Forge Specialties, An FJ62 gets a 5.3 LS V8 (1 Viewer)

[35inchoverdrive]

It seems that page 1 of the 60 forum is often covered with LS-repower threads and questions...so I thought I would pile one more on...

Several years ago, a long time Cruiser buddy of ours had some major mechanical issues with his 3FE. The truck sat for awhile, while various phases of scheming came and went...source a good core 3FE for a rebuild...hot rod TPI GM V8...and finally, "Let's talk about an LS..."

Thankfully, we had a pretty clean 62 to start with. The truck was already sporting and Old Man Emu suspension, ARB front bumper, winch, sliders & swingout rear bumper.

 

[35inchoverdrive]

The customer picked up a used 5.3 LS engine and 4L60 transmission from a 2002 Silverado pickup. This was a departure for us. In the past we've swapped in new drivetrains from Turnkey Engine Supply (check out our previous 80 series engine swap at A 1994 80 Series gets an LQ9 GM V8 ) or takeouts that have been rebuild by a local engine builder.

 

[35inchoverdrive]

*The picture quality will temporarily take a nosedive. There was a dark time in the shop where we only had a really crappy camera. It gets better, I promise.*

We stripped the intake and accessories off. This guy really needed a bath.

After an initial scrub down(so we didn't get GM on us every time we touched it) we used our hotrod '79 Toyota forklift to assist with mockup.

These LS engine mount plates are a good start to fabbing up some custom mounts.

 

[JayDoc]

sub'd

 

[35inchoverdrive]

...the 5.3, 4L60, adapter & stock splitcase are assembled and ready for their first(of many) trips into the engine bay.

...slowly lowering everything into the engine bay. We found that running a chain to the uppermost bolt holes on the backside of the cylinder heads, balanced the engine/trans/tcase perfectly.

 

[35inchoverdrive]

After pulling some initial measurements with the drivetrain floating via forklift, it was time to start fabbing up the frame side of the engine mounts.

...begin with flat stock...add sharpie, a bandsaw and a drill...

...both sides get shaped with a press brake.

 

[35inchoverdrive]

The two frame-side mounts are slightly different for fitment reasons.

To keep everything serviceable, we used a C5 Corvette mount, so replacements can be sourced easily down the road...and because Corvette mounts will make it faster...

...cleaning up the frame to tack the mounts in place.

 

[35inchoverdrive]

The mounts are stitched in place.

This angle shows why the mounts are not symmetrical, so that they fit the contour of the frame properly.

...with the vette mounts.

 

[35inchoverdrive]

With the engine side of the mount stitched together, the drivetrain rests in the truck.

...from the top.

The rig gets rolled outside so that we can use our OEM Toyota SST Flexometer to check oil-pan-to-front-diff clearance and driveshaft-to-transmission-pan clearance.

I'm pretty sure this is how Toyota checks fitment when they are developing new products...

 

[Spike Strip]

Wow. Nice work. You almost make it look like fun!

 

[brownbear]

Love it!

Looking forward to seeing it progress.

The worry wart in me wants to see some bolts on the engine brackets, not just welds holding them on. But I love the mounts. Easy to access and see.

 

[gregnash]

Very nice work.. interesting take on the engine mounts... What size flat plate are you using for the mounts on the frame side? I am not welder by any means but I would be worried that the continual flex/torque of the engine would pull those off. Assuming that you reinforced down the line somewhere.

 

[35inchoverdrive]

Wow. Nice work. You almost make it look like fun!

Thanks! The early parts are often fun and we really love what we do.



With the front right stuffed at full flex, the stock GM truck oil pan clears like a champ.

The driveshaft was tight to the transmission pan, but still spun freely(from what I remember).

...now flexing everything in the opposite direction.

 

[35inchoverdrive]

Love it!

Looking forward to seeing it progress.

The worry wart in me wants to see some bolts on the engine brackets, not just welds holding them on. But I love the mounts. Easy to access and see.

...laying underneath a truck, supported by a forklift...what could possibly go wrong...

We fabbed up some bump stop drops from UHMW to make sure that the diff and driveshaft can't hit anything in the drivetrain, even in the case of a full awn dukes of hazard moment.

 

[MANUCHAO]

Love the angles on them motor mounts !!!
Engine placement is spot on... !!!
Im sure with you guys experience of swapping an LS into an 80 series, you probably find lots of real state in the 60 series eh !!!

 

[35inchoverdrive]

Very nice work.. interesting take on the engine mounts... What size flat plate are you using for the mounts on the frame side? I am not welder by any means but I would be worried that the continual flex/torque of the engine would pull those off. Assuming that you reinforced down the line somewhere.

It's 1/8". It will get fully welded on both sides and the modified transmission crossmember shares in the load. A lot of material would have to tear for them to deflect. This is also one of those situations where it's important not to suck at welding. 1" thick frame side mounts are available a la carte by request.

Love the angles on them motor mounts !!!
Engine placement is spot on... !!!
Im sure with you guys experience of swapping an LS into an 80 series, you probably find lots of real state in the 60 series eh !!!

We did an LS in a first gen Tacoma right before this one. That was a seriously tight engine bay, so this looked HUGE when we started.

...checking fitment of the Hooker cast manifolds. We used a black set for mockup, so nobody freakout when they change color later.

...as the junk camera continues to make everything look terrible. ...better pictures of everything cleaned up later on...

 

[35inchoverdrive]

We like connecting the LS stuff to the stock airbox whenever possible, because it gives the swap a much more retro/clean/factory-ish look.

...mocking up the silicone intake tubing and GM MAF to the stock airbox.

The stock airbox lid will need to be modified.

Let the cutting begin...

 

[35inchoverdrive]

...fabbing up the Toyota-meets-GM intake.

...in the truck.

 

[gregnash]

Thanks for the info... really like the look of the modified FJ62 canister in there. Looks to be a simple, yet well thought out fab.

 

[sbelinge]

Great work, and all the photos are awesome!