Afternoon Projects Thread

[Mountain Goat]

This may not be a new idea, but I thought it would be be interesting to start a thread about simple 60 projects that can be completed in a day. This can include repairing that issue that always bothered you, or a sweet mod to improve the excellence of your ride.

I figured I'd start the thread with a mod: Rear sway bar with quick-disconnect links

I bought a 60 series rear sway bar from G&S. Links and frame mounting brakets were included.

The first issue to come to mind during installation was that my truck has a 2.5" lift so I should use 2.5" extended links. I don't think they are available in the US so I decided to mod the links supplied. Then I figured the way they are designed, it would be really easy to make them quick-disconnect links.

Here's what I did.

1. Measure length of links provided.
2. Cut the ends from the links provided.
3. Cut 7/16" CR steel rod to length of stock rods plus 2.5" (7 15/16")
4. Cut 4 2.5" lengths of 1/2 steel tube. Tube should be able to sleeve rod.
5. Weld tubes onto cut ends of original links in place of original rods. Don't forget to remove the rubber bushings.
6. Insert rod into tube to the end and drill 5/16" hole all the way through. (both ends) Be mindful of orientation.
7. Install sway bar onto rear axle. It only fits one way. Mine is a late 80's model so the axle already had the mounting tabs.
8. Attach mounting brackets to frame rails. The bolt holes are to the rear of the axle.
9. Deburr, clean, paint modified links.
10. Install 5/16" hitch pins into holes drilled.
11. Install matching hitch clips into hitch pins.
12. Lube rubber bushings with silicone or grease and reinstall.
13. Install modified links.

 

[Mountain Goat]

A couple more pics.

 

[Mountain Goat]

The rear sway bar noticeably improves handling. There isn't as much body roll, especially on corners. The truck feels tighter in general, not so much like driving a sponge.

 

[yakimacruiser]

carb trouble

I really need a diagram of the carb on my 84 FJ60. I am pretty sure the float valve is stuck. I am just worried about all the vacume hoses, Holy Crap there are about 20. Anyway any help would be great. Hopefully this would fall into the 1 day project.

 

[Mountain Goat]

I really need a diagram of the carb on my 84 FJ60. I am pretty sure the float valve is stuck. I am just worried about all the vacume hoses, Holy Crap there are about 20. Anyway any help would be great. Hopefully this would fall into the 1 day project.

I've rebuilt both FJ-40 and FJ-60 carbs based on the diagrams in Haynes Manuals. They aren't as good as the FSM, but were good enough to get the job done.

 

[nikos8]

I think a good project that can be done in an hour or two is changing all the vacuum lines.

 

[5280Hawk]

Brake master Cylinder replacement is an easy 1 day job.

 

[John McVicker]

Improve Costco 12v air pump

Here are a couple of quick/easy things I did to improve the $50 Costco 12v air pump.

1) Cut/replace the cheesy batt alligator clamps for some good ones.
2) Cut & add 3 more feet to the 12v elec lines
3) Cut the connections at both ends of yellow air lines. Splice in real automotive air line quick disconects. Will allow use of blow gun in very short burst. Very short, but can be handy.
4) Add a real tire pump coupler, one that will lock on.
5) Added a couple of 30 amp blade fuses, in addition to the one provided.

John

 

[cabron]

All coolant hoses, flush, block drain, thermostat and gaskets. Your rig will like you.

 

[fowldarr]

Valve Adjustment. Sounded scary my first time. Now that I've done it, I would kick myself if I let somebody else. Total took me about 4.5 hours, including drive time to get it warmed up. But I took an hour break to play with my kids before putting it back together. Also changed my spark plugs, air filter, played with my ICS (to no avail) and cleaned out my carb as best I could. Runs better, more power. Still not there.

 

[Dynosoar]

The best mods under $50.00 are almost all quick projects (1-2 hrs. max) Maybe a new thread "best mods under $200"?

Dynosoar

 

[Toadhopper]

Vacuum Secondary Diaphragm is the best under $50 mod Ive done!
I think my rig was operating at about 75hp before I swapped it out
Toad

 

[mtb_rider]

Few weeks back I picked up one of those thick rubber truck bed mats on sale. Yanked the carpet out of the back, laid it on the mat, outlined it with a paint pen, cut it out, laid it in in place of the carpet and screwed the thresh holds back down. Now I have a nice rubber cargo area and seat back. Looks cool and now I don't have to worry about tossing muddy gear back there.

My current project, which I just need to pick bolts up for to finish, is a mount for a fire extinguisher. I took a piece of 1" wide, 1/8" flat bar that was left over from another project, cut it to 16" long. Cut a couple 1" cubes off of a 1" square tube I had, drilled out the bolt holes, and welded the cubes on below the holes to shim it upwards. I will bolt it to the drivers seat mount, right in front of the seat, and use it to mount a fire extinguisher. I'm weird about not wanting to drill into my floorboards, don't know why, and that will keep it secure and handy.

 

[lowtideride]

I dont know about anything I did today could count for much...

But I fabed up a new cross member for the tranny & t-case, Installed a new t-case, and welded up brackets and tank straps for an 80 series gas tank....

 

[Tofudebeest]

I dont know about anything I did today could count for much...

But I fabed up a new cross member for the tranny & t-case, Installed a new t-case, and welded up brackets and tank straps for an 80 series gas tank....

Um, that's more than most of us get done in 6 months.