stevebradford
In the shop
Have a good trip!
FJ62ish
- Thread starter Gsb15
- Start date
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Wow, nice work! Looks awesome. Enjoy all that extra space when camping.
- Thread starter
- #44
Alright, time for my quarterly update.
The 60 has been on the road for 3 months now. It's been on a few decent trips with no major issues to speak of. I'm still fighting EGT on the highway this turbo setup, so phase 2 (starting now) will be to jam an intercooler in there somewhere and to address timing, valve lash and maybe injectors.
Anyway ill start back from July where i left this thread off.
Working with the body off made it really nice to work on the engine. Replaced the side gaskets with some new from Toyota, which were actually reasonably-ish priced. I had the alternator refurbished and Brian Roberts auto, and new lines for the turbo and alternator made at Coast industrial. I also installed a downward facing oil filter housing, that i robbed off of the parts motor that i have.
The turbo came from the Keith Cooper collection, when you have 47 turbos on a work bench to choose from (not kidding), it kind of felt like picking out a puppy to take home.
the one i chose i believe was from some sort of BMW 5L with equal size twins. i figured that it was sized for 2.5L of gas displacement and would work well on the 3.4 diesel.
the challenge was that is V-band, but BMW V-band, which means it doesn't fit anything standard, flanges were too thick to fit in the clamp. I wound up a little angry and broke out the zip disk for some housing modification......i wasn't proud enough to take any pictures, but it seems to be holding up well with no leaks.
the manifold is a little bit more upscale than the log style on my 70. Used some 90* weld in pipe fittings and some 2" tube.
The 60 has been on the road for 3 months now. It's been on a few decent trips with no major issues to speak of. I'm still fighting EGT on the highway this turbo setup, so phase 2 (starting now) will be to jam an intercooler in there somewhere and to address timing, valve lash and maybe injectors.
Anyway ill start back from July where i left this thread off.
Working with the body off made it really nice to work on the engine. Replaced the side gaskets with some new from Toyota, which were actually reasonably-ish priced. I had the alternator refurbished and Brian Roberts auto, and new lines for the turbo and alternator made at Coast industrial. I also installed a downward facing oil filter housing, that i robbed off of the parts motor that i have.
The turbo came from the Keith Cooper collection, when you have 47 turbos on a work bench to choose from (not kidding), it kind of felt like picking out a puppy to take home.
the one i chose i believe was from some sort of BMW 5L with equal size twins. i figured that it was sized for 2.5L of gas displacement and would work well on the 3.4 diesel.
the challenge was that is V-band, but BMW V-band, which means it doesn't fit anything standard, flanges were too thick to fit in the clamp. I wound up a little angry and broke out the zip disk for some housing modification......i wasn't proud enough to take any pictures, but it seems to be holding up well with no leaks.
the manifold is a little bit more upscale than the log style on my 70. Used some 90* weld in pipe fittings and some 2" tube.
- Thread starter
- #45
With the engine and turbo mostly wrapped up, it was time for the body swap. I prepped the 62 as much as i could, stripping everything out of it. The goal was a 1-2 day swap.
we started at 8am at he hanger, loading up the 62 onto the ramp truck and taking it to Keiths shop. We backed the ramp truck into the shop and set up the lift to pick up the body. Spent an hour of so fighting body mount bolts, and trying to be sure everything was disconnected. We then lifted the body off the frame and rolled the ramp truck out of the shop with the frame still strapped down. it went so smooth its kind of felt like cheating.
I spent a little bit of time stripping useful parts off the FJ62 frame before heading out to the scrapper in Brentwood. I would have liked to keep a little more from the frame, but i unfortunately just don't have the space to hoard Sh**y axles.
After dropping off the old frame we went straight back to the hanger, picked up the new frame and went back to the shop. I had to spend a little bit of time fixing a rear cab mount on the body, and removing the massive home made heat shields the P.O. had made for the 3fe.
once the underside was cleaned up we unloaded the new frame into the shop and lowered the body back down and put some bolts in to hold it.
At this point we stood around staring at the days visual progress over a victory beer, before loading it back up on the ramp truck and hauling it back to Sidney, where i rolled it in the hanger, shut the doors and went home... Time.... 9:00pm. not too bad.
we started at 8am at he hanger, loading up the 62 onto the ramp truck and taking it to Keiths shop. We backed the ramp truck into the shop and set up the lift to pick up the body. Spent an hour of so fighting body mount bolts, and trying to be sure everything was disconnected. We then lifted the body off the frame and rolled the ramp truck out of the shop with the frame still strapped down. it went so smooth its kind of felt like cheating.
I spent a little bit of time stripping useful parts off the FJ62 frame before heading out to the scrapper in Brentwood. I would have liked to keep a little more from the frame, but i unfortunately just don't have the space to hoard Sh**y axles.
After dropping off the old frame we went straight back to the hanger, picked up the new frame and went back to the shop. I had to spend a little bit of time fixing a rear cab mount on the body, and removing the massive home made heat shields the P.O. had made for the 3fe.
once the underside was cleaned up we unloaded the new frame into the shop and lowered the body back down and put some bolts in to hold it.
At this point we stood around staring at the days visual progress over a victory beer, before loading it back up on the ramp truck and hauling it back to Sidney, where i rolled it in the hanger, shut the doors and went home... Time.... 9:00pm. not too bad.
stevebradford
In the shop
I would have given you 200$ for those axles.
- Thread starter
- #48
Now started the Process of finishing it up, this is the part where the work to visual progress ratio becomes painful. I had intended to Intercool right away, but after finding that the intercooler i had wouldn't fit and looking at how much time i had, i decided to just go over the top for now.
This portion of the build was just filled with finicky little sh** that i didn't take many pictures of. Small rust repairs in the floor, assembling interior, making a rad crossover to fit the FJ rad, mounting batteries and just generally finishing the engine bay. Also wiring.... a lot of wiring. just about everything for the 3fe is on the wrong side for the 3B.
The first drive home was a mess, i had wired the wastegate shut, but not very well apparently. It would only pick up 1lb of boost, all while smoking out the highway and trying to self destruct with exhaust temp. I was able to mostly sort that out the next day.
that's when my last post was, first drive was the Thursday, and we went camping on the friday. It was a real shakedown run.
The next week i worked on the bumper. i started with a pretty boring C-channel bumper that came off a parts truck. It wasn't exactly how i would build it, but i had it around and it already bolted up. i modified the ends to be a little tighter to the body, added D-shackle eyelets, a hitch and built a tire swingout.
for the latch on the swingout i was able to finally use a Twin Otter door handle and latch assembly i've been holding onto for a couple years.
I found it brand new in the scrap bin at work, with the keys beside it. Being an airplane part it probably cost $1000. Which made my my kinda mad when i broke it on the first day... by hand.... F****n airplane parts. I was able to fix it though, with some better parts and it works great.
This portion of the build was just filled with finicky little sh** that i didn't take many pictures of. Small rust repairs in the floor, assembling interior, making a rad crossover to fit the FJ rad, mounting batteries and just generally finishing the engine bay. Also wiring.... a lot of wiring. just about everything for the 3fe is on the wrong side for the 3B.
The first drive home was a mess, i had wired the wastegate shut, but not very well apparently. It would only pick up 1lb of boost, all while smoking out the highway and trying to self destruct with exhaust temp. I was able to mostly sort that out the next day.
that's when my last post was, first drive was the Thursday, and we went camping on the friday. It was a real shakedown run.
The next week i worked on the bumper. i started with a pretty boring C-channel bumper that came off a parts truck. It wasn't exactly how i would build it, but i had it around and it already bolted up. i modified the ends to be a little tighter to the body, added D-shackle eyelets, a hitch and built a tire swingout.
for the latch on the swingout i was able to finally use a Twin Otter door handle and latch assembly i've been holding onto for a couple years.
I found it brand new in the scrap bin at work, with the keys beside it. Being an airplane part it probably cost $1000. Which made my my kinda mad when i broke it on the first day... by hand.... F****n airplane parts. I was able to fix it though, with some better parts and it works great.
- Thread starter
- #49
One thing i forgot to address was the filler neck... which was a sad realization when i went to fill it up with diesel and couldn't fit the nozzle in. Ive had to use a screw driver to hold the little door open and kind of dribble diesel in from above ever since. That is also on my phase 2 list, as ill also have to drop the tank to fix a fuel pickup issue, it runs out just under half a tank.
- Thread starter
- #50
yea... it kinda sucked, plan was to pull them at the wrecker and just scrap the frame. but we couldn't get them out. it was really a time and space issue. also they had be advertised before with no interest.
stevebradford
In the shop
Next time maybe offer that stuff on here for free, you pick up. before crushing it. It was sad to see it wasted as I need a front axle right now and rear 60 leafs are always handy to have. I'm sure if there was anything for free @seapotato would store it in his field.
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stevebradford
In the shop
Thanks! but I tried for that one last night! it's gone already.
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stevebradford
In the shop
Don't worry Gsb15 I will forgive you someday! 
I have murdered my share of cruisers as well.
I have murdered my share of cruisers as well.- Thread starter
- #56
Don't worry, I've still saved more than I've killed.Don't worry Gsb15 I will forgive you someday!
