The Life & Times of Shasta (86 FJ60 conversion to HJ60)
- Thread starter ontherxs
- Start date
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I think I spent more time staring at your engine than anything else this weekend! Y'all did a beautiful job. It looks great! Now to just get that pesky starter motor fixed... Or replaced... 
Still pissed that the starter went!! It was supposed to be brand new. We had to pull start him at the Eldorado Outpost on our way out 
ontherxs
They call me Tim...
- Thread starter
- #204
I am still so releaved/happy that we're were able to take her from being tits up to where she is today. She drove great on the way home. Incidentally, the exact same route she took on a flat bed when the 2F blew.
“The real glory is being knocked to your knees and then coming back. That's real glory. That's the essence of it.” - Vince Lombardi
“The real glory is being knocked to your knees and then coming back. That's real glory. That's the essence of it.” - Vince Lombardi
Agreed. I kept going over and staring at the work they did on Shasta. Pretty sure Tim thought I was stalking him at one point! Nice work on the truck, guys! Sucks about the starter, but hopefully it was under warranty?
Was great meeting you at CCLR Tim. Wish I had taken a little more time to look this truck over but she's nice for sure. I am really getting the 60 bug.
ontherxs
They call me Tim...
- Thread starter
- #208
Agreed. I kept going over and staring at the work they did on Shasta. Pretty sure Tim thought I was stalking him at one point! Nice work on the truck, guys! Sucks about the starter, but hopefully it was under warranty?
Thanks guys. I'm looking forward to getting some of the other medium sized projects done before the meetup in December. Hope to see you there!
ontherxs
They call me Tim...
- Thread starter
- #209
Got a bunch done this weekend.
- Replaced the faulty starter with and she's alive again! Thanks to Cruiserparts for making that right.
- Alternator is wired and charging. Need to take some more readings to be sure it all correct. - Thread explaining the issues here -> https://forum.ih8mud.com/threads/2h...lly-regulated-alternator.817875/#post-9385993
- Attempted to fix the high beams and did for a while but seems I didn't get everything totally cleaned out. Here is the thread that saved me tons of hours of troubleshooting. Turns out the problem is in the contact switch behind the steering wheel. And I know why its not wprking again I skipeed a step 12. Use fine sandpaper or emery cloth on the plunger tip that goes into the hole and contacts the lever arm.-> https://forum.ih8mud.com/threads/high-beam-lights-fixed-finally.110746/
- Replaced the headlight bulbs trying to chase down a dim PS light. I't most likely the contacts that need a good cleaning and the bulb was fine. Lesson learned troubleshoot first then replace.
- Wired the accessory fuse panel located now under the glove box and connected to the accessory port of the dual battery switch. Clean power in the cab isolated from the start battery!
- Replaced the glow-plug relay with a much more beefy relay and ran larger guage wire with fuseable link from the battery to relay to glow-plug bus bar.
- Had some beer and watched Johnny burn some stuff. Great weekend all around.
ontherxs
They call me Tim...
- Thread starter
- #211
If it was easy everyone would be doing it.
So if you haven't read the latest in drama in a chapter I like to call "Who needs a F*&#in Alternator Anyway", take a moment to catch up here.
https://forum.ih8mud.com/threads/2h...externally-regulated-alternator.817875/page-2
In Shasta land this is what I get for premature celebration without long term (more than a mile) road testing.
Spoiler alert: It worked worked
Spoiler alert #2: It went down in plume of black smoke.
So fast forward after three weeks of waiting and low and behold a new shiny (rebuilt) alternator shows up at my door step. Cruiserparts.net showing once again that they're in it to make it right.
So I have an alt with a proper vacuum pump, an internal regulator, matching female connector, proof that it worked at some point, and a diagram that matches the pins on the back of the alt.
Easy peazy. What go go wrong?
So if you haven't read the latest in drama in a chapter I like to call "Who needs a F*&#in Alternator Anyway", take a moment to catch up here.
https://forum.ih8mud.com/threads/2h...externally-regulated-alternator.817875/page-2
In Shasta land this is what I get for premature celebration without long term (more than a mile) road testing.
Spoiler alert: It worked worked
Spoiler alert #2: It went down in plume of black smoke.
So fast forward after three weeks of waiting and low and behold a new shiny (rebuilt) alternator shows up at my door step. Cruiserparts.net showing once again that they're in it to make it right.
So I have an alt with a proper vacuum pump, an internal regulator, matching female connector, proof that it worked at some point, and a diagram that matches the pins on the back of the alt.
Easy peazy. What go go wrong?
ontherxs
They call me Tim...
- Thread starter
- #212
Not even close.
So after getting the old alt and test fitting the new quickly realized the new alt bracket clearance was about an inch shorter than it needed to be.
The old and busted
Crappy picture of the bracket length
Old alt clearance
New alt clearance
That's not going to work.
So after getting the old alt and test fitting the new quickly realized the new alt bracket clearance was about an inch shorter than it needed to be.
The old and busted
Crappy picture of the bracket length
Old alt clearance
New alt clearance
That's not going to work.
ontherxs
They call me Tim...
- Thread starter
- #213
After a cussin up a storm and a beer (or two) it was decided to push forward with fabrication. To the hacksaw.
But first change the pulleys over to accommodate the larger belt width.
See here the alts bodies are the same size except for the that extended mounting bit.
Part of the plan to turn this spacer around to support the cut end of the engine mount
To the hack saw
Went pretty quick actually.
Here is what was removed and now the new alt fits on the engine mount bracket. Just need to get the proper spacer for the pulley so it lines up with the belt. I also, figure out the tensioner connection at the top which is also no where close to meeting the existing bracket.
Stay tuned..
But first change the pulleys over to accommodate the larger belt width.
See here the alts bodies are the same size except for the that extended mounting bit.
Part of the plan to turn this spacer around to support the cut end of the engine mount
To the hack saw
Went pretty quick actually.
Here is what was removed and now the new alt fits on the engine mount bracket. Just need to get the proper spacer for the pulley so it lines up with the belt. I also, figure out the tensioner connection at the top which is also no where close to meeting the existing bracket.
Stay tuned..
ontherxs
They call me Tim...
- Thread starter
- #214
Good progress last night. I couldn't find a spacer that would work at the hardware store so I decided to trim down the one I had.
As you can see with the spacer at the current width the pulley is to far forward.
Took my time with a dremel cut off wheel and hack saw.
Results after a trip to the grinder to make sure the spacer was flat again
Installed with what I hope is enough clearance.
As you can see with the spacer at the current width the pulley is to far forward.
Took my time with a dremel cut off wheel and hack saw.
Results after a trip to the grinder to make sure the spacer was flat again
Installed with what I hope is enough clearance.
ontherxs
They call me Tim...
- Thread starter
- #215
Next up. A solid connection for the tensioner. As you can see the alternator's connection point is past the tensioner bracket when the belt has the correct tension.
I think this will be the solution. Using a bracket to extend the reach
I'll bolt it down on the top side. This was just to make sure holes would align and the bracket wouldn't be resting on the alt.
I think this will be the solution. Using a bracket to extend the reach
I'll bolt it down on the top side. This was just to make sure holes would align and the bracket wouldn't be resting on the alt.
Last edited:
looking good
ontherxs
They call me Tim...
- Thread starter
- #218
This was the most difficult part.
The silver metal gaskets have to go in in the correct orientation (very difficult on #6)
Then the Brass injection seats
Lastly torque down each of the 6 with 27mm socket to 51 ft-lb
Then drink something amazing for a job well done.
The silver metal gaskets have to go in in the correct orientation (very difficult on #6)
Then the Brass injection seats
Lastly torque down each of the 6 with 27mm socket to 51 ft-lb
Then drink something amazing for a job well done.
ontherxs
They call me Tim...
- Thread starter
- #219
Links to threads that have been helpful for the injector rebuild
https://forum.ih8mud.com/threads/19...wer-and-wont-start.820184/page-2#post-9449922
https://forum.ih8mud.com/threads/2h-pinging-after-injector-rebuild.665555/#post-9446716
https://forum.ih8mud.com/threads/19...wer-and-wont-start.820184/page-2#post-9449922
https://forum.ih8mud.com/threads/2h-pinging-after-injector-rebuild.665555/#post-9446716
elkaholic
Left turn ...freakin wipers!
I think I now know someone who can coach me through injector rebuilds on my 3B when the time comes (I think both engines use the same injectors). Nice work! 
