Harumi the Rusty Rescue JDM HJ60 - Build Thread (5 Viewers)

[BrickRunner]

It's a bit toasty outside so I suppose I can take a break and finally start my build thread.

I picked up this HJ60 back in May have been slowly working out all the bugs.
It runs and drives, but leaks...

2H Engine with H55F 5 speed
PTO Winch (functional)
Factory Limited Slip Full Float Rear Axle
High Roof
24 Volt
Right hand drive

Once it's mechanically sound, I'll get to work on the rust! Oh the rust! Horror!

My plan is to make it a roadtripper/explorer/camper:
FJ60 grille/headlights
Rooftop tent
Turbo
Selectable rear front locker.
Onboard Air Compressor
Lots of gauges!
Stowage for camping gear and tools
Either an auxillary or larger fuel tank

 

[BrickRunner]

After cleaning all the random junk out of the interior, the first thing to do was address the terrifying 'rear heater bypass' and torn intake conduit.

 

[BrickRunner]

Once the 'rear heater bypass' was plumbed in a manner that wouldn't eject coolant whenever the heater was turned on, I ran a jug of Evapo-rust Thermocure and distilled water through the cooling system, following the instructions on the bottle. I proceeded to flush it 4-5 times with water before putting in Toyota Red coolant with distilled water.

 

[BrickRunner]

The BFG's that came on the truck appeared to hardly ever been driven on, but the date codes were absolutely terrifying...
I bought new 33X10.5R15 BFG's all terrains on FJ40 steelies.

 

[BrickRunner]

Once I got it drive-able, I soon discovered the clutch was on it's way out...
I used Nathan's Hot Dog buns to remove the pilot bearing and installed the extended pilot bearing as the input shaft on the transmission was worn:

Pilot bearing not fitting

Took my truck in to have a clutch kit installed. The shop called today and said that there was a seal in place of the pilot bearing, and that the pilot bearing was not fitting. "Too tight". I've never heard of a seal in place of the bearing. Has anyone heard of this? They want to replace the old...

forum.ih8mud.com

Unfortunatly the new rear main seal still leaks so I'm going to have to pull it again and try a speedy sleeve.

 

[BrickRunner]

A previous owner had installed a mechanical oil pressure gauge, and I eventually found out why. At some point the voltage gauge and oil pressure gauge shorted together and melted there respective wires (they share a ground). Some rewiring and a new sender and now I have two oil gauges and voltage, huzzah!

 

[BrickRunner]

I found a compressed air tank attached on the underside of the front bumper, possibly for an air horn?
Someone lost their lunch money in the back seat, I also found some Japanese Yen coins when I pulled up the carpet!

 

[BrickRunner]

The exhaust had an extra hole for better flow or something. Fixed!

 

[BrickRunner]

A few weeks ago, I did a quick drive up into the hills for a stress test. It got warmer than when cruising on the freeway but stayed just below the middle of the gauge.
Chugged up the highway like an old steam engine! (drove from ~700ft to ~3700ft in 14 miles or an average 4% grade). Checked the valve clearances when I got back, all within spec, and put on a new valve cover gasket.

 

[BrickRunner]

Installed the Amazon Clutch Vacuum Booster. The old booster was clearly toast by how the pedal now feels.

 

[BrickRunner]

My rear view mirror was super wobbly and wouldn't stay put. A previous owner had put rubber cement or something to try and stiffen it up to no avail.
I found an aftermarket wide angle mirror that looked like it might fit onto the OEM mount. The OEM ball is slightly smaller than the aftermarket one, but I stuffed in some pieces of rubber sheet to compensate and it seems to hold position. We shall see after some bumpy roads. It just fits between the sun visors and the view is awesome!
The mirror can be found here.

 

[BrickRunner]

While researching locker options I stumbled across an axle code decoder. My code is K085: 9.5" 4.111 Limited Slip Full Float. Huzzah!
Please ignore the crazy shackles...

 

[MarkBC]

You can still get the OEM rear view mirrors, though I'm sure your aftermarket option was cheaper.

 

[BrickRunner]

You can still get the OEM rear view mirrors, though I'm sure your aftermarket option was cheaper

I did see the OEM for sale, but then I saw the price! The one I put in is larger than the OEM and is convex so it has a wider field of view.

 

[BrickRunner]

I eventually want to get a larger fuel tank, and I don't want the spare tire on the back, so inside the spare tires goes!
I fabricated brackets to attach a ratchet strap. The upper bracket attaches to the back seat upper support. The seat support was held on with tamper proof screws (but not cutoff wheel proof). The lower bracket required a backup plate, as the sheetmetal in the bed is rather thin...

 

[RodrigzCrzr]

That's a cool rig. hope to see it up in Ojai some time when I am up there visiting friends.

 

[BrickRunner]

That's a cool rig. hope to see it up in Ojai some time when I am up there visiting friends.

I've taken it to the Ojai Cars and Coffee once so far, and taken my MR2 and 4Runner multiple times.

 

[BrickRunner]

The sound deadening in the bed compressed after sitting for a day with the spare tire brackets clamping down on it. I was planning on pulling this stuff up eventually, so I decided to see how much of a pain in would be to remove, and also check the rust that was bubbling up underneath in on the spot weld seam. It wasn't too hard to remove, chiseling with a large screwdriver, coming up in chunks. The rust was worse than I thought, but not as bad as it could have been. Some wire wheeling, evaporust, welding, grinding, rust encapsulator, and voila!

Welding thin stuff certainly is a challenge!

 

[GarrettS]

Nice work catching that rust.

Welding sheet metal is tough enough as is, but welding rust-damaged metal is sooooo annoying since it’s so easy to blow through.

 

[BrickRunner]

Got the spare tire back in with brackets painted and new straps. I have had the old strap since at least 2007...

I also made some brackets to mount a plate for gauges where the radio used to be. Oil pressure, EGT, and Boost will eventually go there.