83 FJ60 Build up thread

[Project60]

I don't envy the body work. i hate sheet metal work. very tedious which is why i have not messed with mine very much. what your doings looks great.

I find it cool that we have the same exact trucks, even the color.....Hey do you have a pic of the top of your transmission since its out??? i am fighting my reverse lights and would like to see where the back up switch is mounted.....

Yeah, I will get that tonight.

 

[Project60]

Interior Disassembly

Got 1.5 hours on the 60 last night. I started by removing the windshield. It had a lot of cracks in it already and I tried to save the weatherstripping, so... I got out a BFH and took out some frustration. Took just a few minutes... and then 20 minutes to vacuum up the mess . After the effort to save the weatherstripping, I realized someone had glued it in and upon removal I tore it!


Windshield in the trashcran:

Windshield out:

I took some pictures for Skinner and 5280Hawk on how to remove the headliner. I removed the steel retaining clips with a screwdriver and then cut carefully along the headliner. I have to vote you cannot reuse a headliner. The biggest problem I see is that the fabric is very brittle and it would be hard to stretch it back into place and re-glue it.


Headliner folded over rear window and glued down:

Headliner folded over rear door, glued and clipped:

Rear door pillar close up:

Closeup of foam under door pillars and headliner:

Headliner folded over and glued on front windshield:

I marked my headliner to show where I needed extra material for glueing and trimming when I make a pattern from it:

Headliner removed:

 

[SKINNER]

Ah man...don't tell me this!! Just kidding, thanks for the detailed photos.

One question, The reason for my needing to drop mine is to repair 6 holes that are present from a PO roof rack. Of course, there are 2 in the front, 2 in the middle, and 2 in the rear. In your opinion, could I potentially pull the headliner down in sections to repair a single hole and then reattach before moving to the next hole? Or am I going to be pissing in the wind?

Thanks again!

 

[Project60]

Ah man...don't tell me this!! Just kidding, thanks for the detailed photos.

One question, The reason for my needing to drop mine is to repair 6 holes that are present from a PO roof rack. Of course, there are 2 in the front, 2 in the middle, and 2 in the rear. In your opinion, could I potentially pull the headliner down in sections to repair a single hole and then reattach before moving to the next hole? Or am I going to be pissing in the wind?

Thanks again!

I am not sure where your roof rack holes are at w/ respect to the doors, etc. I am not saying you can't be careful and get it "peeled" back for patches, but you will need to be very gentle. My headliner is shot and it is brittle which would make re-installing it difficult. If you are going to have it almost all the way out, you should just replace it.

If you are worried about the cost (especially buying from SOR or others), try pricing out a local upholstry shop. If you already have it out of the car, they can probably make it for cheap. I am going to sew one up myself using stuff from : Your Auto Trim Store

 

[Project60]

I don't envy the body work. i hate sheet metal work. very tedious which is why i have not messed with mine very much. what your doings looks great.

I find it cool that we have the same exact trucks, even the color.....Hey do you have a pic of the top of your transmission since its out??? i am fighting my reverse lights and would like to see where the back up switch is mounted.....

Sorry, I forgot until I went to take a picture the tranny is buried under the box of parts shown above... if you wait a week or so I can get a picture.

 

[Project60]

Interior Disassembly

I got 1hr 50 minutes on the 60 tonight. I got the wiring harness removed from the rear and driver side up to the firewall. I got the heat shields pulled from underneath - one of the mounts will need replacing . I started working on the dash after that... lots of crap on that dash, looks like I will need more boxes!


Dash:

 

[cfdlighthouse]

Sorry, I forgot until I went to take a picture the tranny is buried under the box of parts shown above... if you wait a week or so I can get a picture.

when ever you get to it. its cool!!!!!

Thanks for lookin out..

 

[Zack1978]

I love taking stuff apart, but I HATE to put things back together!


Zack

 

[5280Hawk]

nice. I will be pulling my windshsild any way. If an upolstery place was doing the liner I guess they would pull those windows then.

I will back in town in April 4-5th, If you still want to look at the paint

 

[Project60]

nice. I will be pulling my windshsild any way. If an upolstery place was doing the liner I guess they would pull those windows then.

I will back in town in April 4-5th, If you still want to look at the paint

You might have to have a glass place pull the windows... I have never asked.

I will be in Brazil for 3 weeks starting 4/2!

 

[Project60]

Interior Disassembly

Got 1.5 hours on the 60 tonight. I got most of the dash pulled out... wiring harness, heater core, heater fan, and all the dash!


Picture of what is left:

 

[landbruiser60]

wow, you really are taking that thing down to bare bones. What are you planning on doing to the inside of the body? Great job on the project buy the way. I've been keeping up with this thread and it's amazing how much work you are putting into it. Keep it up!!!

 

[Project60]

Plans

wow, you really are taking that thing down to bare bones. What are you planning on doing to the inside of the body? Great job on the project buy the way. I've been keeping up with this thread and it's amazing how much work you are putting into it. Keep it up!!!

Thanks for all the compliments guys. I plan on taking it down to bare steel and applying epoxy primer to the whole body. Then, fix all the rust by welding in new steel. Apply bedliner to the bottom. Then do urethane primer and finish paint on the body. It will be busy but interesting... my fingers already hurt thinking about the sanding.

 

[Project60]

Body Disassembly

Got 4 hours total on the 60 this weekend. I got everything stripped off the body . Then I scraped all the foam off the roof using a 1" sharp putty knife - it worked well, just took some time. I really wanted to get the foam out as I am going to wash the body and I don't want to deal with wet foam. I got the fuel tank and all the lines, bolts and heat shields off the bottom of the truck too. Making progress now!


Stripped Interior:

Stripped underside:

Foam insulation scraped from roof:

Rust around windshield frame :

I bought a 4 1/2" rust removal pad from HF. I tried it out and it worked well on the flat surfaces. It left a rough finish, more like a sanding. I wanted the rougher finish to help the epoxy primer stick.

It doesn't work well on sharp corners... first time I tried the upper firewall lip, I shredded it in half! I will have to use a wire wheel on the sharp spots or sandblast (yuck, I still have sand in my ears).

 

[Zack1978]

I am sure I could rip my 60 apart, but to put it back together, I am not so sure? Did you take pics of everything before you removed it, in terms of remembering how everything goes back together? I must say that I am very jealous of what you are doing to your truck. I wish I had the skill, or the balls to try something like this. My luck I would end up with boxes of parts and never remember how to put anything back together.


Zack

 

[Project60]

I am sure I could rip my 60 apart, but to put it back together, I am not so sure? Did you take pics of everything before you removed it, in terms of remembering how everything goes back together? I must say that I am very jealous of what you are doing to your truck. I wish I had the skill, or the balls to try something like this. My luck I would end up with boxes of parts and never remember how to put anything back together.


Zack

You are talking about my worst fear! Don't worry, I will make you guys take pictures to show me all the parts I forget! The worst part is that the longer it takes me, the harder it will be to get back together .

 

[cfdlighthouse]

You are talking about my worst fear! Don't worry, I will make you guys take pictures to show me all the parts I forget! The worst part is that the longer it takes me, the harder it will be to get back together .

Thats why i don't wan't to do what your doing. i would be afraid i would loose something, get side tracked, life gets in the way, and before you know it you have forgoten how to put humpty dumpty back together again. it all comes together in the end though. two goals don't run out of parts before it gets back together and don't end up with parts left over while your left scratching your head saying now where does this go?

Great job though!!!!!

 

[Project60]

Compressor and Paint Gun Setup

Got 1 hour on the 60 tonight. I got a new air filter installed into my air compressor setup. It's not an inline dryer, but will help out. I didn't use the regulator that came with it, but I kept my existing filter/regulator combo so that I had two filters/water seperators in line.

I also got a new paint gun just for the primer. I didn't splurge for the HVLP as this is just for the epoxy and urethane primers and I wanted a big nozzle. Besides, for $12 I won't cry when it doesn't get cleaned well enough.

Gotta love when the in-line gun filter and swivel cost more than the gun!


New filter:

New Filter installed:

New paint gun, in-line filter and swivel installed:

 

[Project60]

Body Disassembly

Got 2 hours on the 60 tonight.

I drug the body out to the driveway and shop-vacced the interior. Then I washed it down with comet and a scouring pad. WOW! It was definitely in need of a little hose down.

After washing it, I wanted to see if the air chisel/hammer would work on removing the sound deadening on the floor and interior fire wall. Worked like a champ! But not quite done yet.


Cleaning Supplies:

Interior Vacuumed out:

Interior Washed Out:

Sound Deadening Chiseled Out:

 

[baxter650]

Holy s*** she's gutted like a tuna, don't think i'll be going quite that far with mine.