83 FJ60 Build up thread (1 Viewer)

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do the body as well...

screw it just take out all the wiring and interior and drivetrain and do the whole truck!

would be cool to see anyway.

truck is looking good so far
 
Frame Repair

Got 1 hour on the 60 tonight.

I fixed an out of round shock mount hold on the driver side. I also welded and ground flat the front body mounts (for the front valance) flat and painted them to get something between the body mount cup and bracket. I also welded and ground flat the area in front of the rear wheel wells where I had to cut out the rear cross member.


Front body mount brackets:
100_3933.jpg


Driver Side shock mount:
100_3934.jpg
 
Frame Question

What exactly does the cup on some of the body mounts do? I presume it helps keep the mount from sliding around. Is it necessary? I am thinking of the two in front that I am going to have to remake. Can I not just put a washer there to make the height the same?

Started New thread here: https://forum.ih8mud.com/showthread.php?t=181316 to generate some attention.

100_3729.jpg
 
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Frame Repair

Spent 2.5 hours sandblasting on the frame today. No pictures as it is the same frame, but slightly less rust :cool:.

One tip, I put some window screen around my funnel this time and "pre-filtered" the coal slag. Worked like a champ and got rid of any blockages. Got through the first 100 pound bag!
 
Frame Repair

Got 6 hours on the 60 this week at lunch ;) this work week. I made up new "cups" to hold the front body mounts. The three holes are used to weld them in place with 2 cross drilled holes to drain the water (the original had 3 holes to drain the water).

Got to learn to use the new CNC lathe at work... I will have to use it more often:grinpimp:.

100_3952.jpg
 
that's just too nice to be hidden under the mounts!!!!!
 
If you want you could try hammering the weld flat (or flatter) while it is still hot. Use a large punch in tight spaces. This way you leave the weld material in the weld where it belongs and grind less. Less risk of grinding elsewhere also.

Nice work btw.
 
Thanks

If you want you could try hammering the weld flat (or flatter) while it is still hot. Use a large punch in tight spaces. This way you leave the weld material in the weld where it belongs and grind less. Less risk of grinding elsewhere also.

Nice work btw.

Thanks for the tip! That definitely would have worked out better than the dremel :rolleyes:.
 
Frame Repair

45 minutes on the 60 tonight. I retapped some of the threaded holes in the frame to ensure they were cleaned up properly. Bought an 8mm x 1.25 tap. Looks like it will do most of the holes except the tranny x-member bolt holes.

I started a thread on how to handle the threaded holes with respect to galvanizing, thought it would get more attention outside the build thread:
https://forum.ih8mud.com/showthread.php?p=2631678#post2631678

I ordered up a section of 2' x 3' 11 gauge steel to make the new inner frame rails with. Once it comes in, I will CNC plasma cut them and work and bend them up. Should be later next week when the steel shows up!
 
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So for some reason I just found this thread. Awesome work so far. I live in westminster, could I come by some time to check it out?
 
Project60!
For some reason Ive never checked this thread....
This is one of the BEST and most complete write ups Ive seen on this forum!
Youre doing an AWESOME job!

My hat is off to you!
I would LOVE to do something like this some day for the same reason you decided to take it on....LEARNING!
There is NO BETTER EDUCATION than how youre doing it....
Of course having another rig to get around in helps while this one is down...

Cant wait to see the end product!

Chicago
 
Frame Repair

Got 4 hours and 40 minutes on the 60 today.

I got my 2' x 3' sheet of 11 gauge steel in the mail today. I brought it to work and cut out the brackets using the cnc plasma - that thing is sweet! One of them I had to cut out again as the plasma quit running right at the end of the cut. I tried bending the brackets at work, but the brake is fairly small - had to use an adjust wrench on some of them.

Sheet with brackets cut out:
100_4007.jpg


Brackets cut and some bent:
100_4008.jpg
 
Frame Repair

I did run into one problem. The rear brackets I made for the unboxed section around the spare tire carrier presented a problem.

1 - Don't bend them in the same direction. :eek:
2 - You have to leave room to get the spare tire holder back in. :eek:


Bracket looks good, but I can't get the spare tire carrier in:
100_4009.jpg


I ended up cutting the beautiful bracket and welding in two smaller pieces cut from the big one (solved the same direction bends too :)):
100_4010.jpg
 
Frame Repair

Got 2.5 hours on the 60 this weekend.

I sandblasted the inside of the frame rails where I was going to attach the new brackets. Than I "custom" fitted with a BFH the passenger side bracket leading into the rear wheel well. Turned out good.


Driver's Side inner frame rail sand blasted:
100_4013.jpg


Passenger side inner frame rail (nuts welded to the inside):
100_4012.jpg
 

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