Jzilla's FJ60 to BJ60 conversion

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Welding mounts in, figured I would not put all 7 pictures in, you get the idea...
Welding of engine mounts #1.webp
Welding of engine mounts #2.webp
both engine mounts welded in.webp
 
Fuel tank is brand new from Toyota. There was a recall on the FJ60 fuel tanks a long time ago, I found out about this in the 60 series forum. Anyways, before I bought the truck I checked into this to see if the truck I was purchasing was eligible for a new tank. It was, so the owner took it into the Toyota in California and had them install it for me before I brought it up.
Anyways I figure I may as well protect it as best I can!
FJ60 fuel tank.webp
primed fuel tank.webp
 
Decided that I may as well paint the rear wheelwells as I had already done the front...pressure washed them with steam cleaner and then wire brushed them. Some water got into the truck after washing them, not really surprised as the sealer is from 1984, so I scraped it all out and re-seamsealed with some proform seam sealer that I had laying around.
One picture has the old sealer, the other picture has it scraped out...
rear wheelwell seam with old sealer.webp
rear wheelwell with old sealer scrapped out.webp
 
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Hey this is a great thread I'm about to start this same swap this week, any extra advice? Lol

Sent from my LG-C710h using IH8MUD
 
I'll be doing almost all the same things as yourself when I do my swap. If you're gonna do it, you might as well do it right. I'm liking the build.:D It's truly awesome having a mint 60 body that even has the original pinch wells on the wheel arches and rocker bottoms.

Spencer
 
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Thanks everyone!
Manual steering box is now installed, wanted to keep it manual as I have had it that way for 9 years, I like it simple.
I had painted the steering shaft protectors ahead of time that were on the FJ but when I went to install them with the manual box I found out they are were an inch too short! This is because the PS box is longer. Anyways I took the ones off my 81, and painted them up. So steering box and protectors are now installed with some plastic plugs from the parts store, these plugs also fit the one inch holes in the floorboards! Got 6 for a 1$!

So today I parked the 81BJ60 for good which I have been driving for almost ten years (this February it would have been ten), quite sad!
I dropped the tank and pulled the suction tube out which I had replaced when I first got the truck (they are now unavailable), cleaned it and primed it, once I have paint on it I can finally install it and the freshly painted new tank with everything else. The diesel suction tube is exactly the same as the gas one from the FJ60 except that the FJ has the extra return line as well. Will post up pics later.
Instaled vacuum canister today, that was easy as I had already drilled 3 holes in the firewall previously.
Decided to clean and prime the front axle as well as the tie rod and relay rod.
Also bent up a new hardline for the clutch.
Removed driveshafts from the 81BJ60 cleaned and primed those as well.
 
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Things done since last post:
-Fuel tank installed with new filler neck to body grommet (old one was all dried out and shrunk), new seal up near the cap, put some stainless euro hose clamps on the hose between filler tube and tank, painted up the good diesel suction tube I had and installed it.

-Made up a new fuel line from the sedimenter to the tank.

-All fuel lines painted gloss red (just because).

-Front axle, relay rod and tie rod all primed and painted gloss black.

-Front and rear drive shafts from the 81 BJ primed and painted gloss red.

-Installed the isspro egt gauge wiring (basically done), found a great spot for all those wires! Will show pics later (put the wires where the seatbelt warning buzzer is, don't think I need that annoying noise?)

-Made a new gauge cluster from steel to hold 3 gauges, painted black, will hold pyro, boost and oil pressure, will be bolted to dash (looks not bad I think?)

Now where the fun begins!
Removed the tranny, transfer and bellhousing combo yesterday, cleaned it up with pressure washer/steam cleaner, plan to paint the bellhousing gloss red and spray paint the cast tranny housings gloss red too (might as well?)

3B from my daily driver for almost ten years is now out on an engine stand.
Have a few plans for this, rear main seal (clutch and flywheel removed already), front main seal, new side cover gasket will be going on as lifters have to be removed from there to remove the camshaft (see below), I will end up painting the side cover while I am at it!
Want to inspect the cam bearings and the bottom end as my oil pressure was low. Since the engine is out I might as well I figure for piece of mind. A local engine rebuilder said he would come up to my place and help me out with this (all new for me). I already have a new set of cam bearings from Toyota, was only about $50.
To remove the timing cover I need to take off the harmonic balancer. I was going to put the harmonic balancer from a later BJ on that has the 6 holes for the PS and AC pulleys anyways.
How to get that big bolt off though???? I have a compressor but I think it is too small :( I will proabably try a larger compressor from a friend and see how that goes. I thought a big bar would work, but someone has to stop the crank from turning, and since it was torqued to about 170ftlbs (as the manual says it should be then I doubt that will work) Ideas?
Once I get the bearings checked I can basically put the engine in the FJ and start putting it back together.
But I will find some other small things to do as I always do!
 
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