All posts by Jakob Peyerl

14 year old Exhaust Replacement on a BJ60

The exhaust in my 1985 BJ60 had been on the truck since before I bought it 4 years ago, and was getting progressively worse. According to the journal the previous owner had kept, he had the exhaust pipe/muffler replaced in January of 2005. The truck had 223,536 km. When I bought the truck, the exhaust was already not in great shape; it seemed to have a slight exhaust leak near the passenger door, but I kept it running while it still worked.

Then one fateful afternoon on the way home from school, I floored the accelerator as usual to get up a large hill, and suddenly realized the truck was a lot louder than it should have been. Once I could pull over, I checked for the source, and felt a blast of air on my hand just after the exhaust pipe bends down from the manifold. I then decided I’d try to make it the rest of the way home before examining what was wrong. After making it another kilometer, it kept getting worse, and fearing a flurry of noise complaints, I pulled over on the side of the road, admitting defeat. This was 255,100KM on the odometer.

Not wanting to give in completely and have to take the bus all week, I decided I’d head down to Calgary Muffler Carline and ask about getting the exhaust patched up. Upon arriving, they put my truck up on the lift and I was able to see just how bad the exhaust was. The exhaust pipe was completely severed in half, with black soot coating the underside of the passenger floorpan, framerails, and everything else nearby. There was also more soot on the exhaust hangar, about 6 inches further down.

After examining the condition of the rest of my exhaust pipe, I decided to ask how much it would cost to replace everything back from the good metal at the very front. I was told it would be about $570, before tax. I figured I may as well replace this while I could, instead of waiting for something else to fail in another month. Having work in about 4 hours from then, I asked how soon it could be done. “2 hours or so” was the response, and I gratefully accepted.

1 hour and 50 minutes later, I took a look at the truck, with a new shiny exhaust system of 2.5″ pipe, a new muffler, and a side exit exhaust. It was awesome. I paid the $594, and drove home. It was rather loud, but I could live with it for then. After all, I hadn’t really clarified what amount of sound reduction I wanted. A week later, I drove back, and timidly inquired as to how much it would cost to get a quieter muffler. Al, the helpful owner, was very kind in offering a quieter muffler, free of charge. After a half hour had passed, the truck had a new muffler, and sounded as good as new. Better, in fact. They even properly routed the exhaust around the shocks and spring hangars; the previous exhaust system from 2005 was constantly rattling against the spring hangar and shock whenever it was at cold idle. When I replaced the rear shocks, the old one was dented where the old exhaust system ran. So this was a major improvement.

I’ve now been driving the truck for a few weeks, and the exhaust is great. Al was wonderful in understanding how to route the exhaust exactly as I hoped, and they handled the whole experience really well. I’m quite thoroughly impressed. Though, I’m also rather impressed that the previous exhaust managed to hold up for 14 years and 32,564KM of Canadian winters.

Crafting, RMLCA Style – Macrame Night

Last night was the first annual RMLCA Craft Night, this year being “Macrame Night” in which the night was spent weaving soft shackles out of 3/8’s Amsteel rope.

Peter Straub, the RMLCA’s Social Co-ordinator, described it on the mailing list.

After a very dubious start, Macramé night ended on a successful tone.  We started all watching various videos on the youtube, and regardless of the video, there was some element of the magic to the button knot that we could not get sorted.  Finally, Marc ‘got it’, and he was then able to do one on one tutorials until we all had our fill of shackles!
One of the secrets is the length… 3/8’s rope, start with 8′ of rope.  9′ for the 1/2″ rope.
I suspect there will be some shackles at the club raffle next week.
Thanks to Lloyd, 2x Kevin’s, Craig & Marc for coming out.
Working with the Amsteel blue, our hands looked like we had murdered a village of smurfs by the end of the evening.

Custom BJ60 Rear Bumper Fabrication

I’ve always wanted something better than my stock “Rust à la Chrome” bumper, and when I had to cut off the edges of it this summer while doing bodywork, (upcoming Toyota Trails article about that) I had to cut off the ends of the bumper to weld some sheet metal. Not wanting to drive around with half a bumper, I finally had the motivation to fabricate a new one. First, I bought some 2×4 tube steel, and some 3×1 solid steel. The 2×4 would make up the main bumper, and the 3×1 would be the mounting plates / D-shackle mounts.

I started off by cutting and welding the edges of the bumper, to make it seem a little better than just a tube. I cut a triangle out of the ends, leaving the bottom intact, and then bent the bottom up to meet the top of the bumper. 

This created a better shape, and with this part finished, I could measure the truck. 

I wanted to mount the steel bars to the inside of the frame, and since the old bumper had a cross-member in the way, that received a couple minutes with a sawz-all.

Once the old cross-member was removed, I had to drill holes in the frame to which I could mount the steel bars. Half an hour later, I had finally drilled the 4 holes in the frame that had to be drilled. I mounted the steel plates on with some bolts, and then marked where the holes would be on the bumper.

Using a cutoff wheel and a sawz-all, two rectangular holes were cut on each side of the bumper-to-be, and then it was time to test fit.

To my surprise, it actually fit on, meaning it could be welded in place, and painted. And, because I was stupid and forgot to take photos, you’ll have to take my word that I welded it before the final paint coat. I just used some cheap rustoleum spray paint, this summer the truck will be undergoing a windshield frame replacement, and when that gets painted, the bumper will receive a proper coat of paint. Even now, after only a couple months with the paint on this bumper, it’s already rusting, so don’t expect anything to last unless you prime it first.



Other photos:

The old bumper

And finally, a spot of Canadian parking with the new bumper