"FREEDOM" '82 BJ60 w/3B Build Thread For Our Missions

[The Jade Bean]

Small Update:

We got 5 15x6" rims off the earlier 40 series.












They are identical to the ones we have but painted, not chrome. Pretty sure tire wise we will go with KM2's 33X9.5R15LT.


We also bought a used radiator with the hopes of having it redone since the current one is leaking. However it was discovered it was really to far gone to spend the money to "fix" it. The radiator shop found a new radiator for a FJ60 and then they had to cut the angled hose hookup on the bottom of the used radiator and put it on the correct side of the new one. They also had to cap the bottom hookup on the new one that was on he wrong side. Hope that makes sense! So now we have a brand new and expensive radiator.













Then we bought a very well used but tough front bumper and sliders with the Aussie side protection. I plan on refinishing these with the rims.

Donor BJ:












I think that's it for now.

-Daniel Kent

 

[The Jade Bean]

We need some advice on what route to go with on our exhaust. I've looked at loads of pics and read threads and I'm only finding pieces of my answers to my questions. I want to keep the exhaust short and simple.

I found a schematic here on MUD of the original exhaust routing. Here:



So first question is do I need to use a flex section in the exhaust like this?



Second question is should I go with 2", 2.5" or 3"?

Third question is can I route it like this without issues and would the fumes come up into the cab? The exhaust would run up high along the frame rail and dump just in front of the rear tire.



If it matters, we may at a later unknown date add a turbo.

Thanks MUD!!!

-Daniel Kent

 

[The Jade Bean]

Oh and do I need a muffler?

-Daniel Kent

 

[The Jade Bean]

Does anyone know if the fuel cap has to be OEM or even specifically for a diesel? Thanks!

-Daniel Kent

 

[The Jade Bean]

Ok so I wanted to see how loud it is without a muffler so I cut off what was left and here's what I concluded... It is defiantly loud, but no more really than my '02 Dodge work truck with a Cummings turbo diesel. I will let my wife be the judge and if I put on a muffler it will likely be a flow through style.

I also felt like there was more power and I suppose this could be my imagination, but I don't think so. It could be very well that the old muffler was seriously clogged and putting to much back pressure on the engine.

I also concluded that I will more than likely run the exhaust all the way to the rear cause even though I like the louder sound I don't want it right out the window.

Some pics for your viewing pleasure.









-Daniel Kent

 

[brownbear]

not sure if anyone answered but yes you use oil rated for a diesel. That bottle you have probably isn't too old as that is the current label at canadian tire.

use 15w40. don't bother with full synthetic unless you are going somewhere cold. full synthetic just seems to create more leaks.

on the exhaust, it's better to have a few turns like your picture that goes out the drivers side. 2.5 inch pipe. also install an EGT gauge close to the outlet. Pre turbo if you get a turbo.

No muffler if you get a turbo, yes to a muffler if there is no turbo.

 

[brownbear]

Does anyone know if the fuel cap has to be OEM or even specifically for a diesel? Thanks!

-Daniel Kent

the fuel filler is larger, so probably it will need to be changed, or your throat in your filler opened to accommodate large truck stop pump handles. Like 2 inches in diameter.

Paint it yellow, put diesel only on a sticker near it.

 

[The Jade Bean]

^^^ Thank you! Do you know if there is a fuel / water separator on the BJ?

-Daniel Kent

 

[essar5]

Should be one on your passenger side frame rail, just forward of the midway point.

 

[The Jade Bean]

Should be one on your passenger side frame rail, just forward of the midway point.

Great, I'll check. Thanks!

-Daniel Kent

 

[The Jade Bean]

So is this the fuel separator?


Does it need to be drained periodically? Should I remove the OEM one and install one under the hood like this?



Thanks!

-Daniel Kent

 

[essar5]

That's it. I might do what you are suggesting with a Racor under the hood. I can't trust my "Filter" light so it would make it easy to see how much water I am lugging around. The filter light is supposed to alert you when it is time to drain.

It does need to be drained every now and then. Just loosen the bolt on the underside and let it flow until the fuel is free of water.

 

[The Jade Bean]

That's it. I might do what you are suggesting with a Racor under the hood. I can't trust my "Filter" light so it would make it easy to see how much water I am lugging around.

Ok so that's what they light on the dash is for that says filter. I wonder if you would have to do anything special with the old wiring or leave it abandoned.

-Daniel Kent

 

[essar5]

Ok so that's what they light on the dash is for that says filter. I wonder if you would have to do anything special with the old wiring or leave it abandoned.

-Daniel Kent

Cap and stow the wiring. You won't need it for the glass bowl type separators. Just rely on your eyeballs.

 

[The Jade Bean]

Cap and stow the wiring. You won't need it for the glass bowl type separators. Just rely on your eyeballs.

Right on. Thanks!

-Daniel Kent

 

[The Jade Bean]

Ok, so think I have the exhaust pretty much figured out. Does anyone see why you couldn't run the muffler under the rear fuel tank (heat issues)? It would be right above that guys head in the second pic.








Thanks!

-Daniel Kent

 

[90FJ]

You putting on a swingout tire carrier? Otherwise it'd be in the way, I'd also be afraid of smooshing it on a rock if you hung it low towards the middle of the rig.

I don't know what the accepted clearance is for gas tanks but I think they get within 3" in the stock location?

I really dig the OG style ARB.

 

[The Jade Bean]

You putting on a swingout tire carrier? Otherwise it'd be in the way, I'd also be afraid of smooshing it on a rock if you hung it low towards the middle of the rig. I don't know what the accepted clearance is for gas tanks but I think they get within 3" in the stock location? I really dig the OG style ARB.

Yes I'm going to build a rear bumper with a swing out. You make a good point on being a hang up and the ground clearance. I'll post a diagram in a bit with the route I'm trying to take. The bumper is cool and very stout.

-Daniel Kent

 

[The Jade Bean]

Here's the diagram that hopefully will make sense. Thoughts?



-Daniel Kent

EDIT: There would be at least one area to separate the exhaust just befit the muffler for easy removal when we do a frame swap.

 

[The Jade Bean]

Hood scoop vs louvers...

I would have a scoop made something like this:




Big enough to also put our logo on top of it.

Or...

Louvers like these:





Pro vs Cons on both, personal experience would be good. Thank you!

-Daniel Kent