Project Hilux 101

[muddy_munke]

OK, I need abit of advice. If i don't get it, the world will end...
I have my IFS Box. And I also got me a 2wd steering rod so don't have to worry about extending it etc.
Now, I'm moving the axle forward for a better entry angle. So this suits moving the steering box forward as am going high steer.
But, there is a body mount in the way...
Has anyone had this setup/problem before. I will probably end up just cutting it off. But with Cert etc, is this a problem? Can fabricate up a new one I geuss. But will be tricky...
Anyhow, I was looking at DeRanged and Steve's builds etc to compare too. Steve had removed his mount completely but I think he is using some kinky new way of mounting gaurds etc to the chassis?. And Deranged's one didn't look as far foward as mine so isn't quite the same issue.
If anyone knows what I'm on about could they shed me some light? I can post pictures if needed.

Also, a we bit of progress has been made. Have this WHOLE week off work to try and get most of the build finished.
So far, I have Armoured and completely rebuilt the front axle with IFS Hub swap and big new vented disks.
Removed old 4Y powerhouse which is for sale. Cheap. If anyone wants it. I had a guy come look at it when I had it on Trade Me. It was still in the truck so people could see it running. He came, he saw, he liked. He agreed on a price and I told him I'd have it out for him to pick up soon. I pulled it out for him, nicely labelled everything and even put a cover over it to reduce the grinding dust intake for him until he could remove it from my garage floor. Anyway, the F%&#ing Wanker (from Ashburton) decided to tell me two weeks later that "oh na I don't want it anymore". :chainsaw:
So thanks very F$%*ing much. Now I have a motor sitting in my garage that I can't sell because no one can see it running like a dream!! And I had that money spent on half a High Steer Kit . Now it looks as though I won't get the project finished in time as money is hard to come by!!! So if anyone wants themselves a motor, give us a PM. Alternatively, burn down Ashburton's entire Redneck type population, (as he was a redneck and not everyone there is), and I will personally deliver the motor to your awaiting truck....
Back to the progress, I have made trusses and armouring for the rear axle housing, Just need to get that welded on.
Have made the new front crossmember and spring hangers, to be welded also.
Went for a ticky tour a couple of weekends ago too. I picked up my Cressida. Sporting the 5M to repower the Hilux. Have most of the bits I need to do the conversion. Bellhousing and gearbox, thrust bearing carrier, Flywheel hopefully is sorted and clutch kit is sorted too. But I need to find a 7M Sump and Oil Pump and Pickup. I am led to believe I need this sump to run my High Steer??? If anyone has the required goods. PM me asap if ya want to help me out.

Haven't really done too much else. With this WHOLE week off, I should be able to nail most of the 'To Do List'. (Hopefully)

If anyone cares enough, I have pictures I can post up. In the end they'll end up on here anyway. That is, if I'm not in prision for being a good the good bastard the killed a redneck....
Happy Wheeling.
Daniel

[SupraLux]

If you want to keep your sump, lower your costs and not have to trash that body mount then move it (the steering box) as far forward as you can, rotated up a bit and go for the budget crossover option, which should fit under the standard sump.

Also or alternatively- since you're making new engine mounts, set them in place so that the engine will sit down nicely, then make spacers to raise the engine up to clear the steering setup (you'll probably need a body lift to close the bonnet).

As for the 4Y - what were you asking for it? The last Y-series engine I had I considered myself lucky when I got $150 for it. If the sale of the engine is threatening the entire build then you must have been offered s&*tloads for it...

On the bright side, I still have some cash for you for certain parts...

If you want some advice / help / whatever I'd be happy to bowl around one night and have a beer with you.

Steve

[muddy_munke]

AH!!! I love it when someone who knows that they're talking about helps out!!! Thanks Steve.
I have already got a body lift. Was planning on lifting motor and box anyway for clearance under the chassis. Never really thought about that helping with steering clearance. But now I see the light! Will 50mm be enough of a lift??

We Decided on $400 for the whole motor and box. Which I thought was pretty bloody good. Thats why I'm kind of gutted the Redneck knaffed off!!!

But now, anything I can get will do!! I owe Mum and Dad a bit of money too. So that's why the $400 Would have helped out so much.

Did you get that front chop from Ken? I still have your driveshaft in the back of my car....
Thanks for the help. Beer might have to be consumed at some stage!!!
Cheers Daniel

[MAHINDRACJ4A]

i got told by people i would have trouble finding someone to even take my engine away for free (3y) put it on trademe and had alot of interest and the bidding went to about $350 and my one was missing alot of things and alot of crap was blocked off but was a good runner none the less

[muddy_munke]

Hey all. I neeeeeeeeeeed help. Can't seem to find me some torque settings for the flywheel bolts on my 5M. Can someone advise me. Google sucks. Been reading things for hours but no luck.
Cheers Daniel

[monaro427]

hey there daniel the flywheel bolt torque setting is 75Nm or 54 Ft-lbs, thats out of my manual

[muddy_munke]

AH I owe you a beer. Legend Thanks man

[muddy_munke]

OK. Today I got something done. I removed the 5M from the old car.
Pulled off the auto. and put on the manual. Placed it in the truck and will make engine mounts tomorrow.
Now. After doing all this, I am left wondering if I should have used that large washer type thing...
Explaination!! Where the torque converter from the auto bolts to the ring-gear, there was a large washer/spacer. The same size and stud pattern as the ring-gear/ flywheel bolts. There was also one bewteen the ring-gear and the motor.
When I installed the flywheel for the manual, should I, or should I have not, put the space back. The one between the flywheel and the motor????
I bolted the flywheel on without it at first. But there was only about 1 or 2mm between the flywheel and the motor housing. So I put the space back in.
I'm geussing this may effect the clutch??? Only geussing here, I'm an apprentice sparkey, not a mechanic!!!
I know alot of 5M's have been done. So someone should know.

Other progress made:
Trussed and capped the rear axle.
Rewelded the rear shackle hangers to the chassis. Someone put them in the wrong place
Tacked in place the new front crossmember and hung the springs. Have made new shackles but will see how they work out with the weight of the motor....

All for now.
Daniel

[monaro427]

i only have that washer that is on the out side of the flywheel and not the one in between the flywheel and the motor, but saying that i also have the proper 5m flywheel as well, and you are using the 3y one is that right, ifso it may be wider than the 5m one,

[muddy_munke]

Hey monaro, na I have a proper 5M one. All machined nice like!!!! So your not running the washer between the motor and the flywheel. :scratch:
Do you have much clearance bewtween the back of the motor housing/bearing housing and the flywheel?? I only had a couple of mm. Thats why I put the washer back in there.
Cheers Daniel

[MATT4U]

did you get your flywheel lightned????

have you mounted our steering box yet? when I did mine I used a 2wd shaft, carefully removed the rose of the end, shortned it, re attached it. ya would never know it had been done

also something you may find usefull

Sump
http://www.offroadexpress.co.nz/modules.php?name=Forums&file=viewtopic&t=5695


Crossover
http://www.offroadexpress.co.nz/modules.php?name=Forums&file=viewtopic&t=5192

[muddy_munke]

Na, I didn't get the flywheel lightened.

I have almost finished the IFS box mount. I got a 2wd shaft too. Its all good now though. Just chopped the front body mount off. Will sort it later.

I'm trying to get my hands on a 7M sump pickup and pump. But need to see if I really will need it as need to sort engine mounts yet
It never ends.

Am going high steer too. Cheers for the links Matt.

Daniel

[MATT4U]

good, cause ya dont want a lightned fly wheel.

ya want the mid bowl so ya dont starve of oil when climbing banks to

[Steve_t647]

you can install wing's on the sump also to allow you to carry more oil. The biggest thing is the standard engines in a 4wd have large volume sumps and the oil pickup is over half way into the oil level on the flat. The LS2 and corvette had wing's on the sump to gelp when the g force sends oil up the block it holds about 6 litres of oil

MMMMM LS2 powered hilux come on Lotto where are my numbers!

[muddy_munke]

OK pic whores. Here goes. A we bit of progress has been made. Things are hectic this time fo year. With all two christmas presents I need to buy, I'm stressing hardout! All this stress combined with working long days out of town means I'm struggling getting parts I need etc.

Since last time I posted progress with pictures, computer had a paddy and wouldn't work. But now Dad's finally fixed it so I can post pics again.

I have the motor in place and am half way through wiring it. Still need to plumb it though. Gbox etc all bolted up. My fancy new gbox crossmember is under construction.

The front axle has been in and out sorting front ubolt issues and steering etc. Currently it is in and truck sits quite high. Maybe too high. Will have to see. Will have to make wedges to correct diffhead angle too.

Driveshafts are being made longer and rebalanced this week.

Maybe it doesn't sound like much to read. But I can tell you now. I've had a few headaches getting all this done. But I'm a wuss. So anyway. Here's some pictures. Sucks to be you if you have dial up....





I Trussed and Capped both axles.
Front:





Rear:





Now, With trussing the rear axle, I came to a problem with my breather. I welded a bit of tube around it and drilled a hole through my truss to match. Then welded around the top and linished it back. I Like!!








IFS Steering box mount all done.





Engine Mounts all Done. (Obviously, Engine is in!)





The Motor in the donor!


New Clutch installed


Bellhousing before


Bellhousing after tidyup. Ready to install.



Rebuilt the front axle. Did IFS Hub swap at same time. New disk etc.




Ride Height Time!!

Rear


Front



I can't put both axles under the truck at the same time. Garage isn't high enough.... I will have to borrow the load skates from work and drag the truck out and then assmble it. Could be interesting!!!
Will hopefully get the thing running and on the road by Feb Next year.
Any questions please ask.

Sick of typing now.
That is all.
Daniel

[SupraLux]

Now thats purdy... love the sexy job of the breather through the brace, very nice...

Keep up the good work, and the pics

Steve

[hosehustler]

Top Job :thumleft:

[Sawdoc]

Thats some very cool engineering

[muddy_munke]

Thanks for the comments guys. I wouldn't say its anything flash.
I'm just learning with this build. Then its game on!!!

Cheers Daniel

[mike]

Any progress is nothing but flash wicked pictures. love the progress

Mike

[wopass]

thats CHOICE BRO !

[muddy_munke]

Quick update. I finally got my Motor to go :cheers: . Need fuel pump now. (borrowing mates in mean time).


I sold a driveshaft I had to Steve. Now I need one. After paying a pro to do a damn good job in lengthening my driveshaft's, I've found that my front driveshaft with its dumb double universal at the gearbox end means that I can't get the angle I need to get down to the Diff.
I've got one I can use from ruf_zuki's truck but of course the flange sizes are different at the gearbox end. Does anyone know if the universals can be played with so it has the larger flange on the new driveshaft. Or can I redril the flange on the transfercase
Has anyone else struck this problem? I'm sure someone must have.....

Cheers Daniel

[muddy_munke]

OK. Drivehshaft shit I think is sorted. Thats down the track now anyway.

This weekend has seen a bit of progress in the garage . Front crossmember all welded and gusseted. Gearbox crossmember all welded and in place ready to make some gussets and then paint. Accelerator cable bracket modified. Exhaust made and installed. Although its a pain in the ass and it keeps coming out and going back in! I finally got round to finishing the seats off. Half of the trusses on the chassis welded, this is where I cut out the chassis to put in my front hangers for the falcons. Need to lift body to weld the rest. Rear hangers re welded hopefully in the right place this time!! All the radiator is plumbed and in place for good. Just need the fans now.
As soon as I can get some more bearings for the rear diff, Its all on. Can take it for a drive. After I get it out of the garage and put it all together etc. Ha, its all sounds so easy
Heres some pictures.

Thats is all,
Daniel

Front Half of ZORST:


Sanded welds on zorst, one more muffler to add:


Cool Low Profile Box Crossmember:


In Place:


Front view of crossmember:


Clearance with gearbox on new crossmember:


Front hanger with cool 'fang' like gussets :afro:




My Soloution to having next to no room to get the top rad hose in.


Oh, and if anyone has a cheap as chips going headunit, I need one. Some little shit or shits, broke into my car that was parked on the street outside our house on Wednesday night. I only got home at 2am and it was definately locked as I remember checking it. Between 2am and 6:30am when Dad was up and about, they picked the passengers lock and took the headunit. This is annoying, but whats more annoying, is that they got their hands on the faceplate for the headunit thats in my truck. I hadn't yet got round to taking it out of my car's glovebox from when the truck was parked at a mates place. The took the bloody thing. Its no good to them, they don't have the headunit to plug it into and make it go!! It's in my bloody truck. So now I have a headunit in my truck that has no faceplate so I can't bloody use it!!! I've searched trademe just in case. But I don't think they're that dumb. Little ass bandits.......
So yeah, if anyone has a spare cheapish headunit, (doesn't need to be flash) I'd be happy to take it off your hands.
(And no I can't claim insurance, the car the gear was in only has third party insurance as its a piece of shite. It doesn't cover stereo equipment. My fault I geuss for leaving the stuff out there ....)

This time,
Thats is all
Daniel

[ELEV8]

great stuff mate. your work is amazing. wish i could do that kind off thing.

[muddy_munke]

Howdy.
I got down to it this week and got the tray done. Just needs a lick of paint now.
Not much other progress
I'll blame it on work. But really, I'm just bloody lazy.
Heres some pics.

Before the Chop





Marked Out




Cuts







Putting it back together and welding



Forgot to take pictures of in between here. But Bascially, I just tacked it all and sanded it all back on the ribbed bit. and bogged up the wellside.





Bit rough but it'll probably get smashed up anyway

[muddy_munke]

WANTED

Does anyone have approx 1.5m of 75x50x4(ish) RHS that I can purchase from them?? I have rung alot of engineering places but no one can help and steel and tube only do full lengths (8M).

Can call on 027 3380174 or PM or whatever.
(In ChCh)
My life depends on it.....
Cheers Daniel

[SupraLux]

called and sorted

[muddy_munke]

No need to worry. A very good bastard came to the rescue. No steel needed now.
Cheers Steve

[captainman]

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.

Where can you source the transfer case adapter? Anyone?

[turoa]

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.

Where can you source the transfer case adapter? Anyone?

Howat engineering in wellington can to transfer adapters