Builds Growing the Family: 1985 FJ60 Refresh and build

[JTU]

$100 harbor freight parts washer is a great investment. Took me about an hour to get the the parts clean. Time for some fresh paint.

Before:

 

[JTU]

Third member for the front axle painted and ready to go in.

 

[FJ60Cam]

Nice! What are you painting with?

 

[JTU]

@FJ60Cam this time I used POR-15 chassis paint topped with por15 clear coat.

 

[JTU]

The front axle was just too grimey to clean under the vehicle so I pulled it out and stripped it down.

Prepped for paint:

Primed:

First layer of paint laid:

 

[JTU]

Sprayed the knuckles today. I ran out of the POR-15 that I used for the third member so I used Krylon Idustrial enamel for the axle housing and knuckles. First impression is it runs easily but dries fast and is much harder 24 hours later than POR15 or Rustoleum industrial.


Waiting on the new knuckle studs and hardware to come in. Will look good with fresh OEM hardware.

 

[JTU]

Laid everything out and ready for re-assembly. I broke the inner retaining clips when I separated the birfs. Once I get the new clips everything should go back together perfectly. I installed all new studs have all new nuts and washers.

 

[JTU]

Been trying to squeeze in some garage hours in between work trips.

Everything went together with no surprises until the very last bolt, the top caliper bolt on the driver side. It stripped out, just my luck. Pulled the knuckle back off; I tried to helicoil first but I couldn’t get the coil to thread in properly. The M12x1.25 helicoil kit calls for the hole to be drilled out with a 31/64 drill, since the helicoil didn’t work I just drilled it out a little bit more with a 33/64 and tapped it with a 9/16x18. I had to open the caliper hole up slightly but it worked better than a helicoil would have I think.


All back together.

Installed the OEM extended brake lines and new axle to knuckle lines from Beno. I finally installed the extended Sway Bar brackets from Trail Tailor.

New 555 tie rod ends from Cruiser Outfitters. They come raw steel so I sprayed them with some spray paint.

Back on its front tires and full of fluids.

Some how I lost the bottom two rubber bushings to a shock them I took them off to remove the axle. Gonna have to dissect my shop and try and find where they ran off to.

 

[OGBeno]

Looking really good JTU.

 

[JTU]

Not many updates on the 60 since the last time I updated this thread. Been driving it almost every weekend and made several 300-500 miles road trips in it. It has been dead reliable and has been a blast to drive and enjoy.

Recently I picked up an ARB front winch bumper for it. At the time of the bumper install, I stuffed it with a Warn 9.5XP-S.

I really wanted some auxiliary lights that complimented the ‘80s theme but performed to 2019 standards. The best I could find that fit those parameters was the KC Daylighters LED. The City Racer LED headlights had good dispersion but lack good night beam distance so I got the KCs in Spot beam to help them out.

Day lighters, Spot beam:

City Racer Headlights, high beam and KC Daylighters:

 

[JTU]

I’m planning on taking the 60 out to Colorado(from Mississippi) this summer so I have started doing some preventative maintenance just as a precautionary measure.

As the old saying goes, “An ounce of prevention is worth a pound of cure.”

Started by replacing all the spark plugs, plug wires, rotor, and cap. Just changing these items made a noticeable difference in starting the 2f, especially when cold.

I think the original plugs were way past due. (New on left, old on right)

Next project is re-piping the cooling system with all new hoses from @beno. At that time, a new water pump, fan clutch, and t-stat will also go in. I may also replace the radiator, going to check and see if anyone locally can pressure test it my old one first.

 

[JTU]

Some random pics from the past few months that I have been absent from this thread:

Quick one night trip to the Ouachita NF. This was the first road trip since swapping to the 4:11s. I averaged 14-15mpg for the whole 500 mile trip.

My other project has been building a 416 for camping duty. The 60 pulls this 416 very nicely. I plan on taking the trailer to CO this summer behind the 60.

The other week I drove the 60 down to central MS for the CottonLand camp-out. @wngrog took a group of us to a secret sand pit. The only take of sand dunes we can get around these parts. This was the first time I had driven a manual trans in soft sand so it was a learning experience but the 60 did way better than expected.

Added a Raptor to the fleet. Man do I wish I could stuff that 450hp eco-boost into the 60.

 

[wngrog]

Bump for updates coming soon