Cooter’s Revenge: Vorteq FJ60 (1 Viewer)

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Nice to see the work that went into this! Looking good.
 
Hoping for another post marathon here. I left off with that silly wiring picture...

I pulled all the wiring research I could off of LT1swap.com. Brendan has done a tone of the work for us and he make all the information readily available. It is also a pretty affordable option for the PCM programming. I downloaded the appropriate wiring pin-outs and started disassembling the harness. It did not really take long to do so. If i had used the harness as is, it would have really been a lot less time consuming, but I wanted to make the harness custom length so I had to completely de-pin the PCM connectors and label every wire. Since I did that, I pretty much just disassembled the harness as much as possible down to the individual connectors. I did not do all of it due to shared grounds but got a lot of the way down. Then I laid ckts in one at a time and did any re-routing that I wanted. Once I had all of the original ckts back on the engine in place, I actually figured out how the pcm would be mounted. Then I did the re-pinning as I installed ckts back into the PCM connectors. If I had a ton of space to lay out the harness and leave it somewhere I probably would have done it differently, but work space dictated that I do it on the vehicle.

Disassembling harness in the living room.
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Mid harness install pic: Lots of wires...
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Getting there, prety much ready to put fenders back on and figure out PCM mounting:
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Fenders back on and testing PCM mount and new engine compartment fuse box locations:
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I did not document the re-pinning as it was a lot of sitting on my rolling stool stripping and crimping wires... Once I figured out the length and the routing, I puled the fender back off and put a piece of plywood on the wheel for a table and went to town.

Post pinning and starting to tie power ckts to fuse box. By the way, the fuse box is out of a 2007 Trooper I think. I just walked around the yard until I found a fuse box that looked pretty easy to disassemble with close to the right number of relay ckts and fused ckts. Turns out it mounts pretty nicely also.

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Nuther shot:
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Rats nest in work:

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All ckts into PCM connectors, so loom going on. I had also started it at this point, but we need to go back in time a iittle before we get back to the first smoke video.
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one more:
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Aside. I was working on esting powers and gorunds to all ckts and had the battery rigged up like this. My wife decided to hang out in the shop with me this night ( also the first start night) looked at my temporary battery tray rig and was appalled at the state of the tray and wondered aloud as to why I would not replace this with it having soo much rust. My response was that items such as this were not in the budget...She disagreed. So I got a new stainless battery tray :clap:

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Fuel system: Lots of reading to figure out what to do. In the end I decided to go with a in tank conversion from tanksinc.com. This guy.

I probably could have used something a little different, but it had everything I needed and more. I also went with russell twist lock hose and -an fittings. My rail had a return line, so I had to run both lines. I did so in 3/8".


My tank had a little surface rust and Cooter had already had the recall performed, so I had my tank boiled at the local shop. They did not htink I needed to recoat. We will see how that goes in the end. So far so good. So I went ot modifying the tank for the pump kit. This was paramount to getting the fuse box installed and testing everything out as I needed fuel to make her purr.

All parts in same picture.
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Cutting the hole was a little nerve racking, but I just double and triple checked then went at it.

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You can see that I had more surface rust form in the month of sitting. I did go back after getting everything ready and do another tank clean out and a hefty coating of WD-40 before putting gas in.

Feeling good about the cut.
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All lined up and holes drilled
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Flange ready for welding. I just put a few tacks to hold it in place.

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Pump Module ready to go in. The kit comes with a baffle, but I modified the kit to use the stock baffle in the tank. I did have to squeeze the sock into the stock baffle. I would call it a snug fit.



Close up:
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And idea on how I had to mod the plate to fit into the stock baffle
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Harness and hoses installed.

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I plugged the vent in the pump flange as the tank was already vented.

Made a pretty simple fuel filter bracket out of something i had laying around. Contoured to frame at top.

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Piece of rubber around the filter itself.

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First start coming soon.
 
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I forgot to mention this, but i took this shot with the intention of a post in a thread someday. I have been wheeling for a long time and have built quite a few vehicles, but have never had the pleasure of receiving one of these. I was very excited when I came home to it sitting on my front porch...:bounce::bounce2::bounce::bounce2:

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OK, first start... I will admit that this is actually the second start and the first start fumes were already evacuated. BUT when I started it the first time, I could not figure out for the life of me why it would barely run. I was a little worried until I noticed that I had forgot to remove the plastic from around my air filter. And yes, the garage is closed ( I opened the door immediately after) but I wanted to revel in the fumes for a minute and it was pretty close to freezing outside.

Unedited, excuse the happy dance :smokin:

 
Just fell down a youtube pit for at least an hour.
 
Awesome work @bush !

The happy dance is the best feeling in the world. I like the custom cross-member you did for the transmission. Looks easy to service. The early three-piece is a PITA if you ask me. The later trucks had a one piece that is superior.

What are you using for a shifter? (hopefully I didn't miss that while reading).
 
Thanks @klinetime574! Yes, cross member makes for easy driveshaft work and trans pan access. Shifter is coming, I used a Winters, and there are a few pics. Used to be called Art Carr. I like the positive engagement of the gates and I plan to eventually build a center console with adequate cup holders, cable shifters for the TC, lots of storage and flush mount the shifter.
 
Pedal installation.

Admittedly, I currently HATE the pedal! It sits too high (I'm tall) and my leg falls asleep after about 30-45 minutes of driving (I just haven't fixed it yet as I rarely drive longer than that, but it is HIGH on my list).

I used the pedal directly from the donor vehicle. It angled to the right into the tunnel, so the pedal itself was cut off. I thought for a minute that the remaining piece would be pretty much a direct bolt in, but firewall required it to be mounted a little crooked. See first pic. So I made a plate to shift the entire pedal assembly toward the steering column as much as possible (maybe 2 inches due to harness plug interference) and bolted to OE pedal bolt holes. Once I got the assemble mounted, the pedal itself took quite a few iterations to get to what I have and clears carpet and floor mat to give full throttle motion.

Crooked pedal barely hanging on.
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A little straighter once moved over.
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Another view.
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Working out the plate to shift assembly over.
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Ended up using square tube t connect original toyota pedal to chevy DBW assembly
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I ended up trimming the original pedal arm to fit into the square tube, this also allowed me to shift it to the left another inch. Things was tight like gnat booty...

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I wanted a shifter that had 100% positive engagement and felt a little hot rod/crawler at the same time so I went with a Winter's Sidewinder gate shifter ( the shifter formerly known as Art Carr). I went with a standard gate pattern. Part of the idea is that it will flush mount in a future custom built center console. Knowing that, I did have to figure out how to make it work. So I made a plate to cover the original shifter hole, drilled the riser/console that came with the shifter to match the pattern and had to trim the existing center console to fit over the shifter. I cut a hole in the floor riser just forward of the center concole and drilled a hole under the FJ60 center console to pass the cable through.


A shot when I wast test fitting
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Side shot, you can see how much of the console was sitting on the shifter, I just notched that front corner to allow things to sit almost flush. There is still about 2" under my FJ60 enter console in the front. I used some rubber bushings under the console at the front bolts and the rear bolts are unmodified. Essentially, the FJ60 console now sits at a bit of an angle.
If you look real close you can also see the hole I cut in the floor riser to pass the cable through. Ended up with no binding, although it is a b*tch to get out.

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Finished shot

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I can get a better shot if anyone wants...
 
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Did some measuring and checked angles 5 times, then called Tom Woods and had multiple conversations and email exchanges with Shawn Woods ( his son and resident machinist). Ended up using the original drive shaft setup for the front and had to get a custom double cardan built for the rear due to angles. I pushed things too far back and to the drivers side to use the stock u-joint set up.

I had to clear the trans pan quite a bit to make the front shaft work. A little hammer massage and some filing and some grinding made it happen.

This is test fitting before new shafts.
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I could only get the pan over so far before it started hitting things inside, so out came the file. You can also see where i have been grinding the side down to make a little room.

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Finally...
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Didn't show that I had to trim the pan surface and the pan back at that corner. Ended up using torx head bolts and had to apply some extra sealant to the corner to get it to stop dripping fluid. All seems to be working fine now with no leaks.

Shafts installed... My shafts a woody! :)
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Used Chevy factory transmission cooler lines to almost front of engine, compression fittings with hose barbs, ran under engine to passenger side, then through hole similar to ac line hole to transmission cooler.

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Wrapped the lines in some wire loom to avoid chaffing. No gold bond available ,)
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Trans cooler. Was able to squeeze it under the ac line.

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Missed the pedal module mounting location in the pedal section. Passed the harness through existing hole in firewall and mounted below brake booster.

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x2 great work Jason!

Will be cool to see the custom center console you're thinking of doing to integrate the shifter. Look forward to that!
 
x2 great work Jason!

Will be cool to see the custom center console you're thinking of doing to integrate the shifter. Look forward to that!
Thanks @klinetime574 ! I am also interested to see what I come up with. I have a few more things to finish interior wise before I start, but i am thinking dash to rear floor riser, flush mounted shifter, cable shifters for TC ( I have some left over shifter cable from a few other projects), cup holders that will hold a real coffee cup, storgae, and a place to rest my arm. It will be 10 lbs of crap in a 5 lb bag for sure.
 

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