority of the carpet. This stuff was never meant to go in an automobile but I think it came out surprisingly well, and it was a free upgrade. I used the heat gun to shape the rigid bottom around the contours. I just have to finish up the trans tunnel now.







I also got the center console mocked up and will start working on that next time. Its got 4 cup holders, a lock with 2 keys, a tray for sunglasses and it was only $60! I think it matches decently well.



Maybe this will solve all my seat problems...

[GLTHFJ60]

The lawn chair is pretty sweet, I must admit.

Where did you get the console from?