September POTM - Cruiser Guy, Guatemala

[cruiser_guy]

The OEM water/fuel separator is now installed. I had originally used an old Racor that was laying around the shop and it appeared to work well but every once and a while the truck stalled due to an air pocket in the fuel system. I could see no leakage and a pump or two on the primer usually got things going again. After much brainstorming I thought that the Racor, which was mounted up under the hood, was higher than the remainder of the fuel system and thus potentially under "vacuum". I pulled the Racor out last winter and it has not stalled due to air since then. On a diesel however, water in the fuel is NOT your friend so a separator is important. I decided an OEM Toyota which bolts to the frame rail would be the best choice as it is down low and thus always "pressurized".

As you can see in the dash picture, the red light (red arrow) is for the separator, it comes on on startup, so you know it works (just like all dash idiot lights) and then once running it goes off unless there is a problem. You can also see the push button for the glow plugs (yellow arrow) for preheating the glow plugs before starting. The pyrometer (green arrow) tells me the engine exhaust temps so I don't melt my pistons. It's color coded too, green for safe, yellow for getting close and red for the danger zone! The purple arrow is the boost gage for the turbo.

Next up, once there is a time when the tank is close to empty on a weekend, is the long range tank!!

 

[cruiser_guy]

Since there is still too much fuel in the tank I decided to fix and install some of the interior trim panels I picked up this summer (thanks Kief)!

As one the panels was badly warped, I stripped off the vinyl/foam carefully and reattached it to a new fibreboard backer with contact cement. As I have installed speakers on both sides at the back in anticipation of finding an OEM AM/FM stereo radio (did such a thing even exist?) I needed another speaker hole cut out in the opposite trim panel and I had a spare OEM speaker grille so I used that. I still had the original vent grilles as well so now the cargo area is basically complete (I'm awaiting the arrival of the cargo area rubber from FJBen's junkyard find to complete it).

 

[cruiser_guy]

Today I started work on installing the long range tank. I was down to about 5-6 gallons in the OEM tank (diesel '55's are not too thirsty! ).

I sandblasted the tank in preparation for the install over the past few days. My initial plan was to weld on an angle to the side of the tank and bolt that to the stock anchor locations. I don't like the idea of simply bolting the tank through the cargo floor as was the original idea.

After pulling the stock tank and getting the long range tank in position to scope things out it was clear that there would not be enough room to weld on a large enough angle and then still be able to get the tank in position so I fabbed up a couple of straps from 1"x1/8" steel strap. It was also obvious that having the shackle bolts installed with the nuts inboard would not clear the tank with enough clearance to make me comfortable so I reversed the shackle bolts and the nuts are now outboard. The exhaust will also need to be redone as the pipe would interfere with the front corner of the tank. That will get done next week.

Tomorrow I'll be remaking the rear hanger strap as it is about 1/2" too long and is therefore loose. I need to find a more appropriate size fuel filler hose clamp as the one I have is fully tight before gripping the hose enough and then I'll be painting the bottom of the tank as well once everything is done.

Here's the photo of the stock tank and spare tire carrier before any disassembly occurred. You can see the rear tow hook I added from a '60 series just in case I need it. A photo of the stock tank and the long range tank, though it's not really fair as the long range tank is significantly larger than the stock tank but it doesn't appear that way in the photo. Finally a photo of the tank as I was painting it with the '55 in the background. First it got a coat of Rust Bullit and then topcoated with black.

I figure that two fills in Mexico and the tank has paid for itself!

More photos to come tomorrow once I'm done. Then I'll need a rear bumper/tire carrier and the exhaust work.

 

[cruiser_guy]

The tank had some previous damage that was fixed but I guess it was not fixed well enough. I got it all installed with a better strap and I was putting the fuel in when the gate guard who was watching me commented that it was leaking out the bottom. Not a really fast leak, one drop every 5 seconds or so, but anything is too fast for the black gold that is in fuel tanks nowadays!

Tomorrow I'll go off and have it brazed or whatever to stop the leak. Pictures will come once it is all done.

 

[PabloCruise]

The tank had some previous damage that was fixed but I guess it was not fixed well enough. I got it all installed with a better strap and I was putting the fuel in when the gate guard who was watching me commented that it was leaking out the bottom. Not a really fast leak, one drop every 5 seconds or so, but anything is too fast for the black gold that is in fuel tanks nowadays!

Tomorrow I'll go off and have it brazed or whatever to stop the leak. Pictures will come once it is all done.

Frustrating!!!

How much did it end up costing you to get the tank made?

 

[Kief]

Charles, do most people at the school think you are a little warped or do they appreciate the landcruiser fetish?

Tell Mrs. W. we said hello.. been busy here, haven't kept up on your posts, lookin' great!

 

[cruiser_guy]

Frustrating!!!

How much did it end up costing you to get the tank made?

I got the tank from "Pighead" in Sacramento when we were passing through last summer. It had previous damage that was supposed to have been repaired, unfortunately it was not repaired well enough. He'd had it for a while and never installed it. I figure since I need to go to Mexico occasionally for visa renewals and that, a long range tank to take advantage of cheaper Mexican fuel was a no brainer. For the price I paid the tank will be free after the second trip to Mexico!

Charles, do most people at the school think you are a little warped or do they appreciate the landcruiser fetish?

Tell Mrs. W. we said hello.. been busy here, haven't kept up on your posts, lookin' great!

I think most folks think I'm always fixing the trucks so they are not too impressed. Being the shop teacher and the fact that we are the only gringos living on campus I can kind of do what I want (within reason of course) as far as shop stuff goes.

Petra is in Germany, her mother invited her and bought the ticket so she is visiting her folks. It's just the three of us guys here for now.

 

[Trollhole]

AM/FM was available I'm pretty sure. AM radios were more common though. Those speakers in the rear were not OEM that I'm aware of. Only speakers in a 55 were under the dash.

I stand corrected. http://www.toyodiy.com/parts/p_U_1976_TOYOTA_LAND+CRUISER_FJ55LG-KA.14_6451.html

 

[cruiser_guy]

Well we went to the shop and the guy wants the tank by itself so now I have to pull it out again! I guess he doesn't want to risk sending the truck into orbit if the tank explodes. It should be easier this time as all the reworking of the suspension and the exhaust is out of the way, though still not a fun prospect. I also need to now drill a hole to allow the diesel that is in there to come out and I'll have the guy weld a bung on there so I have a permanent tank drain.

I did notice one thing with the long range tank that might be of interest to others, especially diesel folks. I had only 5 gallons in the tank and after a few turns and up and down hills the diesel gets a little aerated. The stock tank, with the stamped bottom has, I assume, the pickup down in one of the lowest areas. The long range tank with the flat bottom doesn't have an area that is lower than anywhere else for the non-aerated fuel to collect. Consequently I could notice air coming up the fuel line in the way of less power or a slight miss. After a bit of straight road it would be OK again. At least I'll know when the tank is getting close to being empty! Diesel owners know that when pumping diesel it foams up like soapy water.

If you're thinking of a long range tank for a diesel it might be worth while to have one area that is lower than the rest where the diesel can collect and where the pickup is located.

Off to drill a hole in my fuel tank!!

 

[Radd Cruisers]

Last two tanks I made had a bowl in the one lower corner, plus a pile of baffles in the tanks.

The deep bowl will help keep fuel in the pickup on side hills, climbs and decents.


Baffles also serve as a support if the truck were to land on the tank, bottom formed piece of tanks a fair bit heavier than sides and top for strength negating a skid plate for the tank..

Looks good tho, fun thread to read through.

Rob

 

[cruiser_guy]

I got the tank back in last night in the dark before the rains of Tropical Depression 16 hit today. I won't be taking any photos until the rain passes which may not be till the weekend. After looking at photos of other long range tanks I decided that my original 1" x 1/8" straps were probably not enough for the 400+ lbs that the tank and 50 gallons of diesel will weigh, and went out and got 1 1/2" x 3/16" strap iron and made up some new straps. They look beffier and they were tougher to install as they did not bend as easily as the thinner ones.

The shop that patched the tank did not put in a threaded drain as I had hoped (I guess my spanish is not as good as I thought or he didn't listen). He simply put a flat plate on the holes and we'll see if they hold diesel. I put in 5 gallons last night and if there is no sign of leakage I'll put in another 10 gallons today.

I didn't get any info on the pickup location so the tank still has a flat bottom (I was hoping to make a "well" for the pickup) and I guess I'll have an "early warning system" for when I'm running low due to air entrainment in the diesel when the tank is down to 5 gallons or so.

I hope to go off to get the exhaust reworked again (I did that once when I went to 33's) and now it was in the way of the tank.

 

[cruiser_guy]

Well the rain let up a little this morning so I went out and snapped a quick picture of the finished install. You can see the shackle bolts are reversed and the exhaust has also been rerouted to miss the tank. I hope to head up to Mexico to fill up in a week or two. I'm kind of looking forward to the guy watching the numbers roll up as he's filling the tank. If folks want more photos just ask.

Next up, a little interior trim and finish up the door handle gasket install. Still on the hunt for GOOD front door vinyl trim panels if anyone knows of any. Also keep posting up tire carrier photos in the tire carrier thread as I'll need one of those now too.

"Lleno por favor!"

 

[BC40]

Very nice 55 Charles. Perhaps one day I will turn my BJ60 into a parts donor and build myself a diesel piggie.
One thing about putting the shackle bolts in that way, you'll need to drop the tank when you want/need to replace the bushings. Hopefully the bushings are rubber not poly so they'll last a while on the roads you drive down there before that happens.

 

[cruiser_guy]

One thing about putting the shackle bolts in that way, you'll need to drop the tank when you want/need to replace the bushings. Hopefully the bushings are rubber not poly so they'll last a while on the roads you drive down there before that happens.

Yes, I'm aware that the tank will need to be dropped to swap out bushings. It was either that or the risk of the shackle bolts whacking the tank on flex and in my opinion, whacking the tank would be a bigger problem. The bolts were touching the tank on both sides when they were in normally so a slight twist and they would take out the edge of the tank and 50 gallons of black gold would be on the road!





Another question. The leak is not completely fixed. It didn't leak with 5 gallons in it but when I put in 10 additional gallons it dripped VERY SLOWLY for about a day and then stopped (maybe an ounce or two of leakage. Now it is merely a damp area, there isn't even any mark on the pavement after sitting for a few days. Do I pull the tank again and braze it (the patch was welded), or do I let it be and hope that whatever crud is in the tank plugs up the hole? I'm planning on going to Mexico next week to fill it up with all 50 gallons when I renew our visitor visas here in Guatemala.

Here's a few more photos. You can see how this tank is almost flush with the rear frame rail and not significantly lower as some of the other long range tanks are (photo is lightened to show the tak better). The second photo shows the wet area near the patch. Finally another poser shot of the piggy.

 

[cruiser_guy]

I spent a couple of hours replacing the rear door handle pads and installing the rear inner door panels I got from Keif this past summer. Does anyone know if the colors look right? Grey panel and black plastic ashtray, door pull and other trim?

Now I need to start seriously working on the rear tire carrier and getting the scuff plates made up (seems like Central America moves REAL SSLLOOWW when some of these things come up).

 

[n2666s]

Charles.....your piggy keeps getting better and better..........let me know if you decide to go ahead and have another LR tank made;

Lou

 

[cruiser_guy]

I'm going to go pull the tank and get it fixed again before fueling up this weekend with 50 gallons. I'll see if he can put in a threaded plug as well (I found out he didn't put one in 'cause I didn't provide one).

Thanks for the compliments Lou. I can ask what a tank (duplicate of mine) would cost to make if you want?

 

[n2666s]

Charles........awesome if you can get a price, TIA

Lou

 

[cruiser_guy]

Well I dropped the tank again Monday and brought it in. They guy welded it up again and this time I brought a nut and bolt so he installed those as well. Now I have a permanent tank drain. I picked up the tank yesterday but I did not check carefully and I discovered last night that the float is out so I'll be back again today to get my float!

Anyways, I figured he's welded it twice and it still looked a little iffy (he assured me he's checked it) so I decided to braze over ALL the welds anyways just to be safe. A little scary putting a torch to a used fuel tank! Hopefully I can put the tank back in today after I clean up the brazed area a little and make sure there are no visible questionable areas.

 

[cruiser_guy]

Damn tank still leaks!! It's coming out again and I'll braze it again and then put in 15 gallons to see if it holds BEFORE putting it in again. IT seems like it cracks sometimes at the brazing. Any ideas why?

Can someone say FRUSTRATING!!