New FJ60 Build up (1 Viewer)

[TroutFJ]

Ok, after wanting to do an off road build up since I was old enough to know what 4x4 meant, I have finally pulled the trigger. Being a new member to the forum but a long time viewer I think it's now time to introduce myself and "Babe" (the big blue ox) to the FJ community.

She is an '87 FJ60 and has a wide range of character flaws which I'm hoping to successfully address over the next couple of months.

Right now here is my list, hopefully I haven't steered myself into a hole I can't back out of but wish me luck.

1. Removing the body and repairing some fairly significant frame rust.
2. Replacing the stock tranny with a new H55F 5 speed
3. Replacing headers, exhaust, carburetor (the existing ones could use some work, except for the carb.
4. Reversing a really crappy SOA done by 2 PO's ago.
5. Installing an OME lift kit which will hopefully correct the feeling of driving a 3 ton vehicle on a water bed going 35 mph.
6. Installing a ARB bull bar and 9k winch
7. Tossing on a 4+ rear swing out bumper
8. Roof rack
9. Dual battery system.
10. Snorkel (just cuz I don't have enough to do lol)

Work that's already been done (from what I can tell)
1. Rebuild of the front axle and knuckles
2. New slotted brakes and new calipers on the front
3. New master cylinder

I will post pics of the progress! A bit of insight into my experience. I have been in construction for almost 20 years, know how to weld and have done some wrenching on past cars and trucks (namely a 78 ford flatbed I owned a decade ago.) We are going to be using this to get out and camp in and tow a raft trailer all over Colorado, Wyoming and Utah.

Thanks everyone and you'll be seeing me soon I'm sure!

 

[Spike Strip]

You don't mention any front end work which could be the reason for the sloppy steering along with a crap SOA.

Rear brakes should be looked at too.

Nice truck.

 

[nonamemtbr]

It has a good stance. Might be worth looking into fixing whats wrong with the SOA. Possibly a cut and turn in the front if it wasn't done and sway bars front and rear. It could leave you more cash for the H55f. Just my 2 cents for what its worth.

 

[TroutFJ]

From what I see so far they removed the sway bars front and rear, the springs and shocks are shot, they used stacked washers for spacers on the control arms, the angle of the pitman arm seems way off, and the SOA moved the front drive shaft to within 1/4" of the cross arm (?) right in front of the differential. For that matter, any source for sway bars? I've looked all over and can't seem to find anything but I'm probably just not searching in the right places.

 

[TroutFJ]

Thanks for the advice on checking the rear brakes. Definitely gonna be checking those out too! Sloppy steering is putting it lightly. I drove it 5 miles to my shop and it was the worst driving experience of my life. Maxed at 35 with the rear end going three directions and the front end going three different ones lol. At least I knew that going into it so no one to blame but myself

 

[rrv333]

Nice looking 60

 

[4Cruisers]

From what I see so far they removed the sway bars front and rear, the springs and shocks are shot, they used stacked washers for spacers on the control arms, the angle of the pitman arm seems way off, and the SOA moved the front drive shaft to within 1/4" of the cross arm (?) right in front of the differential. For that matter, any source for sway bars? I've looked all over and can't seem to find anything but I'm probably just not searching in the right places.

Used sway bars are available from time to time here on MUD. Post in the Wanted section and search the Parting Out section. I sold a spare rear sway bar last year. The bushings are still available new from Toyota, and extended links, for both front and rear are available from a number of vendors. I just bought a set of front and rear extended links from Man-A-Fre. I'm installing an OME suspension on my '86 FJ60 project vehicle.

 

[TroutFJ]

Thanks 4cruisers! I will dig into that further for sure! Are extended sway bar links necessary with the OME 2" lift? I assumed so but I thought I saw somewhere they were for 4" lifts and above. Gonna start tearing her down today. Hopefully gonna have the body off tomorrow and start fixing the frame after that.

 

[gilamonster]

where in co are you? I, took my front sway bar off-highly doubt it'll ever find it's way back on.

 

[TroutFJ]

I'm in the denver area. How about you?

Also, after a day of hard work I'm almost ready to pull the body. Hopefully buy the end of the day tomorrow I will have it off. Pretty fun tearing her down but I just hope I can get er back together!!

 

[gilamonster]

I'm in GJ, so probably not worth coming over for. You could find one on that side for cheaper.

 

[TroutFJ]

Well after a weekend of hard work and some busted body mount bolts (and knuckles) I got her torn down. Now time to start fixing Babe up so we can have some fun in the mountains this summer!!

 

[TroutFJ]

After getting stuck in Denver due to a nice little snow storm I decided to get some more work done to Babe last night. I started in on the frame repair after removing the exhaust mounts, center rear cross arm and brake lines. I was a bit anxious what I would find after cutting out the rusted out sections of the frame but thankfully the rust was only through on one side of the rails. Got em cut out, cleaned up and a coat of primer on last night and gonna start welding the patches back in tomorrow. If anyone has suggestions I'd love to hear em. I was thinking of adding internal stiffeners between the outer side of the rails and the patches that I'll be welding on. Specifically right above the spring mounts. I'm not sure if this is really needed though. Also, gonna use 1/4" steel for the patches (it's what I have laying around the shop).

 

[mongoose2231]

ooo, this is some courageous work, I love it!! Keep it up

 

[TroutFJ]

Ha! Thanks goose. I'm kinda winging it here. Can build a house outta toothpicks but this is the first car I've seriously dug into.

 

[TroutFJ]

So, after some delays, and family obligations this weekend I got the patches welded onto the frame. Feels good to have that behind me so that now I can start actually installing stuff and it just tearing Babe apart. The stack of parts and pieces are a tad overwhelming! The center rear cross arm that holds up the e-brake line, does it lend much in the way of support to the frame? Doesn't seem to as the metal is awfully thin. The reason I ask is I got in a bit of a hurry and tossed some dubious welds on there. They'll hold as long as there isn't much force applied to that cross arm.
The next step is to swap the tranny and wrap up some minor loose ends on the frame. But that's not gonna start for a bit. Heading out of town for a business trip this week/weekend.
Thanks for all the support folks!

 

[TroutFJ]

Alright, after a week away I'm back at it! Got the tranny and transfer case pulled tonight and broke down the clutch components. I went to pull the rear main seal, thinking it'd be easy but the damn thing is just crumbling apart. I think I'm gonna have to spend some time in there with dental picks or something to get all the rubber bits out. Anyone have any suggestions other than that? I'm a bit worried cause there isn't much room around the crank and the inner flange on the seal is in there pretty good. Not sure what will happen if I can't get it all out...

Other than that I'm pretty stoked on the breakdown. Looks like this weekend I'll finally be able to start putting things back on and not just tearing sh** off!!

 

[2mountainfish]

All I can say is WOW!!! I thought I did a lot of work on my 60, but nothing compared to what you are doing. Great job and stick with it. You will be greatly rewarded in the end.

 

[TroutFJ]

Alright! After some hiccups I was able to get the new tranny bolted on last night! Feeling pretty good that that step is behind me. By and far the transmission was the most in depth mechanical work I've ever done on a vehicle. Feeling pretty proud of that!

Now, while I'm waiting for the left to get from ARB, I'm gonna finalize the exhaust tomorrow, wraps up some loose ends on the frame, and use my ghetto chain lift to pop the body back on. Can't wait to open up more room in the shop and get her looking like an FJ again!

 

[SteveH]

<transmission lust>