The TORFAB HJ60 Rust Removal, err body swap

[torfab]

I have an HJ60 with a somewhat solid body and somewhat solid frame. You can see daylight through the fenders, and can poke holes through parts of the frame.

It's a 1987 HJ60 imported from Canada, 2H Diesel was rebuilt or reconditioned 5 years ago, and has excellent compression (400psi). The H55F shifts beautifully, and is very quiet and comfortable. It has 33" BFG All Terrain Tires, and an OME suspension lift.

The only "RIGHT" way to get the job done in my opinion, is to transplant everything over to a clean frame and body containing zero rust.

I've been on the search for such a machine for a long time, and finally found one in California at Georg's shop (valley hybrids). Now comes the fun part of rewiring the FJ62 with the 24 volt loom, moving the gas tank, engine mounts, etc etc etc etc.

My list is a mile long, but this will be the absolute best way to complete this project

 

[chukardog]

save yourself the effort and just throw that drive train in my 60! Look forward to watching this thread.

 

[GLTHFJ60]

 

[saucebox]

Leave a ton of tech/pics. I'll try to do the same when I attempt the same project over the summer (regrettably, however, without a diesel or the H55).

 

[Butt Ugly Chuck]

...x2!

 

[Spike Strip]

X 10^7

 

[torfab]

First thing on the list is removing the engine and transmission. I had Matt "Todo" over last Tuesday, and he helped disconnect the drivelines, transmission components, and engine components. First removed the front clip, and store all the coolant. Then unplug all the electrical and vacuum pump hoses, etc. Next came the clutch slave, drivelines, engine mounts (3 piece mounts), tranny mount, and linkage.

Here are some pics of the engine yanked out, and a quick before pic.

I'm really bad at taking pictures of these projects, I just get into them and zone out - nothing else matters. I might need a kid to document as I go along next time

 

[torfab]

After this, I wanted to keep the stock HJ60 axles, because they're rebuilt, with new brakes etc. So I needed to remove the donor axles, and swap them with the FJ62 axles.

The key is to keep EVERYTHING to a stock HJ60 including the 24v wiring harness.

Here are a few pics of Rochford moving the axles into the new body, and the old body sitting high and dry waiting to be dropped to the ground.

The trick to rolling these axles around, and keeping them low profile, is to mount empty rims on them. This keeps them low enough to roll under the body, and they still "Roll" instead of having to lift those heavy suckers.

 

[Ropeman]

Great opportunity to get everything clean underneath at the very least. Looking forward to more of this

 

[IrollwithTojo]

Will be following this one Torfab

Nice 40 in the back as well

-Carl

 

[GLTHFJ60]

I keep thinking I should buy a rust free frame / body and transfer the good bits over, but then the VIN changes and it's suddenly a different truck. I'm too attached to my rotten body

Nevertheless, this swap looks like it's going well! Good work thus far.

 

[Mental1]

Will be following this one Torfab

Nice 40 in the back as well

-Carl

Why Thank You! There's been a lot of work done on it at TORFAB.

 

[Mikesta]

Tuned in.

 

[chukardog]

Tor, your neighbors must LOVE you

 

[theside00]

Since you have everything out lets just dump this right into my 80

 

[kling-on]

Make sure you keep all the tags and the frame number and put em on what ever body/frame you use

 

[Michael Hanson]

If I did that in Plano,Texas,my neighbors would turn me into the city,....again. Have fun watch out for the code guys. Mike

 

[Kynot62]

Tor

I know exactly how you feel... My BJ is rolling, driving it to work too. Still a ways to go but the axle and suspension swap should happen this weekend

Tony

 

[IrollwithTojo]

If I did that in Plano,Texas,my neighbors would turn me into the city,....again. Have fun watch out for the code guys. Mike

I did somethin not even close to this, my '88 62 was sitting with no plates on it, the city threatened to FINE us for it...I just about when bat s*** crazy

-Carl

 

[Mental1]

Tor, your neighbors must LOVE you

Actually they DO!!! They even come over with beer and watch us work. We just don't get to drink till we are done of course. So its kinda of painful in that sense. I am however enjoying a beer now. Ok maybe more.