83 FJ60 Build up thread (1 Viewer)

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Frame Boxing and Welding

dslcruzr said:
here's a picture of the frame boxed in with 3/16 plate.
Ken
Click to expand...

dslcruzr, thanks for the pictures! I was leaning towards doing the same thing. I don't think I will do it as long as you have, but close to. Any tips on getting the old C-Channel out? I don't have the body off yet, but what did you need to weld nuts on for?

Fantom, thanks for bits on welding. I will stick to short horizontal welds to box the frame in.
 
I needed to weld nuts on the inside of the frame to bolt on the body mounts and shackle hangers. The rivets that hold on those items go right through both layers of the frame, so you have to cut/drill the rivets in order to remove the inner layer.
Removing the c-channel is quite a chore. If you have a torch, then you're all set (I didn't). I ground the heads off all the rivets (both sides) and chisseld out the channel with a big chissel and brow bar. I had to drill the rivets out of the shackle hangers and body mounts because I was unable to punch them out. Hope that makes sence.
Ken
 
Disassembly work

Got 1 hr 45 minutes on the 60 yesterday. I started to build the body dolly I am going to roll the body around on. I built a frame for both sides, with a wheel under each leg. Haven't attached the legs yet.




I also went out and bought a new air compressor. Lowes was having a sale on their tools, I got 15% off plus had another coupon for 10% off. Had to buy wiring for 220v 30 box in the garage as well. Compressor puts out 13.3 CFM at 90psi - I'd love more, but will do nicely.

 
Following this article with great interest...

Man, I have been so discouraged as of late, seeing my 81 FJ60 parked out in front of our rented house, in the weather, dying of cancer and calling to me to pour a few thousand buck into it for a SOA to go real wheeling etc.

Don't know if I'll take it apart piece by piece but would love to have the time. This article keeps me encouraged but I lose enthusiasm very quickly. Of course, I am brought back to reality just as quickly when I look at the prices of newer 4Runners and 80's.

Keep up the good work to give hope to people in similar situations as mine.:eek:
 
Great write up, have a quick look at my project 60 buildup, it might give you inspiration, all my work was done in the middle of our backyard in the early shots and later was moved to the outdoor verandah of our new house

My wife must love me:D

keep up the good work, dont get discouraged they really are great trucks

my writeup is on MUD if anyone is iterested, "hj60 buildup with pics"

Paul
 
Last edited:
hj60 buildup with pics

Paul,

Wow! I took a look at your build up page https://forum.ih8mud.com/showthread.php?t=114781. Talk about a lot of work to do outside! My neighbors, not to mention the wife, would kill me up before I got as far along as you.

I have to give it to you, it is a lot more work than I am doing. :cheers:

It is time consuming but what I am doing is simple - disassemble, clean/paint and reassemble.
 
Thanks for the kind words, what I have done is not thet hard, just a matter of taking your time and being very careful to get it exactly right.

Unfortunately the aftermarket scene is not as big as the US, ( there is plenty of gear out there though ), means I have to do most of the work myself or ship it 500 miles to get somebody to do it for me. I like doing it, and it keeps costs down.

I really like what you are doing with your rig, I have a daily driven 80 otherwise I would do another 60 for DD duties, I have fallen in love with the 60s

ps mine is the last of the 60s, basically the same spec as a 61, push button transfer, A440 and rubber rear spring mounts

Paul
 
Compressor Setup

Sorry for lack of posts all. I have been away on business for the last two weeks.

Got 2 hours on the project yesterday. Got the 220v hookup pulled into the garage for the compressor. Still haven't wired it up yet.
 
Body Removal Prep

30 minutes tonight prepping for the body removal. I am going to jack the body up and set it down on a wooden "dolly". The dolly is just a 2x4 frame with castors. I got the castors installed and the jacks placed tonight. The body came right up when I lifted with the jacks in all 4 corners, should come off easy if we can keep it level.

I was originally going to "roll" it into the backyard through the grass, rocks, gate, etc. My brother in law jumped in and said I could store it at his house. I rented a 6'x12' trailer to tow it his house for a while.

I finished hooking up the power and the hoses for my new compressor last week as well... didn't count it as time towards the cruiser though.

Air Compressor Hookup:


Jacks in all 4 corners. Could only scrounge up 2 floor jacks, the rest are bottle jacks.




You can see half of the dolly upside down:


Castors on dolly:
 
Body Removal - Dont's

Spent 7 hours on the 60 today. I must say it was an utter failure.

We got the body lifted up and set down on the 2x4 cross beams. That was the start of the bad. It tended to crease the seams on the body and the rust under the rear driver side simply collapsed.

The other problem is that a wood structure was just too weak and the wheels gave out. I ended up putting the wood frame up on jack stands until I can rebuild something out of steel - stay tuned.


Body on double 2x4 cross beam:





Wheel "ripped" off the wooden dolly:


Both rear wheels ripped off:

 
Body Removal - Redo

45 minutes on the 60 tonight. Repositioned the jack stands and removed the wood from the side of the old dolly for better access.

I am going to pick up some 1/8" thick 1.5" square tubing tomorrow to build the frame out of. The frame will attach to body mount locations using the stock bolts, rather than letting the body "sit" on the dolly it will be bolted to it.
 
Steel Tubing for Body Dolly

Went and picked up 48 feet of 1.5" 11 gauge (.120" thick) square steel tubing. Turns out they loaded 18 gauge and I didn't notice until I got home. Went back and they gave me 72 feet of 11 gauge for all my trouble (cut into 8 foot pieces).

Should start working on the dolly shortly, stay tuned.
 
Steel Body Dolly

Spent 1.5 hours on the 60 tonight. I got some plates cut out of 1/8" steel for the castors to bolt to. Drew out a plan for the dolly. Have to clear the rear axle and studs (~61") and still stay inside the trailer dimensions of 70".

Sorry no pics, couldn't find the camera.
 
Steel Body Dolly

1hr 45min on the 60 this afternoon. Got the frame cut out and welded up. Flat steel pieces welded on for the wheels too. Still need to get it assembled under the body and then some attachment points made.

Pics to come.
 
Steel Body Dolly

1hr 50 minutes on the 60 today. Got some more work on the body dolly done tonight. I love welding upside down :rolleyes: . Coming together nicely. I just need to get the attachments made up to connect to the body mounts.

Some pics tonight:


 
Steel Body Dolly

2 hours on the 60 tonight. Made brackets to attach the rear body mounts to the steel body dolly. Each of the attachment points will bolt on so that I can remove one at a time to paint or sandblast under the attachment point.

Rear of Dolly:


Rear Corner:


Rear Body mount attachment:
 
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