Crusty Bob's Transplant

[fe sus]

Because I know how much my fellow mudders love diesel conversion write-ups... and I know how often people say "so I'm thinking of doing a diesel conversion," here is my diesel conversion number 2!
The patients: Crusty Bob is a 6/83 BJ60 with a 5 speed and 314k miles on the clock. The engine is due for a full rebuild and the H55F is getting one as well. Here he is:

After the rebuild the 3B/H55F combo is getting dropped into this as-of-yet un-named 'Cruiser, a 1/87 FJ60 from California (rust free!)

Here are a few photos of the progress so far on the two rigs:
Crusty Bob's engine compartment and interior dash area:


Here's the 2F (see my parts for sale thread: http://forum.ih8mud.com/sale-parts/114317-parting-83-bj60-87-fj62.html)

And here is a pile of parts!

I'll keep posting as the project continues...

[nickw]

Nice to see another cruiser getting the love it deserves.
Keep up the good work.
I look forward to the pics.

Cheers.
N.

[fe sus]

Today I pulled the 2F to prep the engine compartment for the 3B... need to chop those mounts off and weld in the BJ60 mounts...

Came out rather smoothly...

mmmm... beer...

[phatwheels]

Good sh*t. Thanks a million. Just got the DVD. Got the 2H pulled from the HJ60 and its getting a full rebuild. Just did the Wilson switch and put a Ford glow plug relay in place of my missing starter relay, works perfect. Now found my BJ60 is also missing the EDIC relay. It donated some parts in its years in the barn.

[fe sus]

Cool. Glad to hear your back-from-the-dead cruiser revival is happening (just in time for halloween). I pulled my 3B/H55F yesterday. Here are some pics:

[fe sus]

It finally stopped raining long enough for me to start dismembering Crusty Bob.

[fe sus]

So as some of you who've seen my spastic parts wanted/for sale posts may have deduced my second diesel 60 build-up has undergone some substantial changes. Here is what I'm planning on putting together now: 87 HZJ60 with 5 speed, 2 inch OME lift, FF rear axle... interior will be custom, utilizing heated Saab leather seats, bed liner... custom front and rear bumpers... PTO winch (if I can figure out how to mate it to the 1HZ drivetrain), turbo for the 1HZ... parts are coming together... cleaning up the host FJ60 and running fuel and brake lines, new clutch line, etc... new engine mounts, all that good shite. When there's something worth taking a picture of I will... right now it's a few piles of Cruiser parts...

[dieseldan]

I've got a spare decal to donate to your project:

Attachment 103017

[fe sus]

oh YEAH! trade you a radiator?

[dieseldan]

np - just pm your address and I'll send it down to ya.

[archaeology_student]

Whoa, I barely recognized bob chopped up, but the project is looking good!

[fe sus]

Yeah, it took me two trips to the scrap yard, but he is no more... just tearing in to the transmission to play with the bearings... should be fun!

[fe sus]

After a long hiatus... the project is moving forward again! To make a long story short I tried to rebuild the h55f and gave up after months of hassle trying to find the right tools, etc., and just picked up another used transmission yesterday! In the interim my girlfriend and I moved... fortunately it was only a few blocks. I had a friend tow the engine-less 60 down the street with me inside riding the e-brake to keep from running into him... good times!
So... bolted up the new tranny today and need to find a rubber mount for it, then I should be able to pop it in and fire it up!

[mel lowe]

Hey,

Kick a$$ conversion.


Keeps the pics coming.


Based on your thread, I wont be buying a h55 that needs a rebuild.

[Tapage]

still the PTO idea . ?

[fe sus]

Found one... but ended up selling it... to buy a bearing puller... that I no longer need. I guess it'll have to be an electrical winch...

[fe sus]

Howdy all... I've finally been able to get back to work on the 87 3Bt swap... on a side note, I did move a few blocks recently (bought our first house!) and set an all time record for LC MPG!!! Not having the engine yet installed and only needing to go down hill... I had a buddy give me a little tug with my FJ62 and off I went! The scary part was having no brakes, but the e-brake did the job just fine!
Anyways.

Here's an issue to be aware of for you other conversion mined people. The transmission cross member on the older FJ60's isn't compatible with the older H55F transmission mounts. To make this install work you need to bend the posts on the mount so they're both pointing straight down rather than outwards and widen the hole spacing on the cross member. Kind of a PITA. Having donw this swap into an older FJ60 I didn't have this problem. Just an FYI.



I used the lots of 2x4s and other bits of wood, as well as my handy 10' ipe pry bar and was able to get the engine and transmission in place and get 4 of the 8 transmission cross member bolts in. I bolted the cross member to the mount before I attached it to the frame to make things easier. Once the rear end was secured I monkeyed the front around until the mounts were in place to be welded.





Once they were in I removed the hoist and support braces and set my home-brew turbo in place to make sure it would clear the hood:




That's where it sits for tonight... but the hard part is over! Now it's all re-connecting drivelines (okay that can suck) and hoses and the wiring harness!!!

[fe sus]

Just to clarify the cross member issue here is a picture of each of the versions side by side. The older style has brackets that bolt to the frame while the newer version has welded brackets.

[Tapage]

I have the long one ( one piece close to wall ) option in my HJ-60 ( 1987 )

[fe sus]

are you running a five speed or an auto? just curious if theres a mount for the h55f that fits the longer style...

[Tapage]

Originally Posted by fe sus

are you running a five speed or an auto? just curious if theres a mount for the h55f that fits the longer style...

H55F factory with my 2H

[fe sus]

I saw this issue coming and was able to get by it much easier this time than during the last conversion I did. The issue is that the drivelines from the BJ60 have different bolt patterns on the flanges than the drivelines from the FJ60 and are different lengths. Last time around I pressed the spider joints out and swapped in new joints while adding FJ diff flanges to BJ lines. This wouldn't work in reverse i.e. adding BJ flanges to FJ lines as they aren't the right length. Pressing out the spider joints was a PITA and took way to long to accomplish. This time around I skipped that step and used BJ lines that I'd swapped out slip-yokes with parts from an HJ60 (thanks Chris!). The HJ slip-yokes slide right on to the BJ drivelines and have the same diff bolt patterns as the FJ did. I could have used the original FJ yokes had they not been removed before I bought the truck for a transmission swap...

[fe sus]

To revive my old thread... Crusty Bob was finally rolled out of the garage today to turn the key and... the engine turns over just fine, glow plug timer seems to be working... new primer works like a charm so I can be confident there's fuel... smoke does come out of the exhaust as I turn the engine over... but it won't catch. The engine has been sitting for a little over a year now. Any suggestions as why it won't start?

[fe sus]

I have the block heater plugged in and am currently re-charging the batteries (they drained as I was turning it over this afternoon).

[fe sus]

It LIVES!!!!

[Rig of Mortis]

I could sit here and watch that video over and over.

http://www.youtube.com/watch?v=0t20A3X4Cvk

Ha ha.

PS. nice to hear.

[fe sus]

I had exhaust added yesterday and it sounds great! 3" pipe straight back...

[fe sus]

Boost question: in the pictures you can see the blue silicone hose that connects the turbo to the intake. Would this be where I'd tap into for a boost gauge?