d21 project with no name

[muddyhilux]

more of an update.........got truck to the wheel alignment this morning and a pretty good result ae.camber angles on the rear are under 1degree either side so im happy with that,thort it may warped a litle bit more during welding but seems to be pretty good,as for toe it aint to bad,both wheels are pointing slightly to the RHS but thats easy enough to fix by shifting the front RHS spring mount forward slightly before welding solidly,also picked up 2x black rubber door stops which tonight ill turn into hig lift jack mounting points so looking like thngs are starting to fall into place finally

[darinz]

I like your approach. Measure, measure ah near enough weld the sucker!! Sounds a little too familiar to me!!

[muddyhilux]

yeh it got like that in the end,im not out by much tho 1.7mm on left, 2.2mm on right (shouldnt be more than 1mm either side) so only needs to move a mm or so,the guy said hes seen way worse even from facory,i inda wonda if i even bother but yeh,will always be in the back of my mind if i dont

[muddyhilux]

well more of an update,been a good weekend id say,worked on truck yestaday and today,got the front plate mounted and idicators put in aswell as mesh leaving the front looking alot better off




have now 90% sorted the fuel filler pipework,just gota weld a 90degree bend onto the straight pipe which screws onto the deck the shes sorted

have fully welded up all the leaf mount brackets (are yet to add extra plates for strengh but have started cutting them)

also the deck edging has been cleaned up and straightened plus have cut up the angle iron pieces and painted them,will be picking up bolts and they will be bolted on wed / thurs morning,have also cut up some more garden edgeing for the rear flares and also the clamping plates which will hold them

rear mudflaps have been eyed up so will be getting some material for that this week aswell and are planned to be on by the weekend

what else,original gear stick boots have been cut off and replaced by a pair of material boots made up by the mother n law


so yeh,not a bad weekend,think it was anyway and forward progress has to be better than backwards

[muddyhilux]

well more of an update,had a couple of weeks where nothing happened due to ral work getting in the way but we have now made good progress again
rear spots / reverse lights are on and working

rear mud flaps are on and complete

rear flares are now on aswell

rear disk conversion has just been done this past weekend,below are the step by step pics(kind of)

drums removed

axle ready to begin the bolt together process

new mr2 plate attached

disk on

spacer bolted on

caliper on

and the final product


are now just working on the
handbrake cables and fittings etc
have to make up 2 new gear knobs
& drill and bolt on tow bar

then where off to cert,then all the little jobs can be finished off after that bit by bit,ok enough of an update,gota get back to work oh and ofcourse more photos to come once i get time to resize and load them

[muddyhilux]

well next update,havent got a huge amount done as ive had the flu for a week and then just been in hospital for a week getting my gal bladder removed but my brother n law has been moving forward well,new gear knobs i turned up we put on


also had some new parts arrive,big arse ns70z battery as the current battery is dead


new spot lights arrived,decided to go for the narva 160/115 broad beam and a pair of 160/115 pencil beam to get a good light coverage


after getting the light we got them mounted up on the roll bar bracket along with the cb aerial


thats enough for now,will get more photos and updates and upodate again tonight

[muddyhilux]

well more of an update as promised,heres the cb that oscar set up the other day

also heres where the air tank is finally positioned which one of my mates pointed out you couldnt see,oscar also got the air hose and fittings in place and attached so the on board air is ready to charge as soon as its all wired up which is good and anuther step forward

and as for the handbrake we measured up the cables and got the 2 to 1 made up which cost us $150 from auto stop

from there we conected and tried but unfortunatly due to the design of the original handbrake cable going forward then looping back it had too much friction on the inner edge of the curve as you can see in this photo

from here we went to pick a part and got a through the floor stait pull handbrake for $7,a 150x350x3 plate for $7 and put it together to get this


we then modified the original cable at auto stop for $50and put in a bracket and got this

now the handbrake works mint in all positions,depending on weather your on a hill or not its one click more or less but that means nothing,the setup is right up out of the way and for about $225 all up where both realli pleased ae

also heres a photo of the modified driveshaft flange that we got redrilled to suit the toyota PCD


well thats it aging,tonight well be getting the light bar attached,wiring up the antenna for the cb and running all the cables for light bar,electric fan and air con pump

[muddyhilux]

well this is the most updates ive done in months but it shows works being done
last night we got the new batteryu in,also got the light bar mounted



we also ran all the switchboard wring and put in the fuse box


we also modified (cut) the original handbrake surround and got that fitting nicely and looks pretty standard


we also removed all the original air intake plastic piping in preperation for sorting out the snorkel and also looked into and made drawing of new box section that were going to make up to straighten up the rear shocks a little as we have time,not a hole lot of work but every couple of hours add up

[Tuigod]

Kool spot lights dude

[muddyhilux]

well anuther good day yesturday,got all the wiring done for spotlights and dam they are mint,so bright compared to what either of us have had in the past,also got last 2 goles in tow bar drilled and now thats all bolted up nd sorted,cut to length a hole lot of deck bolts aswell as the shock bolts so the threads dont get caked with mud of damaged,also sorted out cb aerial and tested that,goes bloody mint,also got extra bit of 5o box cut to length and reflexed the truck and are now ready to drill holes then will stick bar on top of current shock xmember and straighten up those shock angles,quite a resonable amount actually and will give alot better performane,thats most jobs we got done so both very happy and still moving forward,oh we also got parts list sorted for snorkle so will be getting exaust bends etc and getting that welded up and mounte hopefully by end of this weekend,of and also double checked bolt tightness on shackes and greased them all up small job but a very importand one if we want good flex and dont wana be replacing bushes al the time

[petefj40]

How do you find your hand brake?
And what type of pads are you running?

Well done on the build m8! Looking good.

[muddyhilux]

hey mate,yeh its not too bad,on the flat its couple of clics,up hill its a few more than on flat and down hill it a few less but it does hold,with the angle we have it aint all perfect,im considering making a couple of brackets to get a better line of pull but it does hold on all things weve tried it on,also with all lines being new they aint got much stretch in them so were waiting for them to stretch some more then itll feel more like a normal handbrake,pads are the ferdo,ferado? ones from repco,the box said they were supposed to be the turbo ones with the chamfered edge either end but they actually the non turbo ones with square edges,seem to stop the truck quite well but weve only done short tests,once its on the road we may finsd theyre no good and upgrade to some higher performance type,bit of a wait and see game,
and cheers mate,were both pretty pleased with how its turned out and performance wise its alot better than we expect so definatly cant complain

[petefj40]

Sweet!

Re the pads. I had pads that were great once you got a bit of heat into them. But when they were cold they weren't as good as the standard set I have in now. It's a bit of a trade off.

As for the angles and leverage points for the handbrake? The MR2 rear calipers that we had installed are one complete unit. No angles to have to play with. It's all there, just bolt it on and go!

Keep up the good work.

[muddyhilux]

oh tru,yeh im a lil worried that once they get warm theyll be no good but yeh,wil have to wait and see,and yeh,il put a close up pic of ours on tonight so you can see,we had to remove the extra bracket which comes on the caliper due to us doing a SOA so the cables weve used actually pull the lever forward but also up slightly at the same time cos we didnt get sleeves put over ours,we didnt think it would be much of an issue but we made need to look into it more once weve finished a few other jobs and i might have to make up a new quide bracket and get sleeves added over our cables,and yeh we will,looking to have final cert check in 2weeks time,3 max if i cant get all the leftover welding done fast enough then its off to test her out

[muddyhilux]

ok well heres a bit more of a close up of the cable and caliper without the bracket attached,like i said in my last post where more than likely going to add a modified version of the bracket and get the cable slightly re routed to give a better line of pull



and update wise weve finished moding the rear shock xmember to how we wanted it to be in the end,heres the xmember



and heres the new shock angle which is alot better than what we first set up as a dummie to get it moving



have now got the fuel filler pipe extension welded up so thats sorted and ready to go aswell,we now also have a hole in the front fender and are on our way to having the snorkle in by the end of the week which will be good,thats about it really,havent spent much time on it in the last few days,just been to busy with other commitments

[Nav2NV]

quick question,what rotors did you use?terrano ones or somethign from a different vehicle?any reason you used the mr2 calipers?

as far as doing the mod itself,any tips or tricks you learnt on the way you wish to share?

cheers

Nav2NV

[chrome]

have you figured out a name yet nice work guys

[muddyhilux]

hi nav2NV,we used prado rotors,can get more details if u need them,and mr2 calipers as we purchased the adaptor kit from jafa,his kit is designed to go with hilux / surf axles so it was the easyist way to do it rather than redesigning our own thing,as for tips or tricks,um cant really think of any major discoveries we came accros sorry,all went to plan,taking your time to set up the shackles at the correct angle is the main thing really

and not yet chrome to be honest i dont think its crossed either of our minds latly,we just trying to get the thing on the road asap so we can get out for some fun

[aroma]

looking good i'm jelous
do the radius arm bushes while you have it in bits they a @#!$%#@^&*% to do as just done mine and if you let go,need to weld large 24mm penny washer on to the chassis to close up the hole that it makes
i found out the hard way and got told about it 3 years ago

[chrome]

hi nav2NV,we used prado rotors,can get more details if u need them,and mr2 calipers as we purchased the adaptor kit from jafa,his kit is designed to go with hilux / surf axles so it was the easyist way to do it rather than redesigning our own thing,as for tips or tricks,um cant really think of any major discoveries we came accros sorry,all went to plan,taking your time to set up the shackles at the correct angle is the main thing really

and not yet chrome to be honest i dont think its crossed either of our minds latly,we just trying to get the thing on the road asap so we can get out for some fun

mate it looks like something outa mad max you could call it the TOECUTTER

[muddyhilux]

well its been ages since an update,we have been working on it but had a few things com up ,BUT as it stands oscar will be calling cert man 2moro and with any luck itll get through its final check which were hoping will be wednesday,then off to wof and away it goes

[gimmemud]

How did cert go?

[muddyhilux]

if only it happened,was all planed for 1430 toady and brother n law got a call this morning from mark and due to a death in the family he wouldnt be able to make it,fair enough though,so hes gonna get back to us next week and rebook a time,so for now things are as they were,oh truck now has a set of manual hubs on the way from somewhere so theyll get fitted over the weekend

[tomsoffroad]

Well done. Had a go at modifing one of these few months ago. Goes well.

http://www.offroadexpress.co.nz/4wds/19 ... t-built-it

Wait till you sas it. Just gets better

[muddyhilux]

cheers mate,my stupid comp wont open your link fully but looks dam nice and im sure it goes bloody well as you say,we cant wait to get this out and see what it can do ae,and yeh,sas along with a commy v6 are planned for late next year,maybe sooner,brother n laws gonna just start collecting parts and well do it when we got it all

[aroma]

any more and did you get the cert??

[muddyhilux]

hey mate,sad to say it but not quite yet,weve had major issues with the certification,goes something like this

made appointment

he didnt make it

took a further 5 weeks to get next visit but he sent his boy instead

that was just the biggest waste of time ever,told us spacers wouldnt pass with rims even thought main certifier had and also said handbrake was no good but didnt xplain y and when asked how to fix he said maybe pull it out and put in a range rover axle,the guy just new nothing at all

not happy with results obviosly it then took a further 6weeks to get hold of main certifier,he then told us in not quite the ame wwords, i f&%kd up nd told you wrong,you cant run the spacers so that put us in a right royal mood,he then said handbrake should be fine but hed come have a look

turned up 2 wks later and took 1 min to xplain to us what his boy didnt,it all made sense and it just needed adjusting,(in other words about 12wks to hear a 1 min sentence and do a 1 min adjustment)

anyway,he said hell send off the papers,give it 1 last check when he comes back with plate and thatll be it,that was 2 n half weeks ago though so dont kno whats happing now,have sent off an email so just playing the waiting game again

put nicely i wont be using him again,eva,and ill be recomending to all that ive previously incouraged to use him to not

[J_Dub]

thats a bit rough dude, you would think he would be doin all he can to look after his reputation... thats shit

[muddyhilux]

you would think so but in no way is he trying at all so to you and your brother as a start DONT GO NEAR HIM :!: ,it so aint worth the hassle,it also turns out my 15x10 -70s are illegal aswell so i now also need to get a new set of rims to replace them before my truck gets recerted,and his excuse,he thort id borrowed the wheels just to get cert, ,even if i had he should of failed me and told me to go borrow someone eles,its just bullshit after bullshit after bullshit

[UBZ]

OMG
That is utter b*&%@$#t.
Does your cert plate say your wheels are ok? Report him to the LTSA - I mean how many other guys are driving around thinking their trucks are sweet and legal
Sounds like a good case for small claims , might score your new wheels for free being that you modified them on his advice.