The Life & Times of Shasta (86 FJ60 conversion to HJ60)

[ontherxs]

Time to start wiring. I've been collecting supplies for 6 months.

First of many cables. Capped, soldiered, shrink wrapped.

Big power lines now.

Prior to shrink warp

 

[ontherxs]

Dual battery isolator in.

Mocking up final location of dual battery switch

 

[roadstr6]

Good work guys!

 

[GLTHFJ60]

Running videos (can't have more than two videos in a post now)

That groaning noise is the loose PS belt and pulley. The belt will be replaced so we can properly tighten the adjusting pulley.

Shasta 2H. It's alive !!!:

Shasta 2H. One more for the road.:

 

[GLTHFJ60]

Some pictures, first of the first ever successful extraction with these extracting bits:

The original list:

 

[ontherxs]

Here are some pics of the steps leading up to launch.

Location of power steering reservoir

All P/S lines in.

Routing the cables for the batteries and switch.

 

[ontherxs]

Time to add diesel for the first time. The TRD stickers are coming off. The only thing TRD on the truck is the wicked awesome Bondo.

The green stuff

The brown

Ground between batteries in

Ground to the starter and starter signal wire.

 

[ontherxs]

More Sunday fun day.

 

[ontherxs]

Final ground to motor mount done.

Cut and grind the plate for switch mount

Location of switch. Screws were to short so that is a temporary zip tie.

We're ready to try and start it for the first time after connecting all the cables to their terminals.

 

[ontherxs]

So after everything was hooked up Johnny tried to start it and nothing. Quickly realized the battery switch was off (works correctly). Turned on the batteries and it fired and ran much to the surprise of both of us. Then I went to try so we'd have the great first time video and nothing.

Johnny ran some tests with a meter and found the starter signal wire was only sending 7 volts vs the 11 or so it needs to kick off the starter. A bunch of head scratching and I mentioned that I thought it had a aftermarket alarm at one point.

Johnny, with a look of utter disgust said, "That's the problem, that's always the problem."

Then this happened.

Johnny pulled it all out and put it back to stock. At that point it was much better but it appears there is still an issue with the ignition switch itself being consistent. With a hot wire, it starts right up.

So this week I'm gathering some remaing parts in hopes we can get her over the finish line.

Left to do:
Install new fuel filter
Install new oil filter and replace oil
Bleed power steering
Fill transfer case and transmission
Replace rear pinion oil seal and top off axles
Txf case prload and covers
Install drive shafts
Install headlights and wire.
Install headlight surrounds and grill
Wire alternator
Reconnect other sensors/gauges
Install throttle
Install fuel cut off
Install Wilson switch (glow plug activator)
Replace ignition switch
Replace glow plugs (10.5v)
Replace belts
Build and install exhaust.
Install hood latch and attach reattach hood
Install shifters and boots
Top off remaing fluids
Safety check

 

[GLTHFJ60]

"That's always the problem"

Yours ended up being pretty easy to restore to stock. One new ignition switch later and you'll *almost* never know it had an alarm!

 

[NCFJ]

Congrats guys!!! It is hard to tell from the photo but is the PS reservoir above the pump? The system works much better with the reservoir higher so that the pump is gravity fed. I am with you on aftermarket alarms, they are a pia. A hidden switch for the fuel pump does the trick or a switch to the ignition circuit

 

[GLTHFJ60]

Congrats guys!!! It is hard to tell from the photo but is the PS reservoir above the pump? The system works much better with the reservoir higher so that the pump is gravity fed. I am with you on aftermarket alarms, they are a pia. A hidden switch for the fuel pump does the trick or a switch to the ignition circuit

Good question, but it is. The PS pump is on the PS of the motor and is below the frame rail in terms of elevation. The reservoir return line to the pump has a nice downward slope to it

 

[ontherxs]

How about some video. Shasta rolls.




Shasta and Johnny drive off into the sunset:

 

[ontherxs]

Johnny I can't thank you enough. She's a masterpiece

 

[lt1fire]

awesome

 

[JohnVee]

Looking forward to seeing it.

 

[mtweller]

Awesomeness! Congrats.

 

[ontherxs]

Fabed up the fuel shutoff

Who says chicks can't wire a Wilson switch for the glow plug bus bar?

Been waiting to put my real plate on till Shasta was road worthy. Same plate I had on my '76 International Scout

Another great day. Drove to get the first pump side tank of diesel. Bio Diesel!

 

[GLTHFJ60]

I love the diesel pump shot. I've got one just like it from when we did my 4BT conversion.

It was a big weekend! Just a couple things left to finish up.

Moonshine supervising.

First oil change:

So fresh:

His baby: