Project Sasquatch

[TechChachi]

So ive been taking time to read a lot on this forum because in may 2021 i saw a unique opportunity to buy a 1987 fj60 in relatively good shape for rust and just average original condition wear and tear for $6500. It ran good but did not drive because the driver side trunnion bearings had grenaded. Also there happened to be a 48” long hole on the drivers inside frame area.
Anyways i figured if anyone is interested they can follow my build on here. End goal is a trail-ready / overland build equipped with 37’s and various supporting mods.

1-AA40-CAB-1-B69-410-A-8090-DDB53062-A241 hosted at ImgBB

Image 1-AA40-CAB-1-B69-410-A-8090-DDB53062-A241 hosted in ImgBB

ibb.co

88851917-E566-453-D-97-FD-12-C1-EFEDAFC2 hosted at ImgBB

Image 88851917-E566-453-D-97-FD-12-C1-EFEDAFC2 hosted on ImgBB

ibb.co

 

[diesellibrarian]

"Relatively good shape" and "48 inch hole in frame" don't really jive, but anything is repairable given the time, money, and/or skills. Good luck with your build!

 

[kirvesmies]

So ive been taking time to read a lot on this forum because in may 2021 i saw a unique opportunity to buy a 1987 fj60 in relatively good shape for rust and just average original condition wear and tear for $6500. It ran good but did not drive because the driver side trunnion bearings had grenaded. Also there happened to be a 48” long hole on the drivers inside frame area.
Anyways i figured if anyone is interested they can follow my build on here. End goal is a trail-ready / overland build equipped with 37’s and various supporting mods.

1-AA40-CAB-1-B69-410-A-8090-DDB53062-A241 hosted at ImgBB

Image 1-AA40-CAB-1-B69-410-A-8090-DDB53062-A241 hosted in ImgBB

ibb.co

88851917-E566-453-D-97-FD-12-C1-EFEDAFC2 hosted at ImgBB

Image 88851917-E566-453-D-97-FD-12-C1-EFEDAFC2 hosted on ImgBB

ibb.co

welcome to the asylum for the toyotaly insane. can't fault your optimism.
good luck with refurbish. this site is a wealth of info

 

[cruisermatt]

are the rear springs inverted?

 

[TechChachi]

So ive already done quite a bit of work. here was the start to having it road ready again and at this point i just thought it was all i was gonna do to daily drive it… i was very wrong. I repaired the worst of the frame right away and fixed the front end, took the time to fix every switch light bulb and even got the a/c working and converted to r134a

 

[kirvesmies]

that's gettin' after it. carry on

 

[TechChachi]

Had a bad leak coming from the rear main oil pan and pinion seal so i replaced those and i took it out for a good 1400km trip and in the middle of the week after that my radiator started leaking i left it as it was not to bad yet. I was investigating more oil leaks the main one coming from the fuel pump spacer that i found broken in 2 pieces i fabricated my own out a 3/8” chunk of steel plate. At this point i was getting annoyed with the amount of leaks it had. Luckily the next thing that broke was the alternator had it rebuilt localy to drive it again. So i drove it a couple weeks more back and forth from work until i went to leave and saw a huge puddle of gear oil on the ground i found that it was coming from my t-case shift rod seal. I had it, parked it in the back of my shop and started to think what next… thats when project Sasquatch started

 

[cruisermatt]

those rockers looks surprisingly good for a 60 in BC.

 

[TechChachi]

those rockers looks surprisingly good for a 60 in BC.

The only rust on the body is around the rear fenders, the left rear outside edge of the rocker and two penny sized holes in the drivers floor area. It will all be fixed. everything else is mint. Here is above the gas tank, the rest of the underbody looks like that

 

[g-man]

Check out Trail Tailor in the (edit) vendors... section. Has a kit to replace the inner C channels. Yours are starting to delaminate. Also inspect the crossmember "tube" that the rear shocks mount to. They always seem to crack and break. common repair there is to drive a schedule 40 pipe through the frame to replace it.

Also FYI...that fuel pump insulator is available. Partsouq shows it for $4.52

 

[TechChachi]

just after i bought my 60 i knew i wasn't keeping the 2f or the 4spd i didn't like the fuel economy or the leaks… i was searching high and low for 1hz with a h55f with no luck. I did however find a 3b and two h55f transmissions for a package deal so i brought those home. After i started searching for a appropriate sized turbo i found a new remanufactured garret that was perfect! Next i found a fj80 rear full floating axle. Also i should mention at this point this truck is staying far from stock. might make this thread a little more interesting 37’s, 4.88 gears, lockers, 4:1 fitted 38mm t-case, 4links and coil-overs

 

[TechChachi]

Stripped the engine, sent the head out to my machine shop had all the pre-cups and valve seals replaced. Crack checked no issues installed mls head gasket, Sent my injection pump and injectors out for rebuild. Sandblasted and painted every part on the engine took the time to build my own turbo manifold

 

[TechChachi]

Continued.., ive been busy
engine is mounted
Fuel line plumbed
Secondary battery tray fabbed
Dual odyssey deep cycle batteries installed
2/0 cable ran
Mishimoto radiator installed
Had to make a lower rad hose from 2 different hoses because mishimoto only makes the rad for the i6 gas motor.
Derale performance cooling fans on order
Fabricated throttle rod and pivot
Used the oem choke cable for the engine shut off.
Modified the cluster it now has a glow light where the choke used to be it illuminates with my manual glow switch.
I have fabricated a mount and installed a saginaw power steering pump (still need to install a tensioner)
Using the original 2f crank pulley i took off the riveted pulley and modified to fit the 3b crank so i can run both power steering and a/c

 

[TechChachi]

More photos

 

[TechChachi]

Last few here. Slow process everything takes a lot of time. Next few things i will be getting done very soon is my transfercase 4:1 low gears, cooling fans, 80 series steering box, iss pro egt gauge and boost gauge wired in and a test drive…

 

[Dekeman]

Looking forward to hearing it run!

 

[cps432]

This is an awesome build! Well done!

 

[TechChachi]

Looking forward to hearing it run!

Most of my build is all posted on instagram recent exhaust clips are there,
I just thought i should update the thread as well. Profile is @Sasq_overland

 

[TechChachi]

Heres pics of the 3” exhaust setup i built just a simple setup that sounds good

 

[TechChachi]

Rebuilt my H55f the one i was going to rebuild had a bad output shaft and luckily i bought a h55f for a 2h and it had a good donor output shaft. Parts are very hard to get and i was lucky to make one good trans for the 3b