"bulletproofs" hilux specs and Videos

[Bulletproof]

You are quite right it was a CLROC trip of 2004 and that is Clive on the back. Pity about Linda real "salt of the earth stuff" . On that trip to Haast only Linda and myself got through the bogs of coppercreek. For the last 10 years Andy, Paul and Nigel and others go away for a week 4 wheel driving . Andi has done alot of work to the Hand -bag and has got it going really well. Last xmas at westpot he became the first truck ever to drive the hill out of the little totara.Knowing Andi he won't let us forget it. You will have to join us at our christmas camp sometime. Tim Evans did about 4 years ago. We have alot of fun and push the limits. I will put a photo of Linda on the site sometime as a tribute to a good friend.
Richard

I spy lots of old faces from my past days in CLORC in those pics.

Looks like Clive on the tray in the river, and that is Lindas' old 70, since Andy has had a play with it. All those tracks are bloody good as well. Did you complete the staircase from the old confluence track, or start at that end? Last time I was there was just in time to see it all getting washed away in xmas of 02 (i think).
When I have finished the full rebuild, might just have to head back to the coast for a look. I'll give you boys a holler.

[Bulletproof]

Testing the steep hill on the track from costello hill to little totara. Flag and myself doing the first run through aug 2006




Anzac 08 Going up petrol hill at reefton



Going over the top of petrol hill



Linda Simpson doing what she enjoyed most in the mud of coppercreek at Haast



Washing the hilux after only Linda and myself got through the coppercreek bogs 2004

[Bulletproof]

My rear spring set up , gives positive pressure to the side with no weight.








A video clip showing it working. Click on clip





My roll bar .made from 75x6 Seamless pipe. Arms fold up to load truck



Bulletproof

[Shane]

Testing the steep hill on the track from costello hill to little totara. Flag and myself doing the first run through aug 2006

The track a little more worn in now,great track though...have to do that mowerbones one next time over that way.

[Bulletproof]

In a number of post I have mentioned my dual air system.

Most of the time I run naturally aspirated, but to keep the pyrometer temperature down, for overtaking , Steep hills and bogs and other challenging situations I use the air conditioner switch to turn the supercharger on .

When I hit the switch the electro-magnet on the supercharger engauges and at the same time a vacuum switch closes the naturally aspirated side off by means of a butterfly.
The inlet manifold is off the NZ new hilux which has the 75 mm inlet pipe { not the 60mm found on the imports which restricts air and make hilux gutless } The manifold has been modified to take another intake from the supercharger.

As the boost is increased the compensator on the fuel pump then activates to give the extra fuel

Here are some pic to show the set up {Photo bucket has cut the sides off so to see full picture you need to save as}

Shows the dual system from the air cleaner



Shows the butterfly to shut off the naturally aspirated side and the alloy block I had made for the other intake



Shows the supercharger from air cleaner to intercooler [ the intercooler is off a 3litre prado }



Shows the electro-magnet on the front of supercharger and the belt adjusting pully off a corrolla and the crankshaft pully which is 215mm dia. This is a ring about 30mm thick that fits over the air con pully and is welded on and balanced



bulletproof

[KiwiBacon]

That's a nicely thought out rig.
If you see a white rangie flashing it's lights at you on the coast, it's probably me, stop and let me take a closer look.

[Bulletproof]

I have taken a few pics. of my Tranfer-case modification for any one running the heavy chain driven type.
These are normally operated by an electric motor on the back. This is a worm drive setup, but gives trouble and having electrics under water is not a good idea.

This is the one I am talking about.



I have converted mine over to air working off my ARB compressor. I use the same switch on the gear lever but instead of operating the electric motor , it activates an air solenoid which feeds air to the ram. When the box is engaged the red light illuminates by the gear lever.



Here is a picture of the ram on the side of the box



Picture of the lever instead of electric motor.



The system works really well and you can change in and out of 4 wheel drive at any speed on the move, as long as the hubs are engaged.

Bulletproof

[nzhunter]

Frekkin nice hilux mate, given me a few good ideas of what to do to mine next

I notice your've even changed your handbrake set up to replace the Umbrella style.

[Bulletproof]

One of the most useless things on a Hilux is the handbrake, so this is how I have solved the problem.

I have fitted Subaru front 18mm caliphers with the self adjusting handbrake on to vented hilux front discs.



Others have done this and tried to use the handbrake on the dash. This does not work properly and you still don't have good handbrake.
Instead I have moved the Handbrake lever to the Centre. I have used a Landcruiser Lever that seems to have the right gearing.



I then modified the body to bring the 2 cables inside the truck by the rear seat. This is good because no way can mud and dust get in the cable from this end.
I then went to the wreckers and found an equalizer that would work. This connects to a 6mm threaded rod that goes to the lever.



I then cut up a peice of plastic sewer pipe and using a heat gun shaped it to to fit the body and cover the linkage.The little cover on top is to get to the adjusting nuts.



This is the finished article with a small console on top.



My brakes are miles better than what is needed for certification. For cert. a truck has to go to a 100k and back to 0 three times under in under 2 minutes with a max braking of 4.4 secs.
My truck does the three runs in 1min 10 secs with each braking improving and that is the important thing because it shows I have not got brake fade. 1st run 4.1sec 2nd 4sec and 3rd run 3.9

Hope these photos may be of help.

bulletproof

[Heath]

I like the centre diff spring set up.


I wonder what class that would qualify as for trialling. Might be a way of getting a little more traction without a traction aid.

The twin cable to the cab hand brake would tempt me to find another couple of handle to use as fiddle brakes. Ever been tempted to do just that?

Heath

[Bulletproof]

All the photos of the hilux to date have been on the 35 BFGs because that is what I use most of the time. For next weekend I have just fitted the 35 simexs so here is a pic.



bulletproof

[gary_in_nz]

my god, that is awesome, rekkon it would look good BLACK!!!!

Hey you said some of the previous pictures were taken from videos?? got any links to them online so we can see this in real time action??

cheers

[NJV6]

Richard,

You have taken a good approach to your Hilux doing practical mods and it is the small mods that make the usefull differences I have found.

We were up in your area last Easter (07) and Flag was riding shotgun with me for a day up Karamea (Smiths C & Blue Duck) after he broke his Rear Diff up Denniston. Nuts will remember this. Also good friends of Mike & Sandy, Has Mike got his cruiser back from its mods yet?

The Subaru mod. I have a drum in disc rear handbrake and it is bloody hopeless. Can any late 80's sub fit? Do you change from your original calliper or add the sub one?

[rokhound]

Subaru leone calipers are what I used. They were from a 1986 wagon. I have had the subby calipers for about 6 years and they are great. Some rigs do need a gruntier master cylinder though as you can imagine. Hiluxs don't have an original caliper, so it all has to be changed. I personally don't like where Richards' calipers are mounted, as with the some of the terrain I drive on, they would get ripped off. So mine are mounted up quite a bit higher.
Really like the moulded sewer pipe mod though (that is way cool )

I do have a question for ya Ricahrd. How much force is exerted by the air ram you have? I am thinking about using airrams for low range selection on my dual trans cases, and 2wd/4wd

[Bulletproof]

I will answer the questions to two different posts here. I like to see discussion on these things as it stimulates different thoughts.
Firstly my calipers are off a subaru leonne of 80s-90s being the 18mm front disc brakes with the handbrake. They will easily fit on any hilux ,surf with semi floating rear axle. All you need is a base plate made up that has 4 holes to bolt onto the axle housing of about 16mm flat plate and 2 holes to hold the caliper. I could post a photo tomorrow of the plate. Then you use the front vented discs off a hilux and get them machined to 18mm.
The rear wheel flange has to be turned down about 3mm to make a nice tight fit in the disc and this what locates it.

I also had to fit a packer shim at the end of the axle to take out excess end float of the wheel bearing otherwise the self adjusting handbrake doesn't work properly and you end up with a soft petal because the discs get pushed apart.
I have not had to change my master cylinder as it just fine

Rokhound mentioned his are mounted higher. I personally do quite hard 4 wheel driving and have had no problem.
The reason I mounted mine where they are is to keep a straight as possible line for the handbrake cable which gives the best hand brake . Going above the spring means the lever is heading down hill which creates friction in the cable.
Im open to suggestions if it can be improved.
The only problem I have had with rocks is crushing the pipe to the caliper and have since moved all brake pipes to the top of diff. I have also moved all shock mounts up for same reason.

Regarding the operating pressure of the ram on the side of the gearbox. It is 110lbs the same as the air locker.

I welcome feedback if things can be improved.

Richard

[rokhound]

Yes, I see what you mean on the cable issue. I don't have that problem as I don't have leaf springs. I did have to mod the handbrake mounts a little to make it work, but then the handbrake wasn't so much of an issue to me either as mine was not road legal.

The new Rig I about to start on the other hand will be certed, and has to be at the very least as capable as the Mutt is. I am still at drawing board stage with the new one, but lots of pieces are falling into place. As I will most likely be running airbag springs (in conjunction with coil overs) I will have a considerable amount of compressed air readily available, hence the question about the air ram. Do you find there are any issues with seals or rams getting damaged with silt and shit?. Or is it that when compared to the old electric setup, that it is better.

[NJV6]

Thank you both for the Sub lesson.

If you could get a photo of the plate that would be great. I imagine the surf/hilux rear ends to be not too disimilar to a semi floating Paj rear end.

I noticed you commenting about the photo's being to wide - it is done by this site - if you resize them before you put them up to 600x400 they fit the screen perfectly

[NJV6]

Do you find there are any issues with seals or rams getting damaged with silt and shit?.

That air ram looks the same as the winch challenge people use for free spools on winchs et al so i'd imagine they are ok in the crap.

[Bulletproof]

Thank you both for the Sub lesson.

If you could get a photo of the plate that would be great. I imagine the surf/hilux rear ends to be not too disimilar to a semi floating Paj rear end.

I noticed you commenting about the photo's being to wide - it is done by this site - if you resize them before you put them up to 600x400 they fit the screen perfectly

Thanks for tip on the photos

Here are couple of pics I hope they help
I have welded my original backing plate to the mounting plate for extra protection






Richard

[Bulletproof]

Do you find there are any issues with seals or rams getting damaged with silt and shit?. Or is it that when compared to the old electric setup, that it is better.

The first ram I used did eventually pack up after about 5 years. But even when this did happened I just clamped a pair of vise grips to the rod and held it in for 4 wheel drive for the rest of the trip.

I now have longer 2 way ram 150mm long by 20mm piston .The total travel required is about 30mm so with the longer ram the seal is roughly still in the middle and not where grit would get to.

On the double acting ram I am only using the pressure side as single ram. The advantage of having the double one is I can exhaust it into the cab away from the shit.
In a days 4x4ing it probably only gets activated a couple of times so is not high use.

You can also use a hand brake type rubber on the rod to stop the shit.

Richard

[Bulletproof]

my god, that is awesome, rekkon it would look good BLACK!!!!

Hey you said some of the previous pictures were taken from videos?? got any links to them online so we can see this in real time action??

cheers

Just a small clip of petrol hill at anzac 2008

For anyone that doesnt know about petrol hill. It is a rocky hill climb with solid rock face at the top. In the early days only V8 petrols got up. In the winch challenge last year no modified trucks drove it.

some how the aspect is wrong should have been 16x9




I think you have to double click on picture

Bulletproof

[KiwiBacon]

Just a small clip of petrol hill at anzac 2008

Sounds way different to everything else I've heard.

[Bulletproof]

Another small video clip.

Testing a small bank on the bulletproof chasm track 2005 with Paul Delis and Nigel Harris.

http://s299.photobucket.com/albums/mm28 ... 6aa04e.flv

Cheers Richard

[Bulletproof]

Last video clip



Bulletproof

[fisho]

good pics and info richard . see you on the weekend .
cheers flag.

[lockie]

Can you show us your upper mounting point for your rear shocks please. Are they up through the deck of the hilux?

[Bulletproof]

Can you show us your upper mounting point for your rear shocks please. Are they up through the deck of the hilux?

I got sick of bending shocks on boulders so moved the bottom mount on to the top of diff. To gain the needed height at the top I have lifted the deck 75mm



Another advantage of this is you gain a better departure angle . Also you get less floatation in deep water.

I then went to the wreckers and found some top shockabsorber mounts that looked like they would work. I think they were off a nissan or Mitzy but cant remember and welded them on to my chasis.






Hope this helps

Richard

[NJV6]

Pajero lower rear mounts.

[lockie]

Thats great thanks for that.Another question though ; how much travel do those shocks have?

[Bulletproof]

Thats great thanks for that.Another question though ; how much travel do those shocks have?

Im not too sure but they are the Rancho RS5000 model RS5008. You could look it up on the internet. If you wanted more travel you could build a cross member across the back between the chassis and mount the shocks on an angle to the middle