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

[kulangot]

Respect! Looks really good. I saw the motor sitting over at Johnny's - it looked very good as well.

 

[GLTHFJ60]

When are we bringing this over to my place?

 

[ontherxs]

When are we bringing this over to my place?

The time is almost here. Trying to find a weekend in the summer that isn't booked with family life or trips has been tough. I am hoping with fingers crossed it proves to be the hardest part of this next phase.

Here is a very high level list of things to do shooting for a HAMOM / install party at Johnny's house on Saturday August 2. That is next weekend!!!

Prior to 8/2 (Shasta's transplant day)
I'm going to try to get as much of this done prior to that Saturday

• Read this thread entirely at least twice https://forum.ih8mud.com/threads/i-...skills-so-i-will-fj-60-getting-a-12ht.782751/
• Collect all the parts, fittings, cabling, anything and everything that will be going back in and put it in the back
• Continue research on wiring and glow plug assembly
• Get Shasta to Johnny's on the 28th or 29th
• Drain existing fuel and check tank
• Remove filler pipe
• Remove fuel evaporator spaghetti thing and cap off tubes
• Punch out fuel nozzle restrictor
• Replace fuel lines with B100 lines
• Steam clean 2H and spot paint

Prepping for 2H install

• Hoist 2H into position and determine where the motor mounts need to move to.
• Pull out and carefully remove existing mount
• Hoist back into position and bolt in transmission cross member
• Determine geometry for final location for mounts
• Remove 2H and weld in new mounts / re-spray frame
• Rebuild transfer case
• Put 2H back in final time

Bring it to life

• Determine and run all vacuum lines
• Install P/S lines
• Hook up AC lines
• Hook-up fuel lines
• Put front cross member back on
• re-install rad and rad hoses
• re-install AC condenser and manifold
• install battery tray's
• install dual battery switch
• begin to figure out electrical
• wire up starter
• fill all fluids
• double check all fluids and clean up
• build exhaust and re-install
• test fire
• squash bugs
• reminisce on all the challenges and successes
• install lights and verify safety systems
• create a list of all the loose ends
• drive home happy

 

[ontherxs]

On Monday Shasta made her way to Johnny's to begin the swap.

2H install starts now.

 

[ontherxs]

Step 1 unbolt steering box and steering shaft to move steering box out of the way.

 

[ontherxs]

Step 2. Cut off existing motor mounts then grind welds smooth.

 

[ontherxs]

Good first day progress. 2 hours labor, 2 injuries, a few beers. End results:

 

[ontherxs]

The further we dig in the more Shasta reveals the story of her sordid past. What's wrong with the picture #notfisheye

 

[lt1fire]

nice frame.

 

[NCFJ]

I am in the midst of repairing a similar situation, your frame actually looks much better than the 62 frame I am replacing now.

A couple observations, you cut pretty deep into the frame removing the motor mount. I would weld that up and then plate over it. I add plates when welding in the new motor mounts for the Vortecs anyway.

Wearing sandles while working on metal is a serious invite for foot damage. I don't even grind without long sleeved shirts.

 

[GLTHFJ60]

I am in the midst of repairing a similar situation, your frame actually looks much better than the 62 frame I am replacing now.

A couple observations, you cut pretty deep into the frame removing the motor mount. I would weld that up and then plate over it. I add plates when welding in the new motor mounts for the Vortecs anyway.

Wearing sandles while working on metal is a serious invite for foot damage. I don't even grind without long sleeved shirts.

We will be welding over the top of those cut lines.

As for the sandals, I wasn't wearing shoes and all I got was a shot to the gonads and a crushed thumb!

 

[ontherxs]

We will be welding over the top of those cut lines.

As for the sandals, I wasn't wearing shoes and all I got was a shot to the gonads and a crushed thumb!

NCFJ is right. Safety first. Wear your cup next time.

 

[JohnVee]

NCFJ is right. Safety first. Wear your cup next time.

Please clarify for Johnny that you don't mean his drinking cup, sandal boy.

 

[GLTHFJ60]

The technique:

Success!!

 

[elkaholic]

At a minimum some heavier shoes ... next time to see Mike Sontag, ask him about grinding. His story will make you think twice about the gear you need ...

I look forward to seeing the transformation continue ...

 

[mtweller]

I know a good "old school" frame shop up near Zebulon. IMHO I would get that straightened before fabbing new motor mounts to ensure it'll be square once the frame is.

Howard's Frame Shop
1838 U.S. 64, Spring Hope, NC 27882
(919) 269-9188

He's old school and you might get a little scared when you see his shop. However, nobody in "the city" wanted to even touch my junk. Howard deals with this kind of stuff all the time. Also, he had quoted me like $300 and when all was said and done, only charged me $200. when's the last time someone came in under estimated cost, for anything???

R

 

[GLTHFJ60]

I need to take some measurements tonight to see how far out of square the frame is. Pictures say it's way out.

I'll report my findings.

 

[ontherxs]

So Tim's frame is .5" narrower than mine at the front crossmember and ~1.5" narrower than mine at the factory motor mount location. This thing needs to be straightened before we put the motor in.

I need to make some calls to see what we can do. I'll keep everyone posted. If we can't get the frame done by Saturday then we will focus on body work for Shasta and then Derek's FJ80 front end rebuild!

Moving the news to the build thread.

 

[NCFJ]

I'd check out the frame shop that Ramon posted. Old school is the way to go with a body on frame. How the frame is pulled back has tons to do with maintaining as much structural stability as possible. The frame I am swapping was pulled back poorly and actually compounded the damage to the frame.

Good luck with the frame repairs guys!!

 

[NCFJ]

Oh yeah, on the grinding thing................I've been know to set a shirt on fire from time to time. Under a hood and wearing ear muffs your nose sends a signal "Hey I smell smoke, something is burning" ahhhhh yeah, it's me