Build 1997 FZJ80 to HDJ80 1HD-FTE + H152F

[SNLC]

Modified and welded in the 12mm pickup. This 12mm pickup is from a 79 or 100 series iirc.

Tank is done and ready to install.

Cheers

 

[SNLC]

The vent hard line is specific to diesel Cruisers and of course it is NLA. So we took the old crusty one seen above and refreshed it.

Came out good, we are happy with it.

You may notice the terminals on the top of the tank. Those are for sending unit and fuel pump. No more fuel pump in this tank so that one was abandon. The others being so close to where we had to weld they needed to come out. Even tig welding this (which we did) would have got it to hot and damaged these pass through terminals. These little pass through terminals are riveted to the tank. We drilled out the rivets to pull them. They have two pieces of ceramic on either side to isolate them and o-rings to seal them plus silicone caps on top. We drilled and tapped where the rivets used to be and used the small machine screws seen. We then coated the tops with a silicone based circuit board coating. Probably put a little dab of silicone calk on them to finish them off.

Cheers

 

[SNLC]

Here is a few more pics where you can see how we welded in the pickup and return plus how we changed the depth to match this tank.

Here is the drop in insert all done. You can see we used a diesel pickup screen on it and it also uses the stock OEM sending unit. 100% serviceable for the life of the Cruiser.

Finishing up a little bit on the main fuel and return line on the body and then the tank is getting installed.

Pretty monumental to just about be ready to pull this Cruiser over to the gas station and fill it up with diesel.

Cheers

 

[jomelo]

So rad.

 

[cruisermatt]

nice job. Very few shops going to that level of OEM detail on a sending unit.

 

[SNLC]

nice job. Very few shops going to that level of OEM detail on a sending unit.

The point was the 12mm pickup. GTurbo specifies 12mm fuel line for our setup, what would be the point of just running 12mm from tank to fuel filters?

Definitely some Cruisers came with a 12mm pickup in the tank, we are using one albeit hacked up. It is either the 1HDFTE or 1VD Cruisers, I don’t recall which at the moment and the pickup @Onur sent us. We have the tank out of the donor HDJ80 and it has the same pickup size as an FZJ80. So using it would not have really helped. The diesel 80 tank is the same though it just uses a different insert/pickup. Which I do believe is NLA too.

So we didn’t have a lot of options. Pretty happy we have it 12mm from pickup to IP. We were able awhile back to source the OEM fuel filters with the larger 12mm hard lines coming in and out. Your 1HZ and even your 1HDT Cruisers have 10mm.

Cheers

 

[TurboDennis]

The point was the 12mm pickup. GTurbo specifies 12mm fuel line for our setup, what would be the point of just running 12mm from tank to fuel filters?

Definitely some Cruisers came with a 12mm pickup in the tank, we are using one albeit hacked up. It is either the 1HDFTE or 1VD Cruisers, I don’t recall which at the moment and the pickup @Onur sent us. We have the tank out of the donor HDJ80 and it has the same pickup size as an FZJ80. So using it would not have really helped. The diesel 80 tank is the same though it just uses a different insert/pickup. Which I do believe is NLA too.

So we didn’t have a lot of options. Pretty happy we have it 12mm from pickup to IP. We were able awhile back to source the OEM fuel filters with the larger 12mm hard lines coming in and out. Your 1HZ and even your 1HDT Cruisers have 10mm.

Cheers

Great work on the pickup tube!

It's strange that your HDJ80 donor came with the same pickup tube as the FZJ. Perhaps the original rusted away and the previous owner replaced it with whatever he could find?
All HDJ80's/81's are supposed to have 12mm feed lines. I sourced the tank pickup and lines out of HDJ81 for my build in great condition, so i was lucky there.

Im currently going through a similar ordeal installing the factory sub tank. The tank came out of FZJ80, so the lines are too small. New pickup assembly is NLA, and i could not find a good used one. So im fabricating the entire assembly from scratch, (from 304 stainless).

 

[SNLC]

Great work on the pickup tube!

It's strange that your HDJ80 donor came with the same pickup tube as the FZJ. Perhaps the original rusted away and the previous owner replaced it with whatever he could find?
All HDJ80's/81's are supposed to have 12mm feed lines. I sourced the tank pickup and lines out of HDJ81 for my build in great condition, so i was lucky there.

Im currently going through a similar ordeal installing the factory sub tank. The tank came out of FZJ80, so the lines are too small. New pickup assembly is NLA, and i could not find a good used one. So im fabricating the entire assembly from scratch, (from 304 stainless).

Probably changed out to a 1HZ in the 95 HDJ80 donor then. The 1HZ I know runs a 10mm but I recall looking at the hard fuel line in the HDJ80 too and saying to myself that sure isn’t 12mm. Which is why we didn’t consider using it even if usable (super crusty). Its such a poobox of a Cruiser I wouldn’t be surprised if it was swapped out for a 1HZ pickup at some point.

We tried to get the HDJ80 pickup but it came back NLA.

Anyways, nice to have the tank done and be installing it, like tomorrow.

Cheers

 

[AussieHJCruza]

From memory the MY93 and newer HDJ80s had 12mm fuel lines from factory

 

[SNLC]

We put the tank in today, along with a ton of little things too. We just ran out of time for a test drive, called it a day at 7:15pm.

Tank going in.

Filler neck all done.

I had the honor of putting the go juice in it.

Cheers

 

[wngrog]

Get it Ian.

 

[SNLC]

We did get grill, headlights and corner lights in today too.

Still got to install the valance and turn signals.

Cheers

 

[Lumpskie]

This feels the same as when you are reaching the end of a good book... mix of excitement and sorrow at it ending...

 

[retrofive]

This feels the same as when you are reaching the end of a good book... mix of excitement and sorrow at it ending...

He could pull a @Sea Knight

 

[Sea Knight]

He could pull a @Sea Knight

Hey, it ain’t over til it’s over…

 

[SNLC]

This feels the same as when you are reaching the end of a good book... mix of excitement and sorrow at it ending...

Frodo and Sam just entered Mordor.

Cheers

 

[jomelo]

This feels the same as when you are reaching the end of a good book... mix of excitement and sorrow at it ending...

Don’t worry. @SNLC still has the 79 series at the shop and there is even something else for when that is finished.

 

[Godwin]

Hey, it ain’t over til it’s over…

View attachment 2733741

Time, actually way past time, for an update.

 

[Sea Knight]

Time, actually way past time, for an update.

Hey Jim. You’ll get no argument from me. It’s tough being stuck in Montana for a dozen years. I think that’s where the tale left off?

You may need to come back to Austin and light a fire under me.

 

[Godwin]

Hey Jim. You’ll get no argument from me. It’s tough being stuck in Montana for a dozen years. I think that’s where the tale left off?View attachment 2733926 You may need to come back to Austin and light a fire under me.

I'm headed to Louisiana next week, what's a few hundred more miles. All the tales of driving a 40 across country, sleeping behind abandoned buildings, drinking beer, and meeting strange women and upholding the moral high ground. Yes, we want to know, in the words of Paul Harvey, "the rest of the story."