Builds My 1993 FZJ80 Build

[xetura]

So it ends up that they sent me the wrong part. I emailed them and got a response within 10 mins or so with a new tracking number! The part arrived today and it's the correct one. So kudos to them for fixing the issue so quickly.

The correct part.

Desoldered the internal wiring.

Broke off the old one trying to pry it out. Then popped it out with a hammer and a punch. It was pretty brittle

Tinned the end on the new part.

Installed.

 

[xetura]

New starter bolts.

All done for now and the truck starts like it should. I'll be grabbing a rebuild kit soon and refresh it a bit. I'm able to get the starter in and out pretty quickly.

 

[xetura]

I went ahead and made this wiring diagram for the NSS.

 

[xetura]

Well, I did a thing...

$688 USD shipped ($713+$330 AUD). My downpipe is leaking and the replacement is almost the same price as the headers, so why not? lol. I need to grab some o2 bungs to weld onto the downpipe, then I'll delete the EGR and PAIR setup. Anyone know where to get the o2 bungs for 93-94 rigs?

The downpipe on this version runs inside the frame:

I've got an awd dyno right by my house, so I'm going to do a before and after dyno run.

 

[xetura]

With the header ordered, I started looking for 2.5" mandrel bent pipe to make my own exhaust. I ran across an ad on Craigslist selling a corvette dual 2.5" system for $50. I checked it out and it looked good. It even had both cats on it! They're pretty low profile, so I should be able to use one of them. The downpipe sections (the darker sections towards the top of the photo) are bumpy/dented and I might not use that part, but the rest looks amazing for $50. I might need to buy another mandrel bent section, but we'll see when the time comes.

 

[xetura]

Started by just separating them. I got the cheapest reciprocating saw at Harbor Freight for $22 and it ripped through everything I threw it at.

I got one side of the H-pipe cut, ground down and ready to be patched. The other side of the H-pipe and the o2 bugs are cut down, but still need grinding.

Cats cut out. I used my miter saw for this.

They're in great shape. No clogging at all.

 

[xetura]

These downpipes are funky as hell. On the outside, they look like an intestine , but are smooth on the inside. The inside pipe is pretty thin and there's a divot that affects both layers, so I don't think I'm going to use these.

 

[xetura]

Well, I went and did another thing... I found this m116a military trailer and got it for $400. Needs rewiring, some fabrication and paint, but it's solid. Haven't decided exactly what I want to do with it yet, but it'll make a great hauler in the meantime.

 

[ADVFJ80]

Nice work done here. I was curious about those ebay headlights, but doesn't seem you've installed them yet? I would love to upgrade the lights on my '97, and was curious what the improvement would be like over stock. Like you, I don't want to drop HID or LED into a housing not designed for them.

Keep up the good work!

 

[xetura]

Nice work done here. I was curious about those ebay headlights, but doesn't seem you've installed them yet? I would love to upgrade the lights on my '97, and was curious what the improvement would be like over stock. Like you, I don't want to drop HID or LED into a housing not designed for them.

Keep up the good work!

Thanks! The headlights are actually one of the next things on my to-do list. I got leds for them a few months back and got one side mostly fitted, but still have to do the other side. Then I have to decide how I want to wire the corner lights and the lower running lights they come with. I was thinking about turning the corners into running + turn signals. I spent the weekend working on my new trailer and getting back into welding, but I'll be working on the headlights soon and post some updates.

 

[ADVFJ80]

Great, I'll look forward to seeing how it works out for you! Thanks for getting back to me.

 

[xetura]

I started practicing welding again. Haven't touched it in almost 10 years and even then, I never did it much. For now I'm just using 0.030 flux core until I get more comfortable, then I'll go fill my bottle with 75/25 on start using solid wire. I'm using a Hobart Handler 140 110v mig welder.

After some practice, I decided to start making jerry-can holders to mount to my trailer. Just need to find more angle iron.

 

[xetura]

I also got my Impex order in today.

• New front arm bushings & hardware so I can install my lift
• New battery trays (both sides) tie-downs and hardware to fix my existing tray and install dual batteries
• Pipe, gaskets and plates to bypass PAIR
• The only seat belt recepticle I could get my hands on new. Not the same length as my current one, so I'm going to try and swap the parts I need

Part numbers and such:

1x 74403-60100 Battery CARRIER SUB-ASSY No. 1 $41.04
1x 74043-60010 Battery CARRIER SUB-ASSY No. 2 $41.04
1x 87208-60161 PIPE SUB-ASSY, WATER $23.47
4x 48702-60050 BUSH SUB-ASSY, CONTROL ARM $14.83
2x 48061-60010 BUSH SUB-ASSY, LWR ARM $21.53
1x 73230-60011-B0 BELT ASSY, FRONT SEAT INNER, RH/LH $25.34
2x 90105-18006 BOLT, WASHER BASED $2.81
4x 90119-16003 BOLT(FOR FRONT LEADING ARM) $2.45
1x 74453-60060 BAR, BATTERY SET PLATE $10.73
2x 17148-41010 PLATE, EXHAUST MANIFOLD $6.05
1x 45292-35050 SEAL, MAIN SHAFT LOWER DUST $9.00
2x 74451-60040 BOLT, BATTERY CLAMP $2.81
2x 90170-18007 NUT, HEXAGON $0.86
4x 90179-16015 NUT $1.01
2x 90201-19011 WASHER, PLATE $1.22
2x 82819-60040 GROMMET, WIRING $6.26
5x 90119-08364 BOLT $1.30
2x 89466-20020 GASKET(FOR EXHAUST MANIFOLD PLATE) $7.78
1x 85515-22010 STAY, CIGARETTE LIGHTER BEZEL $7.27
2x 17376-66010 GASKET, AIR TUBE, NO.1 $3.31
1x 15785-66010 TOYOTA GASKET, OIL COOLER $2.59

 

[jaymar]

Impex, the place in Greensboro?

 

[xetura]

Impex, the place in Greensboro?

No, this is a parts place in Japan. Here's a link. I've ordered a ton of stuff there and it's way cheaper than anywhere else I've seen. You just have a to wait a little longer.

 

[jaymar]

No, this is a parts place in Japan. Here's a link. I've ordered a ton of stuff there and it's way cheaper than anywhere else I've seen. You just have a to wait a little longer.

Thanks! I was looking at those prices and thinking, Damn, those are Amayama prices. Also in Japan. Just ordered some of the same stuff; those trays are ridiculous here, but you have to order a bunch of stuff there to make the shipping work. Thanks for the grommet P/N!

Btw--have you ever used a "battery pad?" Toyota makes one, but I've never seen it in an 80...

 

[xetura]

Thanks! I was looking at those prices and thinking, Damn, those are Amayama prices. Also in Japan. Just ordered some of the same stuff; those trays are ridiculous here, but you have to order a bunch of stuff there to make the shipping work. Thanks for the grommet P/N!

Btw--have you ever used a "battery pad?" Toyota makes one, but I've never seen it in an 80...

No problem.

I've never heard of a battery pad before. Is it for vibration or spills?

 

[jaymar]

No problem.

I've never heard of a battery pad before. Is it for vibration or spills?

Dunno, came across the P/N while looking up the PS tray...

 

[xetura]

Dunno, came across the P/N while looking up the PS tray...

Oh, interesting. I've never heard of it before.

 

[xetura]

Got a care package from down under! They're beautiful! I'm gonna hate having to strip the finish off to weld on the o2 bungs lol.

Before I get these installed, I need to replace the fuel injectors, fpr and fuel filter. Then remove the PAIR setup and egr. Once all that is done and I'm up and running, id like to do a base dyno run. BUT, my transmission solenoids are acting up, so they need to be replaced before I get on the dyno. Unfortunately, the solenoids are on backorder from Cobra Transmission until the end of the month. So I'll work on getting the fuel system refreshed, then do the solenoids when they get here, do the dyno run, install the headers + exhaust, then do another dyno run.