The Buzzz build

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Joined
May 8, 2007
Threads
15
Messages
203
Location
Brisbane, OZ
Well I thought it was about time I did a bit of a build up on my current rig - my 1972 FJ55... I've always loved the earlier pigs with the rear tail lights and full fold down tailgate...

Anyway I bought it around 2 years ago off a fellow who happened to live the next suburb over from me who had it sitting in his garage for a while but never registed it.
Even though I was heading overseas in a few days (and could've used the extra spending money) it was just too good to pass up so I bought it and it just sat under a tarp sleeping for 2 months, waiting until I got back....

Needless to say the day I got back I started tearing into it, the first thing I did was put in some 60 series knuckles, discs and 4 runner calipers on the front. Got the axle housing and knuckles powdercoated and rebuilt with all new seals and bearings too.
Also had a factory P/S box laying around from my 1980 parts pig (from which I also robbed the front axle shafts aswell) so I threw that on

My plans for the old bus were always to put a diesel in it but I just wanted to get the old 1F running well first so I could get it registered....but turns out I couldn't get the 1F running well, so the bus sat sleeping under the tarp for another couple of months due to me having the ****s...

So after rebuilding the carb, head and spending too much money only to find gouges on the cylinder walls I decided to cut my losses and I bought a 2nd hand 2H diesel out of a hj75 troopy which had 260k on the clock...the motor ran like a dream and the coolant and oil were really clean when I dropped it. only thing that needed doing on the motor were the oil pressure relief valve and the glow rail.
I ended up going with the 2H for a few reasons - main one being that its a direct bolt in....well almost, but I'll go into that later

Anyway here's a few pics of how it looked years ago shortly after I got it home (with the new shoes I bought it) and the disc swap.....

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Although the 2H did have the superglow system and I managed to get the relays and glow controller with it all, I decided to just go for the simpler Wilson switch option.
So I ended up changing the glow plugs to 8.5V ones. I also made a new glow rail because the old one was half melted. I made it out of some aluminium and just put heat shrink over the sections that didn't have to be exposed, I also got a glow plug controller out of an old HJ45 at the wreckers..

Some photos of the dirty old 2H the day I got it home, which I ended up putting all new gaskets and seals in and giving it a coat of paint (wasn't quite the factory 2H colour :rolleyes:)....and photo of how it now sits in the engine bay! (****py pic but you can just see the new glow rail)

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Some pics of the HJ47 cast engine mounts I used, which line up and bolt directly to the FJ chassis.
also used HJ47 rubber engine mounts, had to notch a little bit out of the top of the D/S one to clear the hard line for the power steer

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Ended up getting the 75 series crossmember with the engine so I chopped it down and made up some mounts that bolt to where the factory bashplate mounts under the chassis, also made a full mandrell bent exhaust, using headers to suit a HJ47 (which I had to modify slightly to get them to exit outside the chassis rail properly).
Ended up tossing the gearbox that was in it and used a 4 speed box/Tcase out of FJ60 that I picked up for $200. (Wanted to get a H55F but was just out of budget at the time :frown:) In order to run the T/case handbrake setup I swapped in the output shaft assembly off a later split case from a FJ45 which I also nabbed the handbrake assembly off....
Some pics....

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I had to drill out the spot welds on the top part of the tranny tunnel and raise sections to clear the HJ75 bellhousing and front part of the tranny ended up having to raise the factory heater because of this....(will take some photos when I get a chance)
Was pretty pushed for room in front of the 2H as well. I ended up pushing the radiator forward around 65mm (used a HJ60 rad which I had to modify) because I was hell bent on using the clutch fan which sticks out a fair whack (didn't want an electric although it would've been a hellova lot easier)
Some more pics....

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Also put in a FF rear end with from my parts pig, along with a set of arb hzj75 rear springs and greaseable shackles....
after I put the rear springs in it was really leaning towards the drivers side, ended up swapping them around and it fixed it! Apparently there's a P/S and D/S so I think I just mixed them up.... :o

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WOW!

Very nice job and welcome. I'm sure we will have a ton of questions, for you. Hope you follow up on the diesel and how it worked out for you.

I like the window crank!
 
yeah like a gazillion more pics, GREAT work, and I gotta see more of what you did for the radiator shrouding/mounting. Keep it up!
 
Did you flip the negatives on those photos, because everything is on the wrong side. Just kidding, looks great. I was just thrown off when I started reading the thread.

I've always loved the earlier pigs with the rear tail lights and full fold down tailgate ...

That's all us sepos get.
 
WOW!

Very nice job and welcome. I'm sure we will have a ton of questions, for you. Hope you follow up on the diesel and how it worked out for you.

I like the window crank!

Thanks s****daddy so far the 2H is going great, am still learning about diesels, never having owned one. Took me ages to work out that I had air in my pre filter/water separator which was causing it to die after 2 minutes or so of running...also ended up changing the micron rating in that same filter because it was getting starved of fuel up big hills.....may have also been clogged....:o
Its worlds apart from my previous pig which had a V8 but it does everything I need it too do....
 
yeah like a gazillion more pics, GREAT work, and I gotta see more of what you did for the radiator shrouding/mounting. Keep it up!

Alrighty few more pics of what I did to the front apron. Ended up taking 15mm off each side of the radiator support and totally removed the bottom section which I then replaced with some 65x35 RHS which just ran as flat to the chassis as I could because the 60 series radiator is taller than the factory one...
Anyway hard to describe so will let the pics do the talking....
1st pic is the front apron marked out.
2nd is what was cut out.

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More pics, might just also mention that the front apron is off my 1980 parts piggy....
1st pic shows the sides boxed back in with 5mm plate, the new return edge lines up flush with the edge of the bracket that holds the front bezel
2nd pic shows the radiator mounts (will post pics up later of what I chopped off the factory 60 series rad to get it to fit)
Another reason I chose the 60 rad was so I could just use the factory HJ60 hoses which all lined up a treat...

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Of all people Ron, it filtered out your user name!!

Bahahaha.

Nice work, OP.

Y'all seem to get all the cool stuff in Oz, for sure.

Are there a lot of Pig's still on the road, there?

Thanks Delancy, yeah there are stuff all pigs around really, I've only ever seen a handful where I am....wonder if there's many Oz pig owners registered here on Mud???
 
Anyhoo more pics....one of the tranny tunnel I fashioned up out of a Hj60 tranny tunnel inspection plate (with the rubber boots) which I grafted onto the oem tranny tunnel (had to raise it to clear the top of the gearbox).
Other pic isn't the best because its all white but you can just make out the top front part of the tunnel that I raised and then re-welded back in to clear the bellhousing...

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