Piggy surgery, the engine is in!!

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Piggy surgery!!

You sounds like a diesel addict to me :) My HJ60 alt was the same way; what I did was pull it and took it to an alternator shop and they fixed it for $150? Never had a problem. The high output route is fab up your own bracket and use a different alternator and some sort of diesel pump. I've really been meaning to update me site, there is a site out there that has a list of the electric vaccuum pumps (I just hooked one up on my piggie off an electric vehicle) and what cars they came in. Then you have a regular old alternator that is availabel cheaply in the aftermarket (like a 21si, $99, 145 and 160 amp models) and a different vaccuum system.

But if I were not too concerned about how many amps you have (I think really only needed if you winch) then I'd try to get on the DTLC list (see www.cisautoweb.com/dtlc/dtlc.html ) and there are guys parting out BJ60s that could probably help you out... Hope it helps!

Andre
 
Piggy surgery!!

Coool, grafting that roof is not a easy task. Measure ten times and cut once?

We fish plated in behind the welds for added strength, did most of that from the inside were its covered with material or so it was on my 60, not sure about a pig.

The 3B install rocks, that was something I have thought about for the past couple of years.


Keep up the good work and look forward to your unvailing.

Rob
www.raddcruisers.ca
 
Piggy surgery!!

There is a sweet parts FJ55 in Okanogan, WA (North of Wenatchee, area code 509) at Dusty's Wrecking on the old highway between Omak and Okanagan. It is a 72 or 73 I think. Almost complete and not destroyed. There is also a good example of a 71 FJ55 in Wendell, ID (area code 208) north of town in a wrecking yard on the right side.

I hope you find your parts.

AR
 
Re:Piggy surgery!!

Rob,
I cut the roof off at the original joints by removing the spot welds so it should fit together a little easier as well as give me something to weld to. My only real problem that I can for see is the rear most pillars as the rusty roof from Califonia had just started on the rear most pillar, almost not perceptible but it has weakened it somewhat on one side. I've left a bit of the old pillar there to give me something to work with.
The next week or so will be the key. After the roof is on the rest should be fairly straight forward.

Aaron,
I'll check out those leads on parts '55's and see what comes from them.
 
Piggy surgery!!

Some updates of the project. Major surgery on this one!
 
Piggy surgery!!

Fitting the roof. Lot's of finicky grinding to make it go together right. You can see the old rusty roof in the background.
 
Piggy surgery!!

Cleaning up the welds to make things look better.
 
Piggy surgery!!

Just the door pillars left to weld in place!
 
Piggy surgery!!

Bondo heaven. Getting rid of trail rash, for now anyway! Since this it has been sprayed with high build primer and we are in the process of blocking it out. One more go round with high build and it'll be ready for finish paint. Then things should move a little faster I hope.
 
Piggy surgery!!

WOW, that looks like you and your daughter are doing a great job. I sure wish my dad helped me restore a cruiser, let alone a diesel one. Can't wait to see more pics. :cheers:
 
Piggy surgery!!

Starting blocking out the high build primer. Looks much better when it's all one color.
 
Piggy surgery!!

The mighty 3B is now installed in the FJ55. Here is the elusive BJ55 :o
 
Piggy surgery!!

PTO mounted to the transfer, and all this is mounted behind a 3B and supported from a modified '60 series tranny support (it seems more secure than the AA adaptor type).
 
Looking real good, how`d ya hook the 3B diesel to the old non split case?

Body work sucks.......

Rob
 
[quote author=Radd Cruisers link=board=1;threadid=8787;start=msg152938#msg152938 date=1084033546]
Body work sucks.......

Rob
[/quote]

I hope that's an observation of the "joys" of body work rather than the quality of body work on the truck ;). It actually looks relatively decent for the amateur that I am and knowing how it once was :rolleyes:

As for the tranny, the diesel 4 speed and older FJ 4 speeds are essentially the same internally. I simply gutted the FJ 4 speed and dumped all the innards into a '60 series case except I used a BJ input shaft. I also needed the rear cover from the FJ tranny to give me the necessary bolt holes and spacings to fasten the 3 speed transfer to. It's all standard Toyota parts configured in a fashion that, as far as I know, was not factory! It gets the job done though with some nice extras like the PTO :D I also used a "Transfer case saver" just to be on the safe side.

If you look carefully at the picture with the engine you'll see the factory A/C condensor as well. The evaporator is in too but I don't know if the lines are visible in the photo where they protrude from the firewall. Any ideas for hooking up the A/C as close to factory as possible would be appreiciated. I've got the factory A/C book here from another lister so the wiring diagrams are available, I just have not dived into that part yet.
 
Looking good. When is your deadline to get this thing done?
 
Rob,
The tranny housing we used is from a '60 series, the guts are from the '76 4 speed with the exception of the 3B input shaft and 3B front bearing retainer.

I gutted the entire '76 4 speed tranny, tossed the "2F" input shaft (it's still in the garage is anyone want's it). Then I transfered all the '76 4 speed guts to the '60 series transmission housing (I needed the 16 spline output shaft for the single piece transfer case output and PTO gears). I used the '76 4 speed top cover to ensure the shifter remained in the correct location in the truck (all the shift forks line up and it seems to work correctly). I used a BJ series front bearing retainer (so the throwout bearing works), and the '76 4 speed rear bearing retainer/tranny cover (as the single piece case bolts to that cover).
From there it was just like bolting up any other single piece transfer case with the addition of the PTO.
It was all Toyota parts from either the '76 4 speed or a BJ 4 speed as well as the 3 speed tranny output gear (for a 16 spline output shaft) and 4 speed PTO gear (16 spline shaft).
 
As for the A/C, there is certainly going to be some issue with the A/C controller. the little black box looks for a signal from the neg side of the coil, much like a tach, to tell the unit to engage or disengage the clutch on the A/C compressor. meaning that you need to trick the computer into thinking it is gettting a signal from the coil. a number of older toyota cars have the exact same black box units to control the A/C(although they are set for 4 cylinders) so you can try one and test methods out on it instead.

That looks great. I really like the idea with the B pillar remaining as part of the roof. Make for a good reference height etc.

-Brett
 
Tucker,

The truck is not yet sprayed. We're waiting for some shop time at the local technical school, probably in two weeks or so. In the mean time with my deadline fast approaching I need to keep moving so the interior (mostly dash and fitting the seats) as well as the engine and mechanicals are underway now. My daughter is sewing new seats with charcoal colored vinyl and a striped cloth (similar to an FJ/BJ60 design) but with the bench seat. She'll be doing the same thing with the interior door panels as the stock ones are warped from water damage and torn.

Brett,

Did Toyota have any diesel powered 4 bangers with A/C imported to the States or Canada? I seem to recall that there was a year or two where Corolla's or Camry's were available as diesel and I know that in the early '80's the pickups were available with diesel but I don't know if they ever had A/C.
 
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