Jzilla's FJ60 to BJ60 conversion

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Inside of gauge pod that I made with all lines coming out, Dec 9, 2011.
Gauges inside gauge pod Dec 9, 2011.webp
 
Last edited:
Gauge pod installed on dash with all the lines coming out of hole drilled in dash. Wiring harness I made to power the lights of all the gauges together, Dec 6, 2011.
Wiring harness for gauge pod Dec 6, 2011.webp
Gauge pod with wiring harness, oil line and boost line installed on dash Dec 6, 2011.webp
Closeup of gauge pod lines coming out of dash Dec 6, 2011.webp
 
Last edited:
Redone brake lines (had extended ones made up at greenline hose for the front and rear), also extended both diff breathers.
As you can see once the suspension was swapped over things were tight!
The two short hoses came from the parts store.
The new extended rubber ones were about 10 bucks less than stainless. (Rubber were about $25 each with tax.)
Brake line comparision Dec 29, 2011.webp
Extended brake line and diff breather installed Dec 29, 2011.webp
Stock brake lines and diff breather, new rear shocks installed Dec 29, 2011.webp
 
She lives!!!!
Insured it today and drove it for a good haul on the highway, runs amazing! Goes like stink now with the stock tires and gears, can't believe it! (Rebuilt cam probably helps performance too.) Also the egt temps are much lower going up hills.

Have only put the sound deadener down on part of the truck but what a difference! Probably helps that there are no big rust holes either!

Side exit exhaust is great so far, no smoke coming in.

I am just amazed at the pep this thing has now, it is amazing.
Did not think that the 4.1s and 33's affected things so much...thought that was similar to stock??
Will update more later :)
 
Very Very nice work!

What a great outcome.

Its amazing what a healthy, well tuned, 3B-T can do!

Ill have to come have a look next time Im over your way, great build.
 
That would be great, let me know for sure when you are around. Thanks!

Did have a coolant leak that I forgot to mention between the thermostat housing and head which was weird because I never touched it. Anyways I removed it and resurfaced it with sandpaper on some sheetmetal, also took the opportunity to paint it and the water neck black ;) Pics of that later.
As posted in another thread I had oil coming out between exhaust and turbo flange, anyhow it just needed a good run, it burned off and stopped leaking:)

So many things I am ecstatic about :)
#1 oil Pressure
So with the new cam bearings in the oil pressure difference is amazing!
At hot idle before I was at about 4-5 psi, I am now at 13-15psi
Cruising along at about 2200 rpm before I was around 20-25psi, I am now at about 40psi!
When it is cold instead of going up to about 60, it went over 85psi.
Overall about a 20psi increase when not idling it seems. Will take a closer look at numbers as I drive it more.
When I was running it in carport for about an hour earlier in the week to break in camshaft I was at 2000rpm and 40 psi.

#2 performance
It hauls now! Most likely going from 33's and 4.1 gears before. I was planning on putting them on later, but wanted to try the stock set-up first since I never had tried it with the turbo, now I am not sure I want to go back to 33's and 4.1 gears. Going up hills is night and day, lower egts and faster speeds, don't have to shift into 3rd since the engine is not working so hard.
Some of the increased performance I am sure is due to the camshaft being rebuilt as 4 of the lobes were below spec, not sure how much difference this would make though?

#3 quieter
Much quieter without having rust holes everywhere. I did put quiet crap sound deadener under the hood and up to behind the front seats, have to finish the back of the truck still. Probably a combination of less rust and the sound deadener though, but it is way better.

#4 gauge pod on dash
So much better to not have to look down at the gauges, so glad I did this, much easier to glance over and not way down

#5 the hood closes properly
The hood never was set-up properly on the 81BJ, it would flutter around and all that. I got new adjustable hood bumpers (came with the FJ, the two front ones on the rad support) and now it sits so nice and tight and still.
I had to replace the latch on the FJ with one from the BJ because there was a part that was bent, anyhow it works great!

#6 wipers work
When I drove the truck up from cali the wipers were really wonky, one of the ball joints was broken on the linkage. Then because I removed the motor to put the linkage on that messed things up further (the wipers hit the cowling). Anyhow after spending some time working on it with a friend, they are set-up perfect now :)

#7 exhaust
Redid the downpipe with the flex pipe and bracket to bellhousing, seems to be super soild and no shaking around.
Also the side exit exhaust is great so far after 2 hours of driving, quieter than before (but it is hard to compare the rusty holed truck with this one) and no smoke smell with windows closed at this point.

There will be more to add.
This is not over by any means, but the hardest part is done:)
Have to swap out passenger seat belt, make centre console/security box, install rear steel panels and put sound deadener on them, make a new front (took the front steel tube bumper off the BJ and put it on for now) and rear bumper and tire carrier, add led interior lights (which I have already), finish sound deadener on the rest of floor, steam clean seats, trace out diamond plate rubber mat (got from amazon) the same as rear carpet and install.

Was going to make up some mudflaps because I don't like how they hug the fender (rust causing?), but I am using the stock one with all stainless mounting screws for now.
That is all I can think of for now :)
 
Yep, there is nothing like replacing a rusty shell of a body with one that doesn't have any holes to quiet a truck up. not to mention how much better it smells without sucking in exhaust!

Nice work!
 
Back
Top Bottom