[VTCruiser]

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 or see "Sight Unseeing" the May/June Issue of Toyota Trails

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...

***************************************
- 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 -

• 1990 FJ62 (67, 69, 76)

- POWERTRAIN -

• 1HZ/H55F (130, 138, 139, 144, 145, 147, 159)
• AAI Turbo Kit - CT26, OE Boost Compensator (335, 378)
• Vacuum shift 4WD (182, 276)

- 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 (375)
• 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)
• Tuffy Console (205)
• Passenger grab bar (281)
• Split Rear Bench (314, 373)

- ARMOR -

• ARB (379)

- ACCESSORIES -

• Shifter-mounted Hand Throttle (283)

- ELECTRICAL -

• Misc. Electrical (181, 182, 187, 261)
• Contour E-Fan Conversion (187, 261)
• RoundEyes Headlights (276)
• Dual Batteries, Luna Isolator (374)

Here is the direct link to the GALLERY

***************************************

[Dirtgypsy]

nice!!!

clint

[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...

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...

[Creeker]

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...

pics? I'm definitely following this one too.

[VTCruiser]

hmm...they were working earlier, I'll have to try re-linking them...

until then, here is a direct link to the gallery...

gallery

[Creeker]

That works. Thanks!


I snooped through your gallery there... nice travel pics too!

[VTCruiser]

Originally Posted by Creeker

I snooped through your gallery there... nice travel pics too!

thanks!

[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

[philos1]

I like the crown royal banner....

[VTCruiser]

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

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.

[VTCruiser]

Originally Posted by philos1

I like the crown royal banner....

[72cruiser]

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

[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.

[boots4]

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.

[VTCruiser]

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.

[72cruiser]

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

[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.

[boots4]

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.

[boots4]

You can see one in this shot.

[Nemesis Gnat]

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!

[VTCruiser]

pictures fixed...

[VTCruiser]

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.

[tntoyota]

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.............

[lowtideride]

Awesome. Good move keeping the brown inside. Me likey.

[goldchaser]

this looks good VT,no rust in roof?
cheers goldchaser

[VTCruiser]

Originally Posted by goldchaser

this looks good VT,no rust in roof?
cheers goldchaser

nope!

[beaufort-fj60]

are you done yet?

[redcorn]

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

[timbercruiser]

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).

[VTCruiser]

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.