Builds 1987 FJ60 Expedition Build

[KeepCruzin]

Sunday Update:

Before the week starts and I get bogged down in the swap, I thought Id share my wiring plan.

I am going to be doing a split system. The engine, glow screen, starter, etc. will be run on 24 volts from the original alternator. The rest of the truck will remain 12volt.
My plan is to use a relay system and split the two harnesses into basically independent systems. The only 24 volt accessory in the cab will be the gauges. The tach will be 24, as will the temp, oil etc. The speedo I will be changing to MPH.

That will be a little custom side build as I have to modify the housing and whatnot.

Build resumes tomorrow at 8:00! Stay tuned!

 

[KeepCruzin]

Another day at the shop.

I was alone at the shop almost all day. They locked up at 10am and I only had a couple tools and minimal hardware with me in the alley. Didnt get a TON done, but I got the air cleaner mounted (kinda). Its REALLY sturdy, no play, super strong. But I could only mount it by two bolts because the bracket doesnt conform to my truck very well. I dont want to re-weld and fab a bracket so I think Ill leave it for now.
I got the fuel filler neck back in, and the exhaust roughed out. I got a few bends tac welded, and should fab it up tomorrow.
I dont have a pipe bender, so Im pie cutting each bend, then bending it with a prybar. Not the best solution I know, but hey, it works.

Im going to mount the Vac chamber and power steering reservoir tomorrow, and connect all the heating elements.

I cant figure out how the damn gas pedal assembly works with the cable...... Gonna check an 80 out and see how it works.

Stay tuned. We're close!

 

[KeepCruzin]

The end is near.....er

I did some serious work today.
Mounted the air cleaner
Mounted the power steering reservoir
Mounted the vacuum pot
Plumbed all the heating lines
Plugged the hole in the block where a L comes up for the rear heaters that I don't need.
Mounted my AC radiator
Built and mounted my new custom throttle pedal.
Thought a LOT about how the heck I'm gonna rig up a throttle assembly.
BUILT MY EXHAUST!!!!

Oh. And I taught myself how to MIG weld. Hahahaha

Please. No judgement of the welding. I can stick weld pretty good, but today was the first time I picked up a MIG. Don't worry, this exhaust is only temporary.

Got the exhaust laid out. Without a bender I had to pie cut, then bend, then weld. I know. It's gonna leak.

Then I started building my gas pedal!
I needed the cable style pedal from the HJ, but the RHD pedal was curved into the wall, so I cut it off and put on my old pedal arm, and welded it all together.

Then I built a plate to mount it on, plugged the old hole in the firewall, and drilled the new throttle hole.

I also put the hood on hahaha

I also measured out the angles and whatnot for my new peer steering lines. The pump is on the opposite side of the engine from the actual steering box, so I need some pretty long lines.

I'm going to drop off the dimensions at a local guy in Napa who said he'd do it for me. Should be in by tonight

 

[fl4031003]

Fj62 lines might work

 

[Slow Left]

That down pipe looks like the same one that comes stock on my FJ60. Is it? If so, do you know what the diameter of the stock exhaust piping is?

The custom exhaust work that @GLTHFJ60 has been doing on 'Moonshine' caught my attention, and made me start thinking....so I'll pose the question to you both:

Would building a custom 3" off a stock exhaust manifold yield any improvement (I'm thinking along the lines of performance - better 'breathing')?

You would have to open up the hole at the bottom of the manifold to fit the 3" pipe, I would suppose, in order to get any benefit of improve gas flow, since if you kept it the same, it would remain a choke point...and then there would be the deflector plate to deal with, too... Anyone doing this?

Anyway, I like the idea of using the v-bands when customizing the exhaust:

https://forum.ih8mud.com/threads/rotw-moonshine-glthfj60.180252/page-121

 

[KeepCruzin]

That down pipe looks like the same one that comes stock on my FJ60. Is it? If so, do you know what the diameter of the stock exhaust piping is?

The custom exhaust work that @GLTHFJ60 has been doing on 'Moonshine' caught my attention, and made me start thinking....so I'll pose the question to you both:

Would building a custom 3" off a stock exhaust manifold yield any improvement (I'm thinking along the lines of performance - better 'breathing')?

You would have to open up the hole at the bottom of the manifold to fit the 3" pipe, I would suppose, in order to get any benefit of improve gas flow, since if you kept it the same, it would remain a choke point...and then there would be the deflector plate to deal with, too... Anyone doing this?

Anyway, I like the idea of using the v-bands when customizing the exhaust:

https://forum.ih8mud.com/threads/rotw-moonshine-glthfj60.180252/page-121

I have been keeping an eye on Moonshine, and I know what your talking about with the exhaust vbands.
The downpipe is NOT the same as the stock 60. I took this one from the HJ61. It has a two foot flexible section to account for the increased vibration caused by the diesel.
It is 2.75inch diameter, not 3 inch.
Larger pipe is less restrictive and thus better for performance, so yes, 3in is great for diesel.

I don't have a "manifold" per-say because there is just a single dump pipe under the turbo charger. It dumps in 3inch but the fitting on the end is 2.75 so I stuck with it. I'll probably straight pipe 3inch later

 

[Slow Left]

I have been keeping an eye on Moonshine, and I know what your talking about with the exhaust vbands.
The downpipe is NOT the same as the stock 60. I took this one from the HJ61. It has a two foot flexible section to account for the increased vibration caused by the diesel.
It is 2.75inch diameter, not 3 inch.
Larger pipe is less restrictive and thus better for performance, so yes, 3in is great for diesel.

I don't have a "manifold" per-say because there is just a single dump pipe under the turbo charger. It dumps in 3inch but the fitting on the end is 2.75 so I stuck with it. I'll probably straight pipe 3inch later

Alright, thanks for the clarification Cruzin. I wish I had 12H-T problems, but my problems are 2F...

All this cool exhaust work has got me thinking about trying to line up 3" pipes from a stock 2F manifold, but if the manifold port stays stock size, I'm wondering if there would be a benefit. Even if it is (possible to bring the manifold port out to 3" diameter), with a 2F I'm wondering how I could quantify the benefit.

Anyways, good stuff with your diesel swap. That's gonna be swell when you get it all set!

 

[The Machinist]

Alright, thanks for the clarification Cruzin. I wish I had 12H-T problems, but my problems are 2F...

All this cool exhaust work has got me thinking about trying to line up 3" pipes from a stock 2F manifold, but if the manifold port stays stock size, I'm wondering if there would be a benefit. Even if it is (possible to bring the manifold port out to 3" diameter), with a 2F I'm wondering how I could quantify the benefit.

Anyways, good stuff with your diesel swap. That's gonna be swell when you get it all set!

Remember that naturally aspirated and turbo charged engines respond differently to exhaust diameter increase. In a turbo application you generally want as much pressure build up as possible before the turbo to spool the turbine quickly, but MINIMAL pressure behind the turbo so that the turbine is not slowed down by the resistance of the air being forced through the pipe. In a naturally aspirated engine, you need a certain amount of back-pressure to help in scavenging gasses from the cylinders. Going with too large of an exhaust on a naturally aspirated engine will reduce bottom end power but increase top end flow; good for race trucks that constantly hover near redline, bad for slow offroading/crawling where the low end torque can keep you from stalling at low speeds.



@KeepCruzin, do you think your going to make it up to Gold Lake this weekend?

 

[KeepCruzin]

Remember that naturally aspirated and turbo charged engines respond differently to exhaust diameter increase. In a turbo application you generally want as much pressure build up as possible before the turbo to spool the turbine quickly, but MINIMAL pressure behind the turbo so that the turbine is not slowed down by the resistance of the air being forced through the pipe. In a naturally aspirated engine, you need a certain amount of back-pressure to help in scavenging gasses from the cylinders. Going with too large of an exhaust on a naturally aspirated engine will reduce bottom end power but increase top end flow; good for race trucks that constantly hover near redline, bad for slow offroading/crawling where the low end torque can keep you from stalling at low speeds

@KeepCruzin, do you think your going to make it up to Gold Lake this weekend?

Great explanation!!

No. I'm going as hard as I can but the wiring isn't in my control. The guy who's doing it said he could get it done by Monday.

I'll be there next year!!!!

 

[KeepCruzin]

Here's what I got done today

Set up flood lights for night work
Cleaned up the ally and picked up all my old parts
Installed front grill
Drilled and seated the throttle cable
Mounted the throttle pedal assembly
Pulled the choke cable
Fabricated a bracket for the throttle cable
Fabricated an adjustable arm for throttle throw distance
Made my own mount for my radiator overflow can thing
Got ready to wire everything up
Pulled power steering lines and took measurements for the new ones I'll have made tomorrow.

Bracket for radiator overflow

Throttle problem

Throttle bracket solution

New floodlights kick butt!

It sounds strange but I was more stoked on how the bracket for the radiator overflow turned out than almost anything else this week. It's the little things that are the most enjoyable sometimes.
I'll get a better picture of it with the reservoir mounted. It's perfect, and really adjustable. Made out of an old battery tray arm.

 

[cruisedeisel]

Beer cans work way better that pop cans.

 

[KeepCruzin]

Beer cans work way better that pop cans.

Ok?????

I have no idea what your talking about but I'll take your word for it.

 

[The Machinist]

[QUOTE="KeepCruzin, post:]


[/QUOTE]

Using quotes goes a long way towards making your point. @cruisedeisel

 

[KeepCruzin]

[QUOTE="KeepCruzin, post:]

[/QUOTE]

Thank you! I was so lost as to what he was talking about hahaha

 

[KeepCruzin]

Last day of "mechanical" work.
I got the throttle finished, and the air cleaner back in.
I re-laid the carpet and insulation in the drivers footwell
Then I put away all my tools, stored my leftover and spare parts, cleaned up the ally, pulled off the cardboard garage, stepped back, and took a good look at my new truck.

The ball is no longer in my court. Iv done everything but finish the power steering, fill the tank with diesel, and prime the fuel system.

Those two things should happen tomorrow or Saturday. Beyond that, Jeff is going to handle the wiring. As a result, the finish date will depend solely on his ability to wire this baby as quickly as he can.

My parents broke the news to me that I will be leaving to go to work next Thursday with or without my truck. I work for my dad operating heavy equipment, and my deadline is almost here.

It would kill me to be working and know that I went that hard for that long only to have it sitting in the ally 95% done......

I likened it to running a marathon, only to have your shoes come untied 10 feet before the finish line.

Regardless. It's almost done

Here's that mounting system I was so excited about

 

[KeepCruzin]

Before

After

 

[The Phoenician]

That's sexy. Great job man

 

[KeepCruzin]

That's sexy. Great job man

Thanks man! I'm really stoked to fire it up!

If I can just get my guy to wire it :/

 

[KeepCruzin]

New fuel filter and modified gauge cluster

 

[KeepCruzin]

Soooo the truck has been done for a week or so now (other than wiring). Iv done just about everything I can other than wire everything. Unfortunately the guy at the shop who said he'd wire it for me hasn't been able to start. He's really busy but its torture being so close and not being able to do anything about it. I really want my truck back!