Project Lemon (82 to 98 hilux)

[De-Ranged]

Thought it was about time I contributed to the site since I've been watching enough
Heres the background
I bought the "Lemon" an 82 yellow single cab 2L petrol Hilux as a work hack with the intention of using it while I worked on my project truck... it only had to last me a yr well that was the plan
it lasted 3 weeks and in that time I only used it 7 times
Had to fix a leak in the feul tank that someone had used bog to try and seal did the tappits and tuned it twice but couldn't stop a top end rattle when hot... that was untill the motor blew! Time for a new motor... couldn't find a replacement and I noticed "SupraSurf's" truck on here and thought why not throw a 5m in picked up 2 cresseda's for $200 and the truck swopped places with the Project and got crissined "The Lemon" (I will never buy another yellow truck!!!)
I have since then gathered the replacement bits and pieces and done a little bit of work now its time to start putting the Lemon together
I have thrown the old chassi due to rust I could lift the whole chassi by my self easily, with the new one I can only lift one end!!

This is from an 86 double cab project of a mates that never made it out of the shed he's good like that I've got one of his other projects
He was turning it into a "monster truck" the front end had been lifted by 8" (+another 4" from lifted springs) I've reduced this down to an estimated 6" (4" from the lowered hangers and 2" from the springs) I took the X member he'd had made and removed the chassi front X member and recessed the lifted one up into the chassi and rebuilt it stronger (he was building his truck as a show pony )

Its also had all the crap that I don't need removed, things like the old shock towers in the front, shock mounts at the back, cut the back off just past the rear spring mounts and a few other bits have gone
I've also taken the cab outriggers from the 82 chassi (had to rebuild the lower half of two due to rust!) and mounted them in place of the 86 ones.
I've then mounted a surf power steering box for Xover steering, the mount has been recessed in to stop the tires rubbing at lock



Next up is the rear spring shackle mounts make them wider the same width as the XD falcon springs there is a reason for this lets just say if it works it might give me abit more travel from the springs... till then

Cheers Reece

[SupraLux]

Awesome stuff... good to see it happening... keep the pics rolling - and nice idea to inset the steering box.

Steve

PS: funny thing - I bought an identicle 82 yellow single cab 2l petrol that threw a leg through the side of the block... lemons - don't go there

[De-Ranged]

its the details like that, that make it fun to build see the bottom pic of the shakles but some things well....

Decided to get the front sorted so I can set the ride hight for the back end... and it means I'll finish the steering arms sooner not long now Steve
Anyway I've got the front springs done and on with greasable shackles (home made!!)
Heres a pic of the "new" springs vs the old ones almost 3 1/2" of lift (unloaded) for those of you who don't spot it these are the original rear springs with the load leaves removed the bonus with these is as well as the 3" lift they also move the axle mount forward by 80mm helping larger tires clear the firewall!

I've also built some greasable extended shackles, note the little "nub" sticking out the side this is a requirement for cert its there to hit the cab outrigger and stop the shackle folding round and trying to swing up above the chassi :scratch: hmmm still don't see how it could happen but there are some arguments that arn't worth the trouble .... now after going to all the trouble of building these and dealing with drilling case hardened steel I'd recomend anyone thinking of doing this to call Steve his price on greasable pins is sharp anyway heres a closeup of them (PS thanks Jaffa these are your shackle pins...)

Next up is clearancing and reinforcing the axle tubes and dif covers oh and milling the steering arms got tomorrow off to wet to work over here so I might have some more progress

Cheers Reece

[Scott]

Man, have you got some GOOD shit in that shed .Get that piece of shit going and see how it goes agains't the 'red wreck' ,got the miss sorted i think .
Cheers scott

[matwelli]

Cool project, is this a chance to try out the IFS designs ?

[De-Ranged]

Good to hear it scotty.... what was it ?? feul pump??

I've just made the call to go 35''s and sorced a set of 5.2 diffs so I think it would be like putting the paj up againgst the wreak except I'd have the upper hand

is this a chance to try out the IFS designs

Na I'm still working on that I'm still trying to find some nice beefy axles, I'll take a pic with showing the dif between surf axles and those in a beam .... I think the only reason they don't blow is becouse the diff heads on the surfs go first... I've actualy started looking as the axles off the paj next stop will be late model prado axles but I don't think they will be the go $$$
I was working on getting the lemon on its feet so I've got a choice of trucks to try this on

Will hopefully have some more progress shots tonight just about finished reinforcing the frront axle tube

Cheers Reece

[De-Ranged]

The first of the 98 good'ies the front axle
Finailly finished the front axle tube, cut out the bottom of the diff pumkin and replaced it with 6mm plate

Added a bit of armor well I was at it oh and well I was doing that decided to move the filler 30mm up so I can up the oil level a bit
Heres a shot looking down the axle showing how much I shaved just shy of 20mm extra clearance

and just for the books I've got 6mm of clearance inside between the ring gear and the bottom used a bit of offcut plate to hold it up off the gears while I welded it
I also added some reinforcment to the swivel housings

I haven't decided what I'm going to do with the shocks so I made the top one small enough it won't interfear with the standard shock mounting
Next on the list is some new CV's as the old ones are a bit rusted! last owner let some water in if you look close in the last pic you'll see some of the rust I'm hopping to smooth it off with a flap disk anyone know a cheap sorce of CV's ??
The other thing I'm going to do is the steering arms (half way there, just got 3 more jigs and a bit of machining to go ) as I'll need them to put the axle together

If anyone wants I can throw up a few more pics sort of a "how to" as I go along... let me know

Cheers Reece

[DJ]

Hi Reese
Ill have $10 on the red wreck not becase its better just the driver is insane
Project looking good just wondering ... with the amount of welding ( looks like arc ) have you checked to see if its still straight?? When you have finished give us ? a yell we will come down and see if it breaks
cheers DJ
ps most of the rewiring has been done on DILLIGAF now onto disc brake rear

[De-Ranged]

You do have a point!

As for the welds its a mix of arc and mig I've arc'ed the bottom in couse I wanted penitration and I've mig'ed the armor plating on the diff head as its just welded on over the original

didn't think about weld worpage I'll have a measure up should be sweet I left the support ring inside intact that should have held it

Cheers Reece

[Scott]

Hows't Reece.
I can't see the photo's[bloody shit computer ],But your lemon sounds Very good .
The 'wreak' seems to be going all right .Got some new dents doing about 90k down the road and the bonnet flies up ,makes it damn hard to see .
Keep working on your 'lemon' and well have to go for a skid in the mud soon
Cheers scott
Ps forget about fixing the Paj & it was the 'wreaks' pump and tank set up

[De-Ranged]

Ps forget about fixing the Paj

funny you should say that, I was having a play down the river this arvo with Mudtrucker and Paj broke a timing belt! as I need it for work I'm gona have to put the Lemon to the side

Had a look through the Haynes manual its the second timing belt I've done... it runs what they call "silencer shafts" :scratch: got me I'm gona throw a new one on and keep my fingers crossed that nothing got bent!!

If its all good tomorrow with the new belt then the Lemon will continue

I bet you've fixed the bonet latch so it don't happen again!!
Oh and before I forget, measured the axle all sweet! had me going there DJ I didn't think it would be an issue

Cheers Reece

[eatenfuller]

comon scott its not a red wreck dont most of them out youre way ride horses

its awesome country up youre way,specially for the twin diff nuts that love the mud.about ten years ago my older brother used to log out of Kopuriki area ,theres some awesome native out there just spectacular(id live up youre way anyday mate but its the on going work that keeps me down here)

[De-Ranged]

Finally got back to working on the lemon.... Don't ever become a contractor

Anyway I've finally finished a few fruity bits for the old girl almost got the front axle together
Along with a complete rebuild (new everything that could wear ) a set of slotted vented discs

Got a jig built up to slot em, so if any of the local boys are keen I'll do the same for a donation to the fridge

Made up a set of 25mm wheel spacers you get sick of drilling holes with these!!


And wait for it ..... I've finally finished the new steering arms :cheers: sorry about the pix might have had one to many woodys hands wer'nt to steady...


these are pretty extreme, 60mm lift of the steering arm mount and they are seriously short, I made em for a 4"+ syspension lift and nice and short so you can move the axle as far forward as possible also angled up the Drag link seat in the hope that I might use all the movement from the balljoints

Will hopefully have the axle together soon :scratch: just missing a few bits when I do I'll post some pix of the steering setup in the frame

Cheers Reece

[SupraLux]

Hey, funky looking arms... is it neccessary to have the extra angle on the end for the drag link TRE to bolt into? Every way I've looked at it the angle just never seems to be enough to warrant having the step, although when I drew a set up for machining I did the same thing anyway... just never got around to doing the actual machining...

What axle parts are you missing, btw? I have the odd bit lying about

Good to see some progress - oh, and the alternative to being a contractor is probably working for someone else... which would give you less time and less money... so stop complaining and get on with it I'm in the same boat... but look, 9 months of labour and a new baby MU has arrived

Steve

[De-Ranged]

yea that angle up for the draglink is a bit of wishfull thinking, to use it all you would need 20" of travel (at balljoint) on a standard balljoint (approx 30degrees of range)
The real reason I did it is to center the ball joint so at extreme drop there is no chance of bind... also gives me something to work towards super twister truck yea what everyone wants for a daily driver

As for the missing parts.... just missing the little plates that bolt the wiper seals on .... for some reason I threw them out, thinking there was a new set in the swivel recon kit might a had one to many woody's that day thanks for the offer steve, I'll just make a new set ....

Oh and I got some more fruity bits
A set of 5.25 Hiace diffs ..... the rear is a bit worn in the spider gears but crown and pinion's all good, I'll get a lockrite and bin the spiders
And since I've now got the difs got a set of 37" Wrangler M/T tires..... can't wait to get this all together

Cheers Reece

[hosehustler]

Genuine Toyota swivel seal kits come with new plates, and they are only about 10 bucks a side , hardly worth making plates for that price, also comes with the felt seal and the rubber seal, give Toyota a call, you'll be surprised, I know I was

[Heath]

Greeeeeen with envy now. Hard enough getting stuff done at work now the machinist has left (not being replace - bugger) still nothing to stop me from using his gear now (except lack of knowledge).

Sounds like a weapon. Let us know how it all goes.

Heath