The bennefit of the 80 series chassis is obvious. Coil springs, great ride, great rear articulation, full float rear axle, factory lockers are possible, it's much more capabile out of the box than a 60. Drivetrain downside is gearing. There is only one crawler box option, it's only 3:1, and it's expensive. However, if you're putting a V-8 in anyway, you could choose your own tranny/t-case. Maybe an HF55 if you like a stick, and you can put a ranger box in front of the tranny and use it for the adapter. Use it for overdrive, and over gear the axles.
760024M-27 | Engine & Transmission Conversion Adapters - Advance Adapters
Then you could also put an orion in, or lower set in a split case from a 60. Or you can just ignore all the gearing options, since you're building for overlanding not rock crawling. But that adapter is almost $1200, and the ranger is just over $1500, so if you want to go manual anyway (some do some don't) it's not a big price diff to gain some gearing options.
The Bennifet of the 60 series body is it's more of a classic look than the 80 series. Nothing wrong with the 80, it's the best looking truck of the last 20 years, but, it doesn't quite scream out of affrica (neither screams that like an FJ45 of course). From what I could see on my brothers truck, the wheel wells are easier to work on to open up. With the longer wheelbase of the 80 under the 60, you'll also loose some of the 60's overhang. Interior wise, I find the old style 60 easier to mod for CB's and such. The rear cargo area on the 60 is also alot bigger than the 80 series. There might actually be a little more room in the back seat too, though I've never gone straight from one to the other. Not having the 3rd row of seats they didn't have to move the 2nd row up to fit the 3rd row. The 60 series interior feels more like a truck to me. It feels roomer too for whatever reason. Maybe it's cause it doesn't have an air bag filled dash crowding you.
That's my take on it. If I had a wrecked 80, and could get a 60 series body cheap, I'd do it. Do a carbed V-8, HF55, Ranger, Split case, and call it good. Or a 4BT NV4500 and orion? I'm sick of EGR Valves and vaccuum selector valves and such though, so I'm ready for simple. I'd prefure a 55 or 45 body, but those don't come along cheap in good shape. I like what my brother is doing with his 60/80. If you go for it I'll definately watch.
