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07-22-07, 08:01 PM
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 #1 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Project Overland
This weekend I kicked off work on my 60 buildup and thought I'd share some photos and details of it's progress. The body and frame of my HJ60 had rusted to the point where I needed to start considering a new home for my diesel powertrain. So a couple weeks ago I bought a rust free donor 1986 FJ60 from California and drove it back to SC.
trip thread: 3,300 Miles in 6 Days - IH8MUD.com Forum
Original HJ60:
Donor FJ60:
While I transfer the powertrain I have also planned a few other mods . The goal for this build is an overland expedition rig which so it needs to be capable and reliable offroad, but comfortable and practical onroad. Here is a summary of the build...
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- BUILD SUMMARY -
Topic, (Post numbers)
- BODY- - 1986 FJ60 (58, 81, 83, 89)
- Painted LC paint code 464 (95, 108)
- Underbody sealed with Rust Bullet "black shell" (159)
- Disco Stripes (249)
- FRAME - - POWERTRAIN - - FUEL SYSTEM - ( 164, 168, 174) - Carter aux pump
- Racor 245R Filter with 12V heater
- SUSPENSION - ( 164, 169) - Re-arched HJ springs, 7 leaf rear, 6 leaf front (151)
- SOR "Performance" Shackles with greasable bolts
- SOR poly bushings
- Greasable pins
- "GT Suspension" Sway bars, 21mm front, 27mm rear (67, 223)
- MAF extended font swaybar links
- Modified Ford F-250 front shock towers (223)
- Pro Comp ES9000 Shocks
- 2"-3" of lift
- *(5/27 - too little time for the coils right now)(118 , 125)
- AXLES - ( 76, 147, 148) - Full float rear
- Factory 60-series F/R Cable lockers
- 4.11 gears
- BRAKES - - Stock front disks
- Rear disks with e-brake (187)
- SS braided lines
- WHEELS AND TIRES - - 15x5.5 late model FJ40 steelies, BFG A/Ts 33x10.5 (winter) (266)
- 16x6 OE chrome steelies, BFG M/Ts 255/85-16 (summer) (314)
- INTERIOR - - Rebuilt HVAC ducts (170, 171)
- Cargo drawers (37)
- Passenger grab bar (281)
- Split Rear Bench (314)
- OTHER - - Electrical (181, 182, 187, 261)
- Contour E-Fan Conversion (187, 261)
- RoundEyes Headlights (276)
- Shifter-mounted Hand Throttle (283)
Here is the direct link to the GALLERY
***************************************
Last edited by VTCruiser; 06-21-09 at 03:48 AM.
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07-22-07, 08:34 PM
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#2 (permalink)
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Site Addict
Join Date: May 2006
Location: Newberg, Oregon
Posts: 1,284
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nice!!!
clint
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07-23-07, 07:30 AM
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#3 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Strip down, part 1
I pulled the powertain on saturday. it took a while because i didn't want to just cut everything off and I was working alone. I also labeled the harness, though I won't use a lot of it on the diesel, it will be helpful to know what was what incase I want to try and reuse any of it for a different application. Anyway, it took pretty much all day, but it came out without a hitch...
the start...
I got a little carried away with the work so I didn't take any pics during the pull, but here is the result....you can see where the battery exploded at some point...
and the garage after a little clean-up on Sunday...
Last edited by VTCruiser; 01-08-08 at 05:58 PM.
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07-23-07, 09:46 AM
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#4 (permalink)
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Drinking the Kool-aid
Join Date: Aug 2006
Location: On a darkling plain
Posts: 182
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Quote:
Originally Posted by VTCruiser
I pulled the powertain on saturday. it took a while because i didn't want to just cut everything off and I was working alone. I also labeled the harness, though I won't use a lot of it on the diesel, it will be helpful to know what was what incase I want to try and reuse any of it for a different application. Anyway, it took pretty much all day, but it came out without a hitch...
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 pics? I'm definitely following this one too.
__________________
'88 FJ62 - 12HT conversion, OME Lift, ARB front bumper, Roof Rack
'04 Prius - stock
'66 Pearson Commander - a hole in the water to throw money into.
__________________________________________________ ________________________________________
And we are here as on a darkling plain
Swept with confused alarms of struggle and flight,
Where ignorant armies clash by night.
Last edited by Creeker; 07-23-07 at 12:52 PM.
Reason: Pics working now.
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07-23-07, 09:52 AM
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#5 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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hmm...they were working earlier, I'll have to try re-linking them...
until then, here is a direct link to the gallery...
gallery
Last edited by VTCruiser; 07-23-07 at 12:00 PM.
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07-23-07, 09:59 AM
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#6 (permalink)
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Drinking the Kool-aid
Join Date: Aug 2006
Location: On a darkling plain
Posts: 182
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That works. Thanks!
I snooped through your gallery there... nice travel pics too!
__________________
'88 FJ62 - 12HT conversion, OME Lift, ARB front bumper, Roof Rack
'04 Prius - stock
'66 Pearson Commander - a hole in the water to throw money into.
__________________________________________________ ________________________________________
And we are here as on a darkling plain
Swept with confused alarms of struggle and flight,
Where ignorant armies clash by night.
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07-23-07, 12:00 PM
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#7 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Quote:
Originally Posted by Creeker
I snooped through your gallery there... nice travel pics too!
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thanks!
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07-23-07, 12:32 PM
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#8 (permalink)
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Forum Lifer
Join Date: Dec 2002
Location: nashville, tn
Posts: 2,637
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consider this my subscription. mass heckling to follow.
can't remember from talkin this weekend, but when is the estimated/desired completion date?
malphrus
__________________
'these are my awards, mother, from army. the seal is for marksmanship and the gorilla is for sand racing.'
...build-up here (stalled)...
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07-23-07, 01:40 PM
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#9 (permalink)
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Site Addict
Join Date: Feb 2005
Location: the valley, yeah that one
Posts: 1,508
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I like the crown royal banner....
__________________
no cruiser right now :(
1995 Volvo 850 Turbo
defender of the good, mo-fessional drunk, total art-fag, and all around nice guy...
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07-23-07, 01:50 PM
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#10 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Quote:
Originally Posted by 72cruiser
consider this my subscription. mass heckling to follow.
can't remember from talkin this weekend, but when is the estimated/desired completion date?
malphrus
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TBD 
really though, it depends. I need to make some decisions about some things (paint for example) that will be big factors in the completion time. I'll go ahead and say hopefully by the end of the year though.
EDIT: thanks for the help this weekend btw.
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07-23-07, 01:50 PM
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#11 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Quote:
Originally Posted by philos1
I like the crown royal banner....
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07-23-07, 02:08 PM
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#12 (permalink)
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Forum Lifer
Join Date: Dec 2002
Location: nashville, tn
Posts: 2,637
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no problem buddy...sorry i wasn't there for pullin the engine.
i guess you enjoyed my 'help' when i showed up around midnight, right? what a great idea, free yuengling, ha ha.
if you want to enter 'build-off' mode, i'm game...i really don't think that josh's bronco is goin to get any more attention since he's workin most saturdays up at the plant now b/c they are down 2 engineers...
i'll let you know asap about the pedal assembly and other parts, but those are goin to be in phase II of the build after i get done with the body, frame, and suspension.
malphrus
__________________
'these are my awards, mother, from army. the seal is for marksmanship and the gorilla is for sand racing.'
...build-up here (stalled)...
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07-23-07, 02:31 PM
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#13 (permalink)
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Is this the end of Rico ?
Join Date: Nov 2005
Location: duh Valley, Dude.
Posts: 1,949
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Did you pull the Engine and tranny as a combo or do them separately?
I'm getting ready to pull the block (head is already off), but don't know which is easier...
Also, I can't remove that front headlight assembly without disconnecting the A/C and I'm trying not to have to do that... Wondering if the whole thing will fit through the opening with the headlight assem. still there?
Sorry if I hijacked this a little... But your project looks great!
S. 
__________________
5/85 FJ60 Rblt & Balanced 2F, H55, 4.11's, Rear FF w/ARB locker, OME 3" & shackles, ARB old style front, Kaymar rear, 33x10.5 BFG MT on black AR rims, and a whole lotta other crap and $$  that took the last 2 years of my life and pissed off the  
Support MUD Vendors: www.marksoffroad.net -- Escuela vieja hablada aquí
BEST WWII STORY EVER WRITTEN
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07-23-07, 03:13 PM
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#14 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Portland OR
Posts: 1,050
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Quote:
Originally Posted by Spike Strip
Did you pull the Engine and tranny as a combo or do them separately?
I'm getting ready to pull the block (head is already off), but don't know which is easier...
Also, I can't remove that front headlight assembly without disconnecting the A/C and I'm trying not to have to do that... Wondering if the whole thing will fit through the opening with the headlight assem. still there?
Sorry if I hijacked this a little... But your project looks great!
S. |
Using an engine hoist (cherry picker) I lifted my engine out without removing the radiator support bracket and I took my a/c compressor off the engine and left it hooked.
__________________
85 FJ60, testing, Cummins 4BTA, manual 4L80E, 203 to splitcase doubler, SOA, 38s, some other stuff.
build-up: Family Haulin' FJ60
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07-23-07, 03:37 PM
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#15 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Quote:
Originally Posted by Spike Strip
Did you pull the Engine and tranny as a combo or do them separately?
I'm getting ready to pull the block (head is already off), but don't know which is easier...
Also, I can't remove that front headlight assembly without disconnecting the A/C and I'm trying not to have to do that... Wondering if the whole thing will fit through the opening with the headlight assem. still there?
Sorry if I hijacked this a little... But your project looks great!
S. |
I pulled the engine, trans and tcase out as a unit which required removing the rad support. as boots mentioned you should be able to pull the block out alone without doing so, however, the hoist points (hooks) are on the head so you may need to get creative in that respect.
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07-23-07, 03:42 PM
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#16 (permalink)
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Forum Lifer
Join Date: Dec 2002
Location: nashville, tn
Posts: 2,637
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when i pulled my 2F/tranny/tcase out of my 40 i had to use a strap and some chain to get it hooked up to the hoist b/c i too had already pulled the head and didn't have those nice hooks...
a load leveler would have made things much easier, so pick one up if you have that option
__________________
'these are my awards, mother, from army. the seal is for marksmanship and the gorilla is for sand racing.'
...build-up here (stalled)...
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07-23-07, 04:05 PM
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#17 (permalink)
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Is this the end of Rico ?
Join Date: Nov 2005
Location: duh Valley, Dude.
Posts: 1,949
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Thanks, guys, for the info and pix! The ONLY thing I'm hesitant to duplicate is Boots' "log cabin" jack stand 
The rest of the info I'll use this weekend!
S.
__________________
5/85 FJ60 Rblt & Balanced 2F, H55, 4.11's, Rear FF w/ARB locker, OME 3" & shackles, ARB old style front, Kaymar rear, 33x10.5 BFG MT on black AR rims, and a whole lotta other crap and $$ that took the last 2 years of my life and pissed off the
Support MUD Vendors: www.marksoffroad.net -- Escuela vieja hablada aquí
BEST WWII STORY EVER WRITTEN
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07-23-07, 05:15 PM
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#18 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Portland OR
Posts: 1,050
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Quote:
Originally Posted by Spike Strip
Thanks, guys, for the info and pix! The ONLY thing I'm hesitant to duplicate is Boots' "log cabin" jack stand
The rest of the info I'll use this weekend!
S. |
The rig is supported down the frame with pair of jack stands, those are there as a fail safe.
__________________
85 FJ60, testing, Cummins 4BTA, manual 4L80E, 203 to splitcase doubler, SOA, 38s, some other stuff.
build-up: Family Haulin' FJ60
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07-23-07, 05:20 PM
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#19 (permalink)
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Site Addict
Join Date: Jun 2007
Location: Portland OR
Posts: 1,050
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You can see one in this shot.
__________________
85 FJ60, testing, Cummins 4BTA, manual 4L80E, 203 to splitcase doubler, SOA, 38s, some other stuff.
build-up: Family Haulin' FJ60
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07-23-07, 05:41 PM
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#20 (permalink)
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250+ Club
Join Date: Nov 2006
Location: Hella Colorado
Posts: 444
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took me a second to realize those springs were unhooked and hangin down... i was like wha?? but i get it now 
dope build up!
__________________
Sept. 1985 FJ60, bike hauler with attitude
Looking for a 2h or 12ht and a h55 
For sale:
1972 Buick Lesabre custom
1970 VW Baja bug (street legal)
1984 Toyota pick up (2wd)
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07-25-07, 08:03 PM
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#21 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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pictures fixed...
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07-26-07, 04:41 AM
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#22 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Wednesday's progress....
it looks like I might be painting the cruiser while I have it stripped down, it really needs it. I am leaning toward a single stage solis for ease, either in freeborn red or tan/beige. So anyway, the strip down continues....
I have pulled most of the lights, chrome and badges from the exterior, doors and windows are next.
The grey interior is coming out, I will be using the brown interior from the HJ.
Last edited by VTCruiser; 01-08-08 at 05:59 PM.
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07-26-07, 04:46 PM
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#23 (permalink)
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Join Date: Feb 2007
Location: Nashville TN...But I miss Richlands NC
Posts: 1,191
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If thats the body stiffening stuff I've see on minis I've always wondered how a Truck would get around without all that cast heavy stuff but you got Compression Ignition............................
Ever heard of anyone taking that stuff out?
Just wondering.............
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07-26-07, 04:56 PM
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#24 (permalink)
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Ride On...
Join Date: Sep 2003
Location: North Florida
Posts: 7,085
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Awesome. Good move keeping the brown inside. Me likey.
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07-26-07, 05:02 PM
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#25 (permalink)
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Forum Regular
Join Date: Oct 2005
Location: land of oz
Posts: 224
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this looks good VT,no rust in roof?
cheers goldchaser
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07-27-07, 04:33 AM
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#26 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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Quote:
Originally Posted by goldchaser
this looks good VT,no rust in roof?
cheers goldchaser
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nope!
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07-27-07, 04:46 AM
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#27 (permalink)
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Former Lifer
Join Date: Feb 2005
Posts: 3,452
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are you done yet?
__________________
Real Americans drink PBR
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07-27-07, 07:19 AM
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#28 (permalink)
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250+ Club
Join Date: Oct 2004
Location: near my girls
Posts: 622
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Looking great Kieran!
My interior is totally stripped and I love it that way.
Easy to hose out after a trip and spills are non existant.
Looking forward to the buildup, I am comtempleting a 4BT or
LT-1 E-85 ready V8 swap on mine.
john
__________________
No cruisers left behind, they all deserve a good home 
BIG WAGONS RULE
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07-27-07, 09:29 AM
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#29 (permalink)
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250+ Club
Join Date: May 2004
Location: Below Da Bridge
Posts: 636
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Rusty HJ60:
Donor FJ60:
 [/QUOTE]
.........Rusty??? Looks good to me. But I'm in Michigan. We have opted to destroy our vehicles over time (salt) instead of all at once (crashing on slippery roads).
__________________
"Love God, love your neighbor." JC
93 FZJ 80 Locked!
97 FZJ80 Collector's Edition- domestic servant
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07-27-07, 09:53 AM
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#30 (permalink)
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UC Webmaster
Join Date: Sep 2003
Location: Vermont
Posts: 3,128
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oh it's rusty alright. The mud in that photo is hiding it all. The hood and roof are the only two clean panels on it. I'll post pics of the devastation when I start stripping it down.
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VTCruiser
