FJ60 Expo Rig

[morgan85]

In the process of planing to turn my 1983 FJ60 into a expo rig. I have wheeled it a few times and come to find out i like the expo set up better. Not really into rock crawling. Me and my wife like driving around seeing the sights and camping, and a expo rig makes more sense for us.


Have not seen alot of people doing fj60 builds so i thought i might give it a try. Going to document every thing also give websites of where I bought the stuff.

To make this a good rig I will be focusing on a few areas of improvident:

Lighting/Electrical.
-will need to do a upgrade kit on head lights. The head lights on these sucks.

-add some more lighting. Thinking of going with LED light bars. They are really bright and use hardly any power.

-changing all lights but head lights to LEDs. Less power used+less gas used= longer time in the field befor fueling.

-2nd battery. Going to use to optima's a red for starting and a yellow for winching and other. Going to use the 12 volt guys winch+battery panel.
http://www.12voltguy.com/ULTRA-DUAL-BATTERY-WINCH.html

Diesel Engine.
-I want to switch to a diesel engine for gas mileage purposes. But do not know which one i am gonna pick. I want to stay with a US mechanical engine. Doing this for ease of parts and if i blow a fuse/alt dies i will not be stuck. Also i think the 2f would have enough power to move 1000lbs of axles but at the cost of gas mileage. Right now i get 16mpg i bet it would drop to 6-10mpg.

-options are
Isuzu 4BD1T/2T-Need to find a adapter to fit.
Cummins 3.3 or 4bta
Mercedes inline 5 or 6
And any other suggestions.

Transmission.
-Would like to keep the 4 spd for price. But on some of these i will have to trade it out unless some one know's of a adapter that would work for those above diesels.

Drive train.
-Would really like to do portals been doing some searching and think i will go with Unimog 404 axles. Doing this for two reason 1 can't really find Volvo C303 and 2 parts are pretty easy to find.

-I looked into getting ARB lockers for my axles i have now and there about $2000 for them. On a few sights and forums i have found the Unimog axles for $1200-$2400.

Tires/Rims.
-More to follow on those. If any one has some suggestions of what they are running i would love to hear about it.

Storage.
-All ready have roof rack. Going to need a rear bumper for tire and fuel cans. Might go with a pre cut weld your own rear bumper.

-Going to go with a storage raised bed in the back like i have seen in some of the FJ60.

Fuel.
-Want to get or make a aux fuel tank. Need to look into has a good quality to low price tank. If any one has any suggestion on a good one that they are using that would be great.

Winch/Recovery.
-Leaning towards a Mile marker 9500lbs or 12000lbs winch depending on loaded weight.

Radio.
-Still looking into this. Right now i have a cheapo Copra $40 dollar radio may upgrade may not.

If any one has any suggestions i am open to them. Going to be starting up on it this upcoming year. Going to get front axle 2013 and next axle 2014. May also get Engine in 2013 just going to see were funds are at how cheap i can get stuff.

Also as i go along some items will be up for sale like 2f engine, rebuilt front axle, rear axle, and maybe trans depending on how it goes.

Well let me know what you guys think.

 

[RDC76]

Nice vehicle choice. I have one set up for expo use. Best of luck to you.

Rich

 

[roscoFJ73]

A diesel will not save you money unless you do extremey high miles.If you do get one,go with a 1HZ.

I seriously dont believe an expedition rig needs portal axles,people travel around the world in stock landcruisers.Everyone to their own.
A 5sp gearbox is a good upgrade with the lower transfer case gears.

For tyres and rims,get something thats easy to replace and is good on the highway as well as off road.
You usually you have to spend a lot of time on the road to get to remote trail heads.

 

[MANUCHAO]

You should check out the 60 series forum and diesel section if you havent already.
Also, Expedition Portal has great information for expo rigs...

 

[Tapage]

I seriously dont believe an expedition rig needs portal axles,people travel around the world in stock landcruisers.

strong X2 on this comment .. ^^^^^

 

[morgan85]

Thanks for the suggestions. I may or may not use portal axles. That will more than likely be last on the list. I am going to try and stay away from a Toyota diesel. I would love to use a Toyota diesel, but the price is steep and also parts are not cheap and takes a while to get here. I think a diesel produced and sold here will be cheaper in the long run.

 

[abruzzi]

I think the problem with the diesel idea (much as I love diesels) is that if your doing it for economy the cost vs the sticking with the 2f is significant, and how many miles do you have to drive before it's paid for itself? If your changing engines either way due to power concerns, then the diesel makes sense, but only if the $3-5k of a diesel conversion would be spent no matter what.

Geof

 

[MANUCHAO]

IMHO:
the way you need to look at a diesel is: RANGE
if a full tank of gas lets me drive X amount of miles... how sweet it would be to almost double the amount of miles.... on the same tank of diesel fuel on a classic vehicle ones chooses to drive...
imagine the distance you could cover with an 38 gal fuel tank...

RANGE is one of many must-haves on an expo rig....

 

[LAMBCRUSHER]

diesel also has the ability to run on severe off camber situations, and also has the option of biodiesel or SVO for those inclined


Toyota diesel with H55 5 speed trans

I wouldn't pee on an optima sealed battery, myself but dual batteries are a good idea


I'd think for expo, a full floating cable locker would be the axle of choice


don't forget your hot water, and refrigerator...


and the underseat storage box along with the tailgate and side panel storage will go a long way to keeping it all together and out from under your feet...

 

[Tapage]

the way you need to look at a diesel is: RANGE.

X2 ..

Although it depends on how you set your IP / timing .. my HDJ80 it's certainly not set for economy and then it's mileage it's like any gasser .. but lot's of fun to drive ..

Well tuned Toy Diesel in stock condition ( I mean not with all extra weight we can put ) could be in the 30mpg range ..

From that point you must start playing with some other variables as R&P, 5th gear in your tranny, tires, etc ...

 

[morgan85]

After looking at some figures and some other stuff i am not going to be putting Unimog axles under the truck.

Instead I am going to go with a full floating rear axle out of a FZJ80. I looked at getting a fj60 full floater but it is going to be $900 dollars, and I have heard that you get them in pretty rough shape. I can get a FZJ80 rear from http://cruiserparts.net/parts/fj80.htm for $500 or $1000 with e locker but i will have to buy lock motor separate.

Planing on going with 4.11 gear front and rear with TJM locker that i have seen price through the shop that i work for in the range of $800-900. I do not have the quote sheet with me but its in that range.

Going to add 4 inch Dakar leaf springs. The one's i have right now are starting to sag.

Decided to go with the Isuzu 4bd2t diesel. I was reading a post from bluehawk on here that has had a adapter plate made up that allows you to use your fly wheel and clutch and bolts up to the 4 speed tranny. I messaged him about where to get it and price just waiting to hear back. It sounds pretty promising.

I think for tire i will go with the Good Year Duratracs. I have them right now in a 33x12x15 and they ride really well. The bad thing with the FZJ80 axle is i have to go up in rim size. I have seen post saying that you can use JDM caliper's and rotter and i could stick with my 15", but i have not been able to find any.
If any one knows of a place to order them from let me know i would love not to have to switch my tires out i just got them this year.

Should be getting my head light up grade kit pretty soon going to install that and also going to order my led lights from http://www.superbrightleds.com/. Going to measure the draw before and after it should be neat to see. Trying to decide on doing a high output alt. I have heard mixed reviews on those of people saying they work really well or they burn them selves out.

Oh also going to tear out all of the carpet so i can bead line it. I believe the carpet is fairly new its in pretty good shape if any one wants it they can have just have to come and get it.

 

[roscoFJ73]

I have heard mixed reviews on those of people saying they work really well or they burn them selves out.

.

It might be a case of both statements being true.
They work really well UNTIL they burn themselves out.

 

[SNLC]

I am putting portal axles under an overland truck.

If I didn't have the portals already I would use 80-series axles.

The reason I would use the 80 axles should be obvious. The reason I wouldn't use the portals if I needed to buy them for the project is they are not going to be put to real use very often. There are some other reasons too, like gearing issues, parts availability on a world wide scale are another reason. The portals I have though use off the shelf domestic parts which is not exactly the same as a Volvo portal. The thing about the portals that is sweet, when you get somewhere where serious off-roading is in front of you, the axles will make you smile!

Frank is spot on about the range. One of the best mods I did to my last overland truck was to increase range. For nothing else, it sure was nice to not have to stop very often for fuel or carry jerry cans.

While the general consensus is keep the truck mild in the mod department and off-road build up department and I tend to agree with this. However, people drive around the world in all kinds of trucks. Half million dollar Unimogs for example. Not a very practical truck to drive around the world, or a very good pick IMHO but hey it takes all types to make the world go around! I met a dude once on the road in Mexico who was/is hitch hiking to the tip of South America, so far he has been on the road for over two years. Maybe not your cup of tea but he is out there doing it, his way!

My general opinion about an overland vehicle is; they are all different. Sure you can find cookie cutter examples of what is a "real" overland truck. The amount of 80-series on ExPo built/used for overland travel is unreal! There is good reason for that though as they make a good overland truck. But really who is to say what tire size is to big, what engine or trans or axles should or shouldn't go under an overland truck? Shouldn't it all simply depend on what the owner/builder plans to do with the truck? Where they plan to go? How they plan to get there? Do they like sleeping inside the truck, on top of it on the ground next to it or inside a hotel? Do they like to buy or bring premade meals or do they like to set up elaborate kitchens and cook up fancy meals in the bush? When they get there do the like to sit around and take pictures or or do they like to get up at dawn and go surfing or do they like to do something else? All these things and more should come into play when coming up with an overland truck and how it is design and set up. Since we all like different things and like to do different things with our free time, I think the trucks reflect that. An overland truck is a far different type of truck than a rock crawler. And as such you don't find nearly as much variation in trucks built for the rocks. But it still takes all types to make the world go around!

Cheers

 

[BigWalker]

Interesting choice of diesels, thought you wanted "US" made? If you haven't looked already go to the 4bt swaps forum, several people using that engine and can help. If you are changeing transmissions I would suggest you look at the engine & trans as a package, this might change your mind about toyota diesels..I personally favor the 4bt cummins as I am dropping one in my 40 now

 

[gregnash]

Interesting choice of diesels, thought you wanted "US" made? If you haven't looked already go to the 4bt swaps forum, several people using that engine and can help. If you are changeing transmissions I would suggest you look at the engine & trans as a package, this might change your mind about toyota diesels..I personally favor the 4bt cummins as I am dropping one in my 40 now

I don't think he meant US made in that context but one that was readily available in the US for easier parts consumption and purchase. Though I have heard of guys that can get parts for the 3B and 2H Toyota diesels from normal auto parts stores like NAPA, Autozone, O'Reily.

 

[doug720]

Range is the key to exploring many areas, even here in the US (at least in the West!). With the 2f and stock fuel capacity, I was lucky to have a 250 mile range off-road at times.

My solution was to convert to diesel and add a saddle tank to my 60. I now have around 42 gallon and have averaged nearly 20 mpg since the 4BD2 diesel swap 17K miles back. This combo gives me over 800 mile range, but, depending on terrain, mileage can be considerably less. So far my lowest mpg has been around 16 at high altitude and big climbs.

Take a look below my signature for a link to my 60 swap and let me know if you have any questions.

60's are great vehicles to explore with.

Good luck,

Doug

 

[MANUCHAO]

Doug, you and others with a diesel engine and an aux fuel tank or bigger than stock tank....have the best combo as far as expo rigs go.....

I got a 45 gal tank and can do around 650 miles per tank..... Im quite happy with that but to think I could squeeze another 200 / 300 miles on the same thank with a diesel... would be amazing in my books... !!!

 

[morgan85]

Ok update time. I got my head light up grade kit from cruiseroutfitters.com for Christmas and going to install it tomorrow. I have decided to do my electrical stuff first.

List of things to do:
-head light up grade.
-LED running lights from superbrightleds.com going to be about $286.11. Going to do it in stages.
-Dual battery kits. Going to use Blue Sea's marine kit going to be around $150. Wanted to use this cause cheaper than most kits and should be water proof since it meant for boating. http://www.westmarine.com/webapp/wc...gclid=CI_Y-7O2ubQCFQGvnQodg1YATg#.UNujMG_dozI

-Still on the fence about a high out put alt.
-21" LED light bar from superbrightleds.com going to be $139.95.
http://www.westmarine.com/webapp/wc...gclid=CI_Y-7O2ubQCFQGvnQodg1YATg#.UNujMG_dozI

Was also reading a old post about parabolic leaf springs. From what i read people liked them but not a big demand in the states for them. Was trying to find a seller to see what prices are but no luck. If any one knows of a seller post some thing up about it.

 

[cruiseroutfit]

Ok update time. I got my head light up grade kit from cruiseroutfitters.com for Christmas and going to install it tomorrow.

Thanks again! I'll be watching your build

Excited to see your project come together. While its totally a different platform, I put a bunch of my thoughts on modifications to my recent 100 Series build, things like storage, bumpers, electronics, etc. Might spur some thoughts: https://forum.ih8mud.com/showpost.php?p=8107409&postcount=22
Might spur some more thoughts on your build?

 

[theside00]

If you are going diesel I would reccomend the 1hdt and the H55f 5 speed. Bullet proof combo for an expo rig.