1KZ surf transformed to Coil SAS club truck

[hosehustler]

just wondering did you use the back disks that came out on factory 70 series or the front ones on doing your disk brake rear end set up thanks

rears

[haydgq]

just wondering did you use the back disks that came out on factory 70 series or the front ones on doing your disk brake rear end set up thanks

Ive brought the 78 series Prado rear disks and they fit and locate nicely, I think all the 70 series Prados are the same disks and mine were $60 each from BNT.

[fweddy]

What sort of hand brake mech do those prados use? I guess its not a viable option else it would be being used?

Has any one tried using a drum hand brake setup like most cars do with rear disks. Just pulled the wheel off a 90 series and had a look under there - without pulling the calliper off and removing the disk its hard to see how it could be mounted but is that an option? It appears the mounting bolts have a different pattern but are there more issues than that?

[Steve_t647]

They are a drum handbrake and a disk foot brake system, if you were going as far as you suggest Fweddy would it not be just as easy to swap in the other diff? Most convert to the disk brake conversion for the braking and the fact they clear the mud and work better after being in mud and wear better after being in mud.

A drum brake is actualy more efficient due to the way it works, as the wheel rotates the friction causes the drum brake to apply more pressure, the disk is clamped and if not on tight enough will not tighten if it starts slipping but is less likley to become gummed up and not operate at all, this is why you may have to replace the brake booster also as drum's require less pedal pressure and volume.

I don't like the drums as have on more than one occasion had no rear brakes after the mud dried and had to pull the drums off before going out the next day, and again the next morning to go home, but still run them

[fweddy]

They are a drum handbrake and a disk foot brake system

So when those disks are being used I take it the drum is just ignored and hence why the MR2/subby/maxima etc callipers are used rather than prado?

What combination did you use Tim?

[IcedJohnno]

They are a drum handbrake and a disk foot brake system

So when those disks are being used I take it the drum is just ignored and hence why the MR2/subby/maxima etc callipers are used rather than prado?

What combination did you use Tim?

The drums are ignored cos if you actually use your 4wd as God intended it to be used (like we do), the shoes wear out very quickly.
Every warrant I have to adjust them up and I have replaced them several times.

I normally don't bother with the handbrake (a product of growing up in freezing winter climates and working on the Ice) however with a turbo timer this is a pain I A. I have even gone to the extent of milling some angled holes through my drums so I can clean the drums out with a hose, but still they wear down every time I go off road.

Go for the Mod like Tim has.
Cheers Johnno

[hosehustler]

All of whats been said is 100% correct, the drum type handbrakes (inside discs) goo up, wear out fast, etc, however they have far better holding power when applied.
In the pic below you can see the manually operated cable for handbrake, this is a mechanical set up in the MR2 calliper I used, similar to the Subaru, and Mitsi which have also commonly been used.
This set up won't ever give the same handbrake power as the drums, however it is good enough if set up properly for cert/wof, and is as reliable as hell for offroad....perfect for a conversion.......no more drums
Oh and I had 2 new cables made for the task, they utilise the exsisting hilux lever inside the cab.

I normally don't bother with the handbrake (a product of growing up in freezing winter climates and working on the Ice) however with a turbo timer this is a pain I A.

Oooooh I have a turbo timer.....and and AUTO with that magic little "P"

[IcedJohnno]

All of whats been said is 100% correct, the drum type handbrakes (inside discs) goo up, wear out fast, etc, however they have far better holding power when applied.

I normally don't bother with the handbrake (a product of growing up in freezing winter climates and working on the Ice) however with a turbo timer this is a pain I A.

Oooooh I have a turbo timer.....and and AUTO with that magic little "P"

OK Tim, I concede! There is ONE Good thing about driving an Auto!!

[LOLYF]

What sort of hand brake mech do those prados use? I guess its not a viable option else it would be being used?

Has any one tried using a drum hand brake setup like most cars do with rear disks. Just pulled the wheel off a 90 series and had a look under there - without pulling the calliper off and removing the disk its hard to see how it could be mounted but is that an option? It appears the mounting bolts have a different pattern but are there more issues than that?

I did it this way with my first disk conversion, used the complete backing plate from a prado modified to fit my hilux axle housing. It is a fairly strait forward swap. When I got sick of the hand brake filling up with crap i ditched it and have gone with the suby set up.

[hosehustler]

just wondering did you use the back disks that came out on factory 70 series or the front ones on doing your disk brake rear end set up thanks

They are rear discs from a 70 series prado/cruiser

[hosehustler]

Here's a finished parked at home pic, heading up to the Godley glacier in acouple of weeks so the flexing/trail pics then

[PR]

OOOOOOOOOOOOO that so shiney

[Jezza]

Looks bloody good , are you going to have another shot at that hill?

[petefj40]

All of whats been said is 100% correct, the drum type handbrakes (inside discs) goo up, wear out fast, etc, however they have far better holding power when applied.
In the pic below you can see the manually operated cable for handbrake, this is a mechanical set up in the MR2 calliper I used, similar to the Subaru, and Mitsi which have also commonly been used.
This set up won't ever give the same handbrake power as the drums, however it is good enough if set up properly for cert/wof, and is as reliable as hell for offroad....perfect for a conversion.......no more drums
Oh and I had 2 new cables made for the task, they utilise the exsisting hilux lever inside the cab.

I normally don't bother with the handbrake (a product of growing up in freezing winter climates and working on the Ice) however with a turbo timer this is a pain I A.

Oooooh I have a turbo timer.....and and AUTO with that magic little "P"

Looks good Tim!! Nice and shiny.
The hand brake via the disc isn't as good as the drum. But I think it's a small price to pay for hassle free brakes. I'm very happy with the rear discs on my setup. So I'm sure you'll be happy with yours.

[kaney]

very nice tim!

[Bulletproof]

[quote="hosehustler"]
This set up won't ever give the same handbrake power as the drums, however it is good enough if set up properly for cert/wof, and is as reliable as hell for offroad....perfect for a conversion.......no more drums
Oh and I had 2 new cables made for the task, they utilise the exsisting hilux lever inside the cab.




Hi Tim
To get a good handbrake you have to forget about the handbrake lever in the dash and fit a cruiser one in the middle of the truck with cables going in a straight line to the brakes. My one works fine.

Cheers Richard

[hosehustler]

Cheers for that Richard, I may go that way if I ever have WOF issues, having said that I have to say that the current set up is way better than adequate, superior to the old Mitsi callipers I had on the earlier surf, passed Certification and WOF
Oh and with the auto the "P" has to be used to get the key outta the ignition, however for the offroad situations where a handbrake is needed this one will work fine

[haynzy]

Cheers for that Richard, I may go that way if I ever have WOF issues, having said that I have to say that the current set up is way better than adequate, superior to the old Mitsi callipers I had on the earlier sur, passed Certification and WOF

Hey m8 any pics or diagrams of how you ran the cable, no point reinventing the wheel

[hosehustler]

Cheers for that Richard, I may go that way if I ever have WOF issues, having said that I have to say that the current set up is way better than adequate, superior to the old Mitsi callipers I had on the earlier sur, passed Certification and WOF

Hey m8 any pics or diagrams of how you ran the cable, no point reinventing the wheel

Yours is a different setup than the coiled surfs, if you're intendng to run two cables down either side then have a look at a std 4 door surf and see if that setup tickles your fancy, otherwise i'd do what bulletproof has and fit a handbrake lever on the floor by the gearstick, check out his "specs" thread for the details of his handbrake lever....you won't get a more powerful pull setup than his

[haynzy]

cheers for that, I was lookin at mine today and couldnt see how the stndard setup would work

[hosehustler]

Looks bloody good , are you going to have another shot at that hill?

won't have time to climb way up there on this trip, but by god that was FUN
I don't think i've laughed and hooted as much since that day.....one day again i'll go up there

[hosehustler]

Another finishing touch I thought may come in handy to others, wired up the winch and did it a little different to the norm but i'm certainly not the first to do it this way
Winch is a pretty standard low mount winch, Ramsey 8500pound cheaper of the USA made winches, still with the dollar now at 49c I'm glad I bought it 6 months ago


Decided to mount the solenoid box up nice and high and under the bonnet, this keeps it outta the mud and a bit drier. there's a couple of issues in doing that, first is to get some longer cable to go from the solenoid box to the winch motor, I just used the cables the would nomally have gone from solenoid to battery and got two made to length at the auto sparky, cost $26


The other issue is plugging in the cotrols when the solenoids are under the bonnet, simple fix is to run an "in cab" control, very simple, brought a bit of black 3 core from bunnings $8 and a switch etc from jcar and ran some wiring to the cab, also disconected the signal wire power feed from coming off the solenoids and it now comes off the ignition and then back to the solenoids, this means the winch switch only operates when th ignition is turned on (stops the kids playing), and the plug in controller could also be used if ever needed
used a missile launcher style switch which s spring loaded. up for winch in, down for winch out, return to centre means it must be held on for winch to operate and the cover stops accidental operation.

[monaro427]

thats how i mounted my control box in the engine bay high and dry

[hosehustler]

Another teething problem i've had has been the rear springs, the early 80series I used provided perfect length and flex, but I tend to carry a fair bit of recovery gear, tools, parts, hi'lift jack, and 5kg of extinguishing agent, all adds up and the spare wheel hanging outbak contributes to the "draggin it's ass effect" and I haven't even put the overnight gear in
Take it all out again and it's perfect
So i bit the bullet and put a set of aftermarket Dobinson 80 series rears in (STD length), they carry 30% extra weight than a std 80 series set, height was just perfect for a surf (4-5 inches lift), , chucked all the gear in and it's a nice height and has some length left for the overnight gear

Took it out over the weekend offroad for it's maiden voyage and it's just great offroad, better that i'd hoped for, i'll add a few pics to this thread over the next few weeks as I hit the hills but apart from a few trail pics I think it's a finished thread as far as tech goes from me, hope all of you that have been following have enjoyed the build as much as me....
catch you on the trail
Tim

[Jafa]

Good stuff Tim, looks the shizzle. We'll have to catch up for a wheel at RR10, if it ever happens, probably more chance of catching up on the West Coast somewhere

[PigFmr]

looking good there tim ,and no i aint done much more to mine as yet,bloody harvest is neally ovr now and then back into it,u going to lake daniels?? maiden trip ??

vince

[hosehustler]

looking good there tim ,and no i aint done much more to mine as yet,bloody harvest is neally ovr now and then back into it,u going to lake daniels?? maiden trip ??

vince

Hi Vince, Got the weekend off already....I'm definately going to lake Daniels
Is kev coming

Good stuff Tim, looks the shizzle. We'll have to catch up for a wheel at RR10, if it ever happens, probably more chance of catching up on the West Coast somewhere

H Trev, yep a coast trip is definately on next time you're down here
oh and thanks very much to you and SNR for the parts I sourced from ya

[hosehustler]

Time for a bit of an update I guess, I've been busy enjoying this truck
So far since I got it road legal I've clocked up 4000K's Iv'e done several 4x4 trips so far had a play out at the waimak, done the Waipara, Ashley, Ashley track, Okuku, and an overnight trip on the Conway in which we went from the inland Kaikoura rd to the beach.
Have to say its been better than I had hoped, teething problems thus far have been rear springs and thats all so far.
The motor hasn't used any oil or water, makes brilliant power, and absolutely loving the auto
Starter was playing up, pulled it out and $10.63 for a new set of contacts and it's as good as new.
Onraod manners are superb easily travelling at the speed limit, and offroad well i'm loving coil springs man what a differance from leaves.
Have done some further work on the interior, wanted good storage in the rear with all the heavy stuff down low, and able to sleep in it as we do a few overnighters, so I got some plastic bins, plywood and screws and set to work with the skilly and jigsaw.
The front half is easily removeable (4 srews) and the seats fold back up, the rear part with the 4 red bins is permanent, they have good space for winch accessories, tools, spare bits and pieces, wet weather gear etc.
The bins up top are for clothes food, all the light bulky stuff.
Here's the result;







Also added somewhere to hang dirty ropes, it also doubles as a bit of security for the rear wheel, the top section is removeable to get the spare off but only after you take off a padlock


I haven't taken many pics on the trail yet, this weekend i'm off to lake Daniels on the west coast so should get some good shots in there
here's a few though, will update the pics after the weekend.

[kiwipete]

Very nice set up Tim. Have you made an attachment to the truck for the awning?

[J_Dub]

your freakin me out, thats exactly what im doing to the back of my surf, though im making a new back rest for the back seat, as my spare wheel sits behind pasenger seat. But im doing the same where the front half unbolts so the seat can be used, having the rear section permanent, having the front storage kept clean and dry for clothes etc, im just looking for suitable bins