Project Hilux 101

Starting a project or modification? Then post it's progress here and show us some pic's.
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muddy_munke
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Project Hilux 101

Post by muddy_munke »

Now, I'm not sure how to post pictures...(Help)
But, I'm in the process of modifying my Double Cab Hilux.
I brought it November 06 and drove it until the Warrant and Reg ran out.
Had all these plans and ideas in my head but no where to work on it. It sat outside at a mates place for a few months doing nothing.
I finally convinced my parents to let me borrow the garage to do the work in. :D The fun began.
Image
Image
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The truck
The truck was as follows when I brought it:
1989 Double Cab Hilux
Repainted in Black 8)
4Y Motor. 300 000kms
Bugger all rust in Cab, Tray not so flash.
31inch Mud tyres.
Bag of new rubber bushes in the glove box :lol:
Big ugly alloy bullbar.

The Plan
Its my first project, first major thing I have ever really done to a vehicle so its a learning curve but I'm loving it.
The planned mods are as follows:
1,Falcons in the rear, rears up front. (I know its been done lots but its a good start for my first project and its cool 8) )
2,Rather large 37inch Tyres (new whitespoke wheels)
3,Wider rear axle
4,Ifs hub swap
5,Disk brake rear Urgarded front disks etc
6,New motor, (thats another story)
7,High steer or crossover, havent decided yetbut have IFS box.
8,Bar work and bumpers etc
9,New comfy seats 8)
10,Winch and compressor we bit down the track.

This is all I can think of at the moment. I know all this stuff has been done before. But like I said, it's my first project and I don't want to jump to far into the deep end. However, I am trying to do things a we bit differently. A we bit of trial and error I geuss. I have put alot of thinking into fabrication etc but even with stuff I have done I want to change or add to already. :roll: It never ends....

So far I have almost finished the Falcon swap, half done the disk brake conversion and half done the comfy seats. I'll post pics when I learn how to. Its hard to explain things without pictures so I'll wait until then.

The motor,
Now I brought this with all intentions of modifying it. So wasn't to worried about the stupid motor. Now I have to decide what to put in.
Currently it has the 4y. 300 000kms and a buggered Clutch. So I need ideas etc for motor conversions.
I kind of want diesel for rivers etc, but i geuss petrol can be water-proofed too.....

Anyhow. When I know more about posting pictures. I'll throw some up so you can throw suggestions and comments my way.

Cheers for reading,
Daniel
Last edited by muddy_munke on Mon Nov 19, 2007 7:55 pm, edited 3 times in total.
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MAHINDRACJ4A
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Post by MAHINDRACJ4A »

there are lots of engines you could transplant into it the skys the limit, anything from a 1uzfe,1ggte,7m,5m,1/2jz

depends on how much you want to spend really and how much power your after

mark wrote:The first thing you have to do (if you haven't already) is create a new album in Gallery (Photo Albums in the menu) and upload some photos to it. The instructions for this are in the Site Help FAQ.

The second part to posting images in the forums is to link to those photos that you have uploaded into the photo albums. You can do this by following these steps:
1. Browse to the photo that you want to link to (I usually do this in a seperate browser window, or a different browser tab if you have Firefox or IE 7).
2. Decide if you want the thumbnail image (small one) from the album page, or whether you want the big version of the image (by clicking on the thumbnail).
3. Right click on the image you want to link to and either select "Copy image location" if using Firefox or similar, or select "Properties" and copy the Address (URL) field in the popup dialog if using an inferior browser.
4. You will now have the URL of the image on the clip board ready to paste into the forum.
5. In your forum post window click the "Img" button once. A special tag will be appended to the end of your post that looks like [img]
6. Paste the image URL after that tag. This can be done by selecting Edit->Paste from the menu, pressing Ctrl+v or by right clicking after the tag and selecting Paste from the context menu.
7. Click the "Img" button again to close the [img]tag%20with%20a[/img]. You should end up with something that looks like Image
8. Preview your post to make sure that you have linked to the image correctly, and when happy with your post click Submit.

Hopefully that is detailed enough to make a brain surgeon out of you. I guess it seems daunting, but once you've done it twice you'll know what you are doing.

Note that you can link to any image on the Internet using the same technique. It doesn't just have to be in the ORE albums.
Last edited by MAHINDRACJ4A on Sun Sep 23, 2007 1:23 pm, edited 1 time in total.
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1977 Mahindra CJ4A - 1GGTE 260hp Supra Engine - 3" Lift
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rangimotors
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Post by rangimotors »

sounds like it will be cool, have a read of this and post up some pics, it should help http://www.offroadexpress.co.nz/modules.php?name=Forums&file=viewtopic&t=7367&highlight=post+pics
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muddy_munke
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Post by muddy_munke »

Thanks for the help with the posting of pics. Sorted now.

Finally got it in the garage about 3 weeks ago. Being away with work and stuff I don't get as much time as I would like to work on it.
Image

This is the build so far.
I saw similar mounts to these and thought these things up in my head for the front hanger for the Falcons. Good idea and the look kind of cool. But I will be modifying them to have a 'slider' or bit of steel angled back to the chassis so they don't get caught on things.
Image
I cut into the chassis :shock: and welded these in place. Figured there would be more weld and strength doing it this way. Might lose a we bit of ride height as they sit higher than welding them to the bottom of the chassis but not enough for me to worry about..(copied the idea from a mates truck). I will be gusseting the top of the chassis to compensate for cutting the bit out on the bottom.(still have to do that though)
Image

For the rear of the falcons, I decided instead of just welding 50mm box onto the bottom of the old shackle mounts, I'd make some flash new ones.
I got some 100x50x4 box and put a holesaw through the top. Cut some tube the right size for bushes and welded it into place. I capped the box with 6mm plate for added strength and it looks nice too 8) .
And no the shackles won't be stying this length before anyone says anything. :D
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Image
I will be getting the springs redrilled a bit further back that other builds. This is because it's a double cab and I need the axle a bit further back so the tyres clear the back of the cab when flexed up. Here's a snap of the tyres and wheels.
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37x12.5x15 Wranglers. Were reasonably cheap. So I'll see how they go as everyone seems to comment on them.

Other half completed jobs I have done so far are the disk brake rear and the comfy seats 8)
Image
The disk brake rear I have just copied other builds. Got the brackets laser cut copying a set my mate had for his rig. Then got the hubs(if thats what you call them) machined so the disk would slot over them.
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Have brought galant calipers to finish the job, just waiting until the falcons etc are done.

The comfy seat conversion 8)
Previously it had the knarly bench seat, which was cool to take 6 people. But when your on a steep hill you slid down the seat. Not all that handy when wheeling.
So out with the old, in with the luxury. Picked up some Primera bucket seats for not much. Seems how it had the bench seat there were only a total of 4 mounts. I needed 8. So for $1 off trade me I brought some Hilux Seats and cut the mounts off. I welded them on in the correct place and this is how they look 8)
The drivers side isn't bolted in yet so that is why is isn't square.
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Image


I know I have alot of options for the motor. I want as much power as I can get for the beast. I will need it with the tyres. Lucky I already have 4.88 Diffs. I geuss I can spend around $3000-$4000 dollars give or take....
But don't really know what to put in it yet.
Anyhow, thats about it for now. Sorry for any spelling mistakes. I'm too young to know how to spell properly :roll:

Thanks Rangimotors and MAHINDRACJ4A for help with posting pictures.


Cheers Daniel
Last edited by muddy_munke on Mon Nov 19, 2007 7:56 pm, edited 1 time in total.
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rangimotors
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Post by rangimotors »

build looks great mate can't wait to see it out there on a few trips, you look pretty capabe with what you can do your self so with that sort of coin for an engine it should be a beast 8)
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Post by hosehustler »

I see the falcon's you have are a 4leaf set from a wagon, I had these on mine but found them to flexy/soft, all good off road but really rolly polly on road, I got a set off a XF panelvan, they are 6 leaf and ride 40mm higher and have more pleasant on road manners, flex just as well off road :wink:
I think the utes ae 6leaf as well :scratch:
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muddy_munke
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Post by muddy_munke »

Interesting option on the motor....... Cheers though.
And the falcons are a six leaf pack. I'm going to play around with it to see how i like it. The four does seem soft. Had one side of truck sitting on them and could flex springs by pushing on chassis with my thumb!
Anyhow, I'll prob end up adding the leafs back. We'll see.

Daniel
Last edited by muddy_munke on Tue Oct 02, 2007 8:16 pm, edited 1 time in total.
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Post by SupraLux »

Thats some nice work - good out-of-the-box thinking too... good to see.

Engine-wise your best option in that budget would be a 2JZ stright 6... you might also fit a 1UZ V8 in if you do everything yourself.

I'd advise against that Chev V8 without the computer... I know they go bloody awesome with it - I put on in a cruiser a while back and it was stunning. Why go backwards and carb something like that as he suggested since it will cause you problems offroad.

Steve
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Post by Goose »

Looks good :thumleft:

Good on ya for doing it your self, the fab looks great.

One option to think of for your motor if you like your diesels is a 3.0TD, (hilux, will need gearbox adapter/new gearbox)or a 3B/13BT (3.4L landcruiser nonturbo/turbo Note: will need gearbox adapter). Both would give you good usable power, although the supra conversion is popular for a reason, easy (comparitivly) and good power......

Lots to think about, keep going!!!! 8)
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Post by ToySurf »

How far back did you get your falcon springs re-drilled?
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muddy_munke
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Post by muddy_munke »

Yeah read about the motor being carb. I wasn't to keen after that. Would love that much power though.
There is a 3L TD Surf wrecking on Trade Me. I'm going to ring the guy tomorrow to see how much he wants for the motor and everything. How many km's would be too much to not bother with??? Obviously the less the better. But just wondering as the motor he his selling has done 210000kms. http://www.trademe.co.nz/Browse/Listing.aspx?id=119147415
As for the supra option, I have thought about it, but think I will shy off this idea as everyone has done it already.

I haven't got them drilled yet. Was thinking of taking them in this week.
Other people have had them drilled around 120mm back from the original hole I believe. However, with mine being a double cab and having a different shape wheel arch to a Surf, mine will be a bit further.
With my front spring hangers where they are and drilled they way they are the end up distance is around 170mm. However this isn't as far back as MATT4U's I belive he did his 185mm??? I'm not sure how far is too far though.....

Haven't got much more progress, mig ran out of gas :(
So been thinking up how I'm going to do a few more things. Also someone had put the idea of bobbing the tray.... So we'll see what happens there!!!!

Cheers for looking and the comments guys. Back to the cold garage for me.

Daniel
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Post by ruf_zuki »

ive got a mate that taking his vg30det out and replacing it with a rb26 at the end of this osca season so you should snap that up
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Post by Frugil »

Well done Dan, not looking bad at all. It's about time you sorted a place to do it and got it underway...... :P How on earth did you convince the parents?????

Perhaps a solid reliable commercial style NISSAN engine would be a wise choice :lol: :lol:

Have fun

Ken
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Post by muddy_munke »

Things have come to a we bit of a slow patch at the moment. Have a few other things on my plate. Have taken my springs in to be re-drilled and have made some little sliders, an addition to my front hanger for the falcons. Hopefully nothing will get caught up on them. with these additions.
Still can't decide on my engine. And thanks for the ides Matt and Ken, but a Nissan engine will not be found under my bonnet. :shock:
Hard trying to find a 3L Diesel with all the right bits. Could be keen on a Lexus but I hear you need lots of extra bits, same with a 1jz or 2jz.
http://www.trademe.co.nz/Browse/Listing.aspx?id=120348115
I like it...... The only problem I am having is I am un-aware of all the extra bits I actually need. I know there are some and I will have to buy them. Thats not the problem, it's just knowing what I need to look out for and track down.
Any comments would be helpful.
Cheers Daniel
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Post by MAHINDRACJ4A »

most bits for lexus conversion can be brought off trademe

the bellhousing or adaptor plate
flywheel
clutch

just to name a few
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Post by Steve_t647 »

look for a 3.8 holden, you can convert to manual or keep the auto and get a transfer case adapter, hard bit is finding the holden donor.
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Post by MAHINDRACJ4A »

Steve_t647 wrote:hard bit is finding the holden donor.


not unless you have the money $$ :lol:
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Post by SupraLux »

MAHINDRACJ4A wrote:
Steve_t647 wrote:
hard bit is finding the holden donor.

not unless you have the money $$



I have one and they are not that expensive or hard to find... :) You have 2 options with the Holden - keep the auto or go 5-speed - the 5-speed has a couple of options too - you could stick with your factory G52 or fit a later Surf R151.

Each has its pro's and con's - I'm fitting mine up with the auto at this stage - and I believe another guy locally is doing the same with one he's doing - so if you were going to go this way we will probably do a group-buy of the transfer case adaptor out of the US to avoid having to deal with Marks adaptors and their nz agent. It would also save quite a few $$$

One advantage of staying auto is that you get a bit of control at lower speeds - kind of like a cheap crawler box - although the disadvantage would be power surging (having to give it some to get it to climb then having to back off again quickly so you don't fly over what you just climbed). If you have a good tight auto this would be minimal, and some left-foot braking would probably minimise it.

If you wanted 5-speed then you have three options - Marks adaptors (crappy finish, expensive NZ agent, pain in the ass to try and deal with in my experience), Castlemaine Rod Shop (never dealt with them) or Dellows (nice looking product, good reports from those that have used them) - all aussie companies.

Oh, and up the top you said you wanted to do a conversion that is different to what everyone else has - so in that case you probably don't want one of these engines as they have been done... so has the lexus, the 1J the 2J the rover, chev V8, Ford windsor, etc..... I'm afraid most things have been done... might be best to pick the best bang-for-buck and go with it... This one has its advantages in that you can get good power and torque in a compact engine thats relatively easy to find and donor whole cars can be bought cheapy.
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Post by SupraLux »

muddy_munke wrote:Hard trying to find a 3L Diesel with all the right bits. Could be keen on a Lexus but I hear you need lots of extra bits, same with a 1jz or 2jz.
http://www.trademe.co.nz/Browse/Listing.aspx?id=120348115
I like it...... The only problem I am having is I am un-aware of all the extra bits I actually need. I know there are some and I will have to buy them. Thats not the problem, it's just knowing what I need to look out for and track down.


Thats an ok price for one of those. Check with the boys at k-road auto spares in auckland - they have good toyota bit stocks and are very helpful.

What you need (I can source all this for you) is either an aftermarket bellhousing to bolt your gearbox up or an auto bell with an adaptor plate setup (around $200), a flywheel (around $450-500), a heavy duty clutch kit (around $400), some time, random other bits and fab skills, which you have.

If you get the complete wiring setup then its not too bad to get running - a couple of power wires, a couple of earths and you're done...

Steve
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Post by hosehustler »

I fyou want to do something a little different, there's a 2JZGTE in Buy/sell for sale.


3litre, twin cam, twin turbo 8)
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Post by muddy_munke »

Tim, That would be a pretty out of it conversion. Nice looking motor too. Drules.... :P

Steve, thanks for the input, I realsie what I said and yeah every conversion under the sun has been done. Your right, best bang for buck.
I really wanted a diesel. But they're hard to come by and expensive.
Looks as if I could end up doing a petrol motor instead. I have aquired the W56 gearbox off the Surf I got. I want to use that as is has more than just 4wd Hi and 4wd Low as my current box has. Also, my current gearbox is noisey and hard to get into third sometimes.....
So anyway, back to the motor. Will keep an eye out for a bit longer until I really need to think about buying one.

Cheers Daniel
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Post by muddy_munke »

Progress has been made. Not much but a we bit. Money has dried up as Polytech fees needed paying!!!
But rear end is all back in. Have made a start on the front now. Trussed the axle and rebuild kit for it seal etc. Have made a start on the new front cross member and threw the tray on the back to see how it looks.
I'll throw some pictures up next week when I'm back from being away from work.

Cheers Daniel
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Post by muddy_munke »

Have got a 5M I can get my hands on and I'm keen to get this thing back on the road/mud. Now I just need to confirm.
With the 5M motor, I need a W58 Bellhousing so I can bolt the W56 I have lying around straight up to it?
After lots of searching etc I am a tad confused.
Any help would be good.


Cheers Daniel
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Post by hosehustler »

There used to be a real good article written up by suprasurf with all the relevant info regaurding the swap....unfortunately the article has been removed or is "hidden" on his site so I can't post a link :(
I can tell you though you need a "M series" bell off a "W" series celica/supra, only this one will do the job.
Some early crowns or cressidas had a 5M in them with a manual gearbox which wasn't a "W" series box and therefore will bolt to the 5M but will not bolt to your hilux gearbox.....so be careful to get the celica/supra bell :!:
you also need the clutch fork, thrust bearing carrier, clutch and a flywheel (all celica/supra) to make it a clean simple conversion.
Also be aware that the "G" series engines from the celic/supra (2litre DOHC 6 cyl) also will bolt up to "w series boxes and therfore a hilux box....but will not bolt to a "M" series engine.
Hope that helps, be careful when you purchase to get the correct parts :wink:
any questions don't hesitate to ask.
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Post by Smurf »

The link Hosehustler mentioned

http://www.4wd.net.nz/supra/
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Post by hosehustler »

Smurf wrote:The link Hosehustler mentioned

http://www.4wd.net.nz/supra/


Thats the one :mrgreen: :wink:

But it's only half the article :(
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Post by Smurf »

yeah working on that, can't find the rest.. :?:
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Post by muddy_munke »

Thanks for the Link. Very handy. Will be keeping an eye out for the extras I need now. If anyone has anything I need and wants to sell them to me. Let me know :D

Cheers Daniel
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