Walking baby......hide the tools! My 2 year old loves to "help" in the garage, typically by shoving tools in random places.

Another local!

You can ride in it whenever you like... if you'll take me for a spin in the 930 too.

;)

I cut out both front pans and replaced them with panels from CCOT.

This is my first time doing open heart body work and I've made plenty of oopsies.

I warped the drivers side panel because I put too much heat in it while welding.
You can also see where I cut on the wrong side of my guide tape and got half way across with the nibbler before I realized my mistake.

http://i371.photobucket.com/albums/o...ps5a986b42.jpg
Drilling out all those spot welds was lots of fun.

http://i371.photobucket.com/albums/o...ps91f829a9.jpg

http://i371.photobucket.com/albums/o...psaef87d0f.jpg

I put the tub on it's side to reinstall the frame gussets.

http://i371.photobucket.com/albums/o...ps394e1caa.jpg

http://i371.photobucket.com/albums/o...ps5badaa46.jpg

http://i371.photobucket.com/albums/o...psa6af346d.jpg

I also cut out and welded in patch panels for the few trouble spots where there was a lot of pin holes.

http://i371.photobucket.com/albums/o...ps1cff7420.jpg

http://i371.photobucket.com/albums/o...ps71e262c6.jpg

http://i371.photobucket.com/albums/o...ps06ea8d4c.jpg

http://i371.photobucket.com/albums/o...ps56f2b221.jpg

http://i371.photobucket.com/albums/o...psaaf895f4.jpg

http://i371.photobucket.com/albums/o...psb0303ab8.jpg


...as you can see, I'm not a trained welder nor do I play one on tv. I am doing the best I can with what I have and I am already seeing an improvement. I can tell you that my biggest headache has come from weld contamination and unexpectedly running into a thin spot and having it blow through.

I've also decided to cut out the botched rear wheel openings with bushwacker flares rather than return them to stock.

http://i371.photobucket.com/albums/o...ps4b7a6fbe.jpg

I also wasted a bit of time and money on the front brakes. I really wanted to dump the drums and was looking for the least expensive way of accomplishing that goal. In my FJ-naïvety I somehow landed on GM Monte Carlo calipers and JTO brackets.

http://i371.photobucket.com/albums/o...ps9ef6f4fa.jpg

Well, after doing a bit more reading, I've decided that's not such a great idea for front brakes so I've picked up a set of '82 Mini truck knuckle/hub assemblies and will be converting the front axle over to FJ60 vented rotors and 4Runner 4 piston calipers. I'm on the hunt for a set of fine spline outer birfs too so I can dump the Warn locking hubs for a set of Asin hubs.

The GM calipers are going to be moved to the rear axle. I'm going to pick up a FJ80 1" MC, a mini truck booster and a proportioning valve from Summit to complete the brake system.


Also, I haven't touched the 3 speed transmission or transfer case because I've got a 4 speed setup I got on Craigslist last year. I'm going to run the current setup until I decide on an engine. Then the 4 speed will be rebuilt and installed.

http://i371.photobucket.com/albums/o...ps119ac82e.jpg

http://i371.photobucket.com/albums/o...ps84cb248f.jpg

I've got a mini truck PS box installed on a JTO pedestal. I'm running into all sorts of problems with it not clearing the exhaust manifold. I've tried two types of center dump manifolds and one rear dump and they all interfere with the PS box. I'll have to get creative but I can't even address that problem until the tube is back on and I can install the steering column to see where I'm at.

...more to come.

More screw ups today. Like I said, I found out the hard way that the sill should be installed first before the quarters. The right side come out just fine, but I had the driver's quarter cut too short. D*mn! So, I cut it back off and readjusted it with the sill centered correctly and wouldn't you know it... I cut off too much of the patch panel. Rats!

So, I had to get a bit creative and carefully cut a patch for the patch. :bang:

http://i371.photobucket.com/albums/o...psb6cf5399.jpg

http://i371.photobucket.com/albums/o...ps754d0977.jpg

http://i371.photobucket.com/albums/o...ps2ea6d20b.jpg

Then I was able to install the sill cover:

http://i371.photobucket.com/albums/o...ps8f7a57c8.jpg

http://i371.photobucket.com/albums/o...ps4218957f.jpg

I guess you could say I decided on a choice of powerplant!

After a lot of soul searching/wallet searching I decided the best choice in dumping my small block for something more Toyota'ish and modern would be a 3F-E. I landed a good donor from Georg at Valley Hybrids this weekend. Here are some photos of the carnage.

This started out life as a '88 FJ62 but by the time I got it had been reduced to a FJ31:

http://i371.photobucket.com/albums/o...pse123e523.jpg

I took it to my uncle's shop in Ripon and three hours later had the whole thing stripped to the bone:

http://i371.photobucket.com/albums/o...ps6d42c0d1.jpg

The whole front wiring harness was removed and tagged:

http://i371.photobucket.com/albums/o...ps11d381fd.jpg

Oh yeah, this is going to be a piece of cake:

http://i371.photobucket.com/albums/o...ps6b59960f.jpg

Once everything of conceivable value was removed, the FJ31 was cut into a FJ15.5:

http://i371.photobucket.com/albums/o...psa60bc3ec.jpg

http://i371.photobucket.com/albums/o...ps87951837.jpg


Loaded up and ready to go home:

http://i371.photobucket.com/albums/o...ps73579885.jpg

Got back late last night but had enough time to get it off the trailer and disassemble some of the ancillary components:

http://i371.photobucket.com/albums/o...ps152ade50.jpg



Also, I wasten no time in tearing apart the stock wiring harness. I cut off everything from the FJ62 that I didn't need and only kept the alternator to battery leads, the fuse panel and the ECU components. I then took my stock FJ40 harness and began grafting the two together... lots of fun. Here's a photo of the state of affairs last night:
http://i371.photobucket.com/albums/o...ps741b986d.jpg

I'm committed now.

http://i371.photobucket.com/albums/o...psd9244ffc.jpg

More to come!

Got a load of stuff back from the powdercoating shop. I also took all the hardware to a local plating outfit and had everything plated in yellow zinc.

Now, we start the process of reassembly.


http://i371.photobucket.com/albums/o...ps9f4bf2b2.jpg

http://i371.photobucket.com/albums/o...ps5241c6d8.jpg


http://i371.photobucket.com/albums/o...ps13494765.jpg

http://i371.photobucket.com/albums/o...ps7cd3a8cc.jpg

http://i371.photobucket.com/albums/o...ps83bb3408.jpg

http://i371.photobucket.com/albums/o...ps9652d16b.jpg

http://i371.photobucket.com/albums/o...ps21ce0cfd.jpg

http://i371.photobucket.com/albums/o...ps2546a157.jpg

http://i371.photobucket.com/albums/o...psfc66a0ee.jpg

I'm starting the mock-up to be sure everything fits right. The front motor mounts have given me fits. I've played with it quite a bit and am still not able to get the crank sitting dead center in the frame. I slotted the mount holes and used 1" spacer between the driver's motor mount and frame bracket and got it as best as I think I'm going to be able. After re-reading through several other 3FE conversion threads, it kind of looks to me like everyone's engine is a little off center so I'm hoping this won't cause any issues. I did test fit the radiator and fan shroud and it looks like it's going to be a pretty easy fit.

I've got the entire injection system bolted back on (temporarily). Reason being, I had all the hardware and brackets yellow zinc plated locally and although the shop did a good job on the parts, they screwed me royally in another way. I had carefully counted/measured every nut and bolt and placed them, in groups, in labeled zip lock bags describing the contents and where they came from. I thought this would make reassembly a breeze... and it may have... if the plating shop had not dumped their contents into a plating vat and then thrown away the bags.

So, I got a large bucket of stuff and had to figure out where everything goes. DO'H! (I'll probably be asking for some help on that score later too)

Since I am now working off of memory alone, I decided to start putting everything back together before I forget where everything went. Thankfully, I've got almost all the major mysteries solved now.

Here are some photos of the progress:

http://i371.photobucket.com/albums/o...ps2546a157.jpg

http://i371.photobucket.com/albums/o...psff3477cd.jpg


http://i371.photobucket.com/albums/o...pse685f4e1.jpg

http://i371.photobucket.com/albums/o...psd1a511d6.jpg

http://i371.photobucket.com/albums/o...ps2119de60.jpg

I think I'm going to run a power steering cooler in front of the radiator:

http://i371.photobucket.com/albums/o...ps47084140.jpg

http://i371.photobucket.com/albums/o...pse34a6600.jpg

Looking good in primer!

http://i371.photobucket.com/albums/o...ps6877e5ad.jpg

I got the gauge cluster restored and finally reassembled:

http://i371.photobucket.com/albums/o...ps5573fb13.jpg

I'm a little concerned about the clearance for the e-brake cable. Not a lot of room here:

http://i371.photobucket.com/albums/o...ps3089a3ca.jpg

Another enthusiast graciously donated a ignition coil perch to replace the one Farmer Joe ripped off during the ill-fated V8 swap:

http://i371.photobucket.com/albums/o...ps26fce608.jpg

I've traced out the route for the clutch and rear brake circuit on the firewall. I'll actually bend the lines once the engine is out of the way:

http://i371.photobucket.com/albums/o...ps406b5730.jpg

I also found a good bracket to hold the speedo cable away from the exhaust manifold:

http://i371.photobucket.com/albums/o...ps005dc15b.jpg

Zang.

http://i371.photobucket.com/albums/o...psbf9bafa1.jpg




I also found a problem with the passenger side seat bracket. It looks like it must have broke at some point in the past and the repair was (shockingly) poorly performed. The right seat leg is about 2.5" off the floor:

http://i371.photobucket.com/albums/o...ps060cb096.jpg

I suspect this is the cause of the problem. Looks like this has been rewelded at some point and I think I'm going to have to cut and redo it.

http://i371.photobucket.com/albums/o...ps2b68a3ec.jpg

http://i371.photobucket.com/albums/o...ps307733eb.jpg


Still several mysteries though... for example, I have no idea what these rubber grommets on the hard top sides are for:

http://i371.photobucket.com/albums/o...ps1c4e694d.jpg

Also, I rerouted the fuel delivery and return as I was not happy with the way I had the lines positioned:

http://i371.photobucket.com/albums/o...ps7841815d.jpg



Starting to look like a truck again!

http://i371.photobucket.com/albums/o...pse409d8b8.jpg

Working on more wiring:

I got the wire harness test fit to make sure the connectors will reach the ECU:

Check.

http://i371.photobucket.com/albums/o...ps2648d099.jpg

And I also cut the upper fuse panel tab off and repositioned it to accomodate the larger FJ62 fuse panel:

Check.

http://i371.photobucket.com/albums/o...psad8f674a.jpg

I used a strong magnet to hold it while I tack welded it in place. It didn't come out that pretty because I couldn't see what I was doing. I'll try to clean it up next weekend. But, I'm really happy with the way the fuse panel sits in there. It looks very factory!

http://i371.photobucket.com/albums/o...ps1710daaf.jpg

The air cleaner mounting proved to be a real ordeal. I couldn't put it in the stock location (passenger fender) because there just isn't enough clearance between the blower motor and the battery mount. In the end, I opted to move the entire assembly, MAF and all, to the driver's side fender and just re-weld the mounting ears in a position needed for the new location.

http://i371.photobucket.com/albums/o...psbee2d820.jpg

http://i371.photobucket.com/albums/o...ps41bf5504.jpg

http://i371.photobucket.com/albums/o...ps9b63965e.jpg

I put on the hood to check for clearance and with the canister/MAF positioned here. I have about 1.75" of clearance between the MAF and the hood:

http://i371.photobucket.com/albums/o...pse3ce70b2.jpg

I had to slightly bend the vacuum lines so that they don't rub, but you can see there is room between the plentum and the canister on this side:

http://i371.photobucket.com/albums/o...ps1713ea97.jpg

The gap between the radiator hose and the MAF is also tight but I think it'll be fine:

http://i371.photobucket.com/albums/o...ps3f0e8d17.jpg

http://i371.photobucket.com/albums/o...psb309b3db.jpg

With a bit of trimming of the MAF body, I may even be able to mount this thing without removing the engine lift hook (bonus):

http://i371.photobucket.com/albums/o...ps8e02cd8c.jpg

http://i371.photobucket.com/albums/o...ps0d6c9e20.jpg

My 55mm hole saw arrived so I made good use of time and buttoned up the harness. Here's how it looks:

http://i371.photobucket.com/albums/o...ps2dad5e9e.jpg

http://i371.photobucket.com/albums/o...ps872ebdd3.jpg

http://i371.photobucket.com/albums/o...ps5b2bae2d.jpg

http://i371.photobucket.com/albums/o...pseab3878c.jpg

With the blower ducting in place you can barely see the added grommet:

http://i371.photobucket.com/albums/o...ps7592674b.jpg

Here's how the air cleaner legs are coming along:

http://i371.photobucket.com/albums/o...ps257b28e1.jpg

http://i371.photobucket.com/albums/o...psf9f46bb8.jpg

It's going to work fine, I think.

:)

http://i371.photobucket.com/albums/o...psdb2be187.jpg

http://i371.photobucket.com/albums/o...ps20bed80c.jpg

I got the intake plumbed. I've ordered some parts to make it look a bit cleaner, but this is essentially how it's going to look:

http://i371.photobucket.com/albums/o...ps6ae5a21a.jpg

http://i371.photobucket.com/albums/o...psa52ab694.jpg

I was never really happy with the way I had mounted the main ignition relay and new "switched ECU relay" to the FJ62 fuse panel. It was a good idea, poorly executed. Also, I was not happy with my choice of the firewall/engine bay to mount my two non-weatherproof headlight hi/lo beam relays. That was just a bad idea.

So, I picked up a 4 position relay panel off Amazon and am going to mount it to the underside of the dash on the driver's kick panel. I made up a simple bracket out of some sheet metal and some riv-nuts:

http://i371.photobucket.com/albums/o...ps2bc8abb6.jpg

http://i371.photobucket.com/albums/o...psb77716ac.jpg

It's a bit bulky but should fit just fine in the space provided:

http://i371.photobucket.com/albums/o...pse7e6ae11.jpg

So, I tore into the fuse panel again... "snippety snip..." Cut all the wires needed to power the two ignition relays:

http://i371.photobucket.com/albums/o...ps24c126c4.jpg

Here's the new panel ready to go in, complete with properly color coded pig tails (I knew I kept all that spare wire for a reason!):


http://i371.photobucket.com/albums/o...ps46ca1347.jpg

I'm going to wait until I have the pedal cluster out of the way before I graft it in. There's just no room to maneuver in there right now.


More to come...

The relay panel should work like a champ. It's a tight fit in there and there's not a lot of clearance for the turn signal flasher, but it will fit. The real challenge for me will be welding the mounting bracket to the tub in such a contorted and odd angle. Luckily, you won't see it often so it can be ugly, as long as it's solid.

Here are a few more pics:

http://i371.photobucket.com/albums/o...pseb9826d3.jpg

Here's where it's going:

http://i371.photobucket.com/albums/o...ps7ef836b1.jpg

Tight fit, but it works!

http://i371.photobucket.com/albums/o...psdb4ac1e7.jpg


http://i371.photobucket.com/albums/o...psf675703c.jpg

I got some more work done on the 3FE. I got the engine bolted down, the radiator mounted and the shroud trimmed and attached.

http://i371.photobucket.com/albums/o...ps7daa2fe4.jpg

I also mounted the overflow container and ran a bunch of vacuum and EVAP lines.

I'm not thrilled with these clamps I used on the intake but they'll do for now:

http://i371.photobucket.com/albums/o...ps634ce1fc.jpg

I re-wrapped the engine harness and moved the leads for the fuel pressure regulator VSV and the MAF. I think this looks nice and tidy:

http://i371.photobucket.com/albums/o...ps83ad6770.jpg

I need to find a longer 1/2" molded 90 degree elbow hose for the valve cover vent hose but otherwise, everything else is now hooked up:

http://i371.photobucket.com/albums/o...ps29c54963.jpg

I used my spare parts bin of NPT junk to cobble together a 5/8" barb to connect to the ISC. I will find a more permanent solution once the engine is up and running:

http://i371.photobucket.com/albums/o...ps2bdd58c9.jpg

Did I say, "Up and running"???

It RUNS!

I got the truck to the point where I was ready to test it today and didn't get very far at first. It would crank and get fuel, but not spark. It took me three hours of wire tracing to find the culprit (broken wire connection). I was really bracing myself for weeks of brutal uphill battles tracking down gremlins and solving problems. Well, as it turns out, all I needed to do was patch that one switched power wire to the ignitor and she fired right up.

God, fuel injection is going to be sooo nice.


Now, I don't have any exhaust or O2 sensors and the throttle cable hasn't been adjusted yet so I this was just to see if it would run at all. My buddy Sam heped too.


Success:

<iframe width="560" height="315" src="http://www.youtube.com/embed/NgmEcsa7AIs" frameborder="0" allowfullscreen></iframe>

Awesome