Build 1987 FJ60 Revival

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Beautiful looking truck!
Regarding the clips for the chrome strip at the windows:
 
Medium size update for today... I was able to get the rest of the chrome trim removed from the doors but I did end up breaking some of the clips, so I'll have to source those.

The shop has been really busy with customer cars recently so they haven't been able to spend as much time on the FJ as I had hoped. Thankfully though I'm starting to see the light at the end of the tunnel with the restore. Here are a couple pics of the progress the past week or two.

Happy to report that the truck has finally been primed and painted! Fingers crossed, I'm planning on beginning assembly next week and hoping to have this thing road worthy again by the end of January.

As a side update, I ended up purchasing a tan '84 FJ60 from TN that I am also planning on lightly restoring. Thinking I caught the FJ bug... its not as rusty as the white one so I'm up in the air on which one I want to keep vs. sell. I'll upload some pics of the tan one once we start working on it.

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happy to see you kept it the best 60 series color. Amazing work so far dude
 
Beautiful looking truck!
Regarding the clips for the chrome strip at the windows:
Thanks! Will probably end up grabbing like 20 of those!
happy to see you kept it the best 60 series color. Amazing work so far dude
Thank you! Same here, wouldn't have it any other way. I'm planning on keeping it as original as possible aside from an OME steering damper, 31x10.5x15 KO2s and some Bilstein 4600s!
 
Its finally starting to look like a Land Cruiser again but putting it all back together is taking a little more time than expected, but thats just how it goes. The paint looks so good in person and I'm really, really pleased with how it turned out.

Anyway, heres a quick update on progress so far. The doors/hardware, fenders, and hood have been put back on the truck. All of the windows have been reinstalled as well. I went with an OEM front window gasket to retain the chrome strip. We also painted the red tow hitch and trail tailor rear crossmember black.

Hoping for another update early next week!

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Well, its a month later and not much has happened. Finished installing the TrailTailor C Channels and working on getting the body fitment on the front-end correct. The fenders and headlight bezels are especially troublesome, and I think this is an issue overall with FJ60s as I took a look on BAT and lots of the restored/repainted FJ60s on there have funny fitment of the hood/fenders/headlight bezels.

Anyway, I'm hoping to finally fine tune the panel fitment this week and get this thing out of the shop!

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Are you sure you have the headlight bezels on tye correct sides?
I think so, but the ones on the truck now are from another FJ60 and the body guy is just using them for fitment purposes. I have the better condition originals in a box that I'll install when I get the truck back to my house.
 
Wow has it been a while. How about an update?

Lots has happened since February. The White Fj60 is 99% completed. I installed 31x10.5x15 BFG KO2s, fully assembled the interior, fab'd new vapor barriers for the door panels, and cleaned/updated some of the vacuum routing/wiring in the engine bay. After replacing the rusted metal in the wheel wells they were sanded down to bare metal and painted black. Below are some pics of some of the things I've done since the last update:

Fab'd new door panel vapor barriers with new butyl rubber for all 4 doors. I also installed new Pioneer speakers with foam backing tape behind the speakers to reduce vibration:
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Wheel well post-rust repair. Sadly the wheel wells could have been taped off better but I didn't have the time to do this myself so the guys at the shop helped with it. I can clean them up later.
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Bad pic, but the door panels and interior in general is in GREAT condition aside from the drivers seat. I had all the hardware for the interior organized in labeled zip lock bags which helped immensely with putting it all back together.
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Finally, this is LC on its obligatory first Costco run. I think it sits pretty nicely with the new tires and OEM suspension. The paint looks great and I'm loving the fishbowl look with non-tinted OEM glass.
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Costco run X2
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I'm probably going to be listing this FJ60 for sale soon as I have absolutely wayyy too many projects going on at home right now. My tan FJ60 is also done with the windows out repaint and bodywork so I have that one at the house and am slowly putting it back together as well.

I know the market has shifted a bit since purchasing the white FJ60 last year. I've sunk a lot of time and money into it and believe it will keep someone happy for a long time. Its definitely not perfect by any means but I've done the majority of the heavy lifting so far with the windows out repaint and rust repair, TrailTailor rear C-channels and rear bumper cross-member, plugs, fluids, etc. It runs great and the previous owner installed a Saginaw power steering pump upgrade with bracket, new oil pump and I believe they rebuilt the head. The truck is a clean title zero accident FJ60, is fully de-smogged and has ~300k miles. The only items left that I would do are take care of a few minor rust areas underneath the body and then repair the drivers seat. How much do ya'll think is a fair price to list for?

Also, heres a pic of my backyard for giggles. Its bad and the misses isn't happy with me...

After taking this pic I threw some plastic tarp under both FJ60s so they wont rust from the dirt/grass. I definitely have slight addiction to FB marketplace and have purchased a few new projects to keep me 'busy'. I'm thinking of creating a build thread for the tan one but can just keep it going in this thread, too. Its not running and has been sitting since 2004. I got it to pop off with ether but it cranks over like a cylinder or two has low compression. I have the carb off now and am rebuilding it. The PO also used a bunch of gasket sealer on the intake manifold where it meets the head, so that'll be fun to fix. This one will need new carpet and a few other odds an ends. Hopefully not a motor though, lol.

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I purchased this thing sight unseen from California at an auction earlier this year. Its a super rare manual '85 Tercel 4WD SR5. Clean title and zero rust. It was sitting for ~14 years and I got it running after draining the tank and cleaning the carb. Definitely a fun little car to tinker with and a keeper for sure.

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I'm probably going to be listing this FJ60 for sale soon as I have absolutely wayyy too many projects going on at home right now. My tan FJ60 is also done with the windows out repaint and bodywork so I have that one at the house and am slowly putting it back together as well.

I know the market has shifted a bit since purchasing the white FJ60 last year. I've sunk a lot of time and money into it and believe it will keep someone happy for a long time. Its definitely not perfect by any means but I've done the majority of the heavy lifting so far with the windows out repaint and rust repair, TrailTailor rear C-channels and rear bumper cross-member, plugs, fluids, etc. It runs great and the previous owner installed a Saginaw power steering pump upgrade with bracket, new oil pump and I believe they rebuilt the head. The truck is a clean title zero accident FJ60, is fully de-smogged and has ~300k miles. The only items left that I would do are take care of a few minor rust areas underneath the body and then repair the drivers seat. How much do ya'll think is a fair price to list for?

Also, heres a pic of my backyard for giggles. Its bad and the misses isn't happy with me...

After taking this pic I threw some plastic tarp under both FJ60s so they wont rust from the dirt/grass. I definitely have slight addiction to FB marketplace and have purchased a few new projects to keep me 'busy'. I'm thinking of creating a build thread for the tan one but can just keep it going in this thread, too. Its not running and has been sitting since 2004. I got it to pop off with ether but it cranks over like a cylinder or two has low compression. I have the carb off now and am rebuilding it. The PO also used a bunch of gasket sealer on the intake manifold where it meets the head, so that'll be fun to fix. This one will need new carpet and a few other odds an ends. Hopefully not a motor though, lol.

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I purchased this thing sight unseen from California at an auction earlier this year. Its a super rare manual '85 Tercel 4WD SR5. Clean title and zero rust. It was sitting for ~14 years and I got it running after draining the tank and cleaning the carb. Definitely a fun little car to tinker with and a keeper for sure.

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Hell yes! I have an 85 Tercel wagon too. SR5, 4wd, 5speed. Much rustier than yours. I also have those same wheels, which seem to be more rare than some of the other Tercel wheels you see. A 60 and a Tercel is a great two car solution.

How was the carb rebuild on that? I've got two spares carbs and one's in pieces, I really need to finish the job. Really fun little car.
 
Alright I decided to get this party started and continue this thread for my next FJ60 project. This one is a tan 1984 that I purchased a few weeks after purchasing the white one. I bought it sight unseen from someone in TN who parts these out. He let me know that he had it for sale and that he considered it 'too clean' to part out which I agreed with and bought it from him. About a month after that it showed up to the shop...

These aren’t the greatest pics. My dad took them for me and he’s always busy at the shop so he took these rather quickly.

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I've always liked the tan more than white so when this one popped up I had to have it. It has lower miles (~180k), much less rust than the white one, and has all of the original SMOG equipment still intact. However, it did come with its own issues:

1. Its been sitting since 2004 and hasn't been started in ~21 years.
2. The paint was in rough shape and its been sprayed before.
3. The interior is not in that great of shape and one of the POs must have used it around a farm or something.
4. The bumpers are in rough shape. I'm debating robbing them off the white one before I list it for sale, but I'm up in the air on that still.

I had it shipped directly to the shop to get started on the paint and body. This one got the same full windows out refresh that the white one did. One of the rockers needed to be replaced and so did the rear left door, but the seller provided me with both of those. The quarters were in decent shape so I didn't have to source new panels through Wolf Steel and instead patched the few minor areas of rust which was a time save.

This is after the rocker replacement. You can see the frame and undercarriage of this one is really clean aside from the surface rust so I’m happy about that at least. I’m going to sand down the frame, treat it with Ospho and paint it factory black afterwards myself.

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Clean frame with a little ‘desert’ rust.

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The paint and body work continued and the doors, windows and trim were removed. I don't have as many pics of the repair process on this one since I got really busy at work and couldn't make it out to the shop as much. The quarters had minimal rust and the body guys were able to save them. As I said in the previous post this one has definitely been repainted before and there was evidence of bondo on the passenger quarter panel.

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All of the doors aside from the left drivers side were able to be saved and re-used. They were removed from the truck and painted at the same time.

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The A pillars and door jambs were painted. You can see the cracked dash and the weathered carpet in this pic that will both need to be replaced.

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The rear cross member wasn't in terrible shape and didn't need the TrailTailor treatment, so I had one of the body guys cut out the rust and weld in a plate to reinforce.

These are pics of the quarters after repair. Primed and ready for paint!

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Finally it was time for the spray booth. I opted on not removing the fenders this time around so that I didn't have to adjust panel gaps too much afterwards.

Primed!

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Paint time!

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This is a day or two after the paint baked in the spray booth. PPG and other quality paint/clear was used and I'm extremely happy with how it turned out. It didn't even need a wet sand or buff! This is probably the nicest the paint has and ever will look. Only a little better than the factory single stage :cool:

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The funny (and probably stupid) thing is I haven't gotten it to run yet. All that work and I can't even drive it yet. Oh well, I'll get that sorted soon.

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I towed the FJ60 to my house and put it in my already jam packed backyard. Thankfully the Hilux thats next to the garage in this pic has been sold, so I have a 'little' more room now and motivation to get the 2F running.

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Now its time to start working on getting it running. Honestly I probably should have started with this in the beginning but oh well.

I took some ‘base’ pics of the engine bay so that I have something to refer back to once I start taking things apart. Overall, it doesn't look like its been messed with much. The factory smog equipment is still in tact but some of the wiring is torn. The PO also installed what looks like a trans cooler, I doubt it still works or doesn't leak, so I'll probably end up removing it. Its definitely really, really dirty and will require a lot of cleaning up. You can tell its been sitting in someones yard for 21 years evidenced by the hornets nest on the radiator, lol.

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The first day I got it back to my house I got excited and jumped the gun and sprayed some ether in the carb to try and get it to start. I could immediately tell by the way it cranks that it has low compression in a cylinder or two.

The next day I took my compression tester and went to work. The results kind of scared me.

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For more background, a day or two before I compression tested it I had removed the carb to rebuild it. I’m sure the compression test results are a little lower than they would have been had it been installed, but that doesn’t explain 25 psi in cylinder 5 and 0 psi in cylinder 6. Honestly, I got a little upset about the results and lost the motivation to work on it and just went to bed.

Yesterday I decided to pull the valve cover to check the rockers and valves to see if any were sticking. With how dirty the rest of this truck was I was expecting to see sludge and a lot more grime but to my surprise it looked really clean.

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Getting excited again I set up my camera and took a video of the engine cranking with the valve cover off. I watched the video afterwards and sure enough the exhaust valve on cylinder 6 is stuck open, so that explains cylinder 6. But what about cylinder 5?

Before cranking the engine over for the first time I made sure to put MMO in each of the cylinder’s and let it sit for a few days. While compression testing I also tested the rings by pouring a little oil in the cylinders after the first test. This helped ease my nerves a little because the compression didn’t increase with the oil, leading me to believe the low compression is stuck rocker/valve related vs. worn rings.

With the valve cover off, the valves appear wayyy out of adjustment, I pulled on all 12 rockers and 7 of them are super tight. I’m going to try and free the rocker and valve on cylinder 6 which I think will bring that cylinder back to life. However, I still need to game plan my approach for cylinder 5. I'm hoping it'll come back to life with a little run time or after I adjust the valves. I'll have to settle for a cold adjustment since the engine isn't running yet and will adjust them again later when I get the engine running and hot.

I know these compression results seem scary to some, but I really don’t want to pull the head or replace the engine. I’d rather try and bring this dinosaur back to life and I don't think getting to that point requires either.

Okay that’s it for today. Thanks for reading this far, I’ll hopefully post an update in a few days with some good news.
 
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Hell yes! I have an 85 Tercel wagon too. SR5, 4wd, 5speed. Much rustier than yours. I also have those same wheels, which seem to be more rare than some of the other Tercel wheels you see. A 60 and a Tercel is a great two car solution.

How was the carb rebuild on that? I've got two spares carbs and one's in pieces, I really need to finish the job. Really fun little car.

Dude, I love these things. Its super retro and everything is original on it. Agreed, the wheels are definitely a really nice touch and I'm glad they were still on it when I got it. They're really rust prone like you said and glad I was able to find one that wasn't crusty. But... I do like the patina that crusty ones have. Kind of a catch 22 that this ones not crusty because sure its 4wd, but I can't bring myself to drive it in the rain or snow which is what Toyota made it for in the first place.

My carb rebuild consisted of pouring sea foam and carb clean down the carb haha. Luckily it didn't need much. I used an old gatorade bottle with premix/2 stroke gas and put the fuel line in it to get it started the first time. The only thing I replaced on the carb was one of the diaphragms. Haven't had a chance to tear it apart yet with all of the other projects I have going on right now but will probably start messing with it again after I get the tan FJ60 running. I did replace a few of the driveline parts so far (KYB struts, CV axles, ball joints, inner/outer tie rods, sway bar bushings, etc.).

You got this. Will be so awesome once you get it running, well it already is with the paint job.

Thank you! I sure hope so. Cylinder 5 is the one I'm worried about but I'm hoping the valve adjustment or a good heat cycle with bring it back some. I only have to get it running enough to bring it into my garage so I'm not working in the cold. I have approximately 2 weeks to do that before it gets too cold here in Chicago, lol.
 
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