A HILUX IS REBORN..... the itch!!!!!!!

Members' DIY projects
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Musselcracker
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sorry for the ignorance what are we looking at here
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dustbuster
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Location: KZN

the last photo was the backing plate for the drum brakes and the drive shaft that goes in the axle housing, the thing with the studs is the bearing housing that bolt onto the axle you can see the cir-clip and the bearing retainer
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Musselcracker
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so what are your thoughts/options on the bullbar?
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Musselcracker
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sorry for the all the posts... while you have got the axle off and in pieces why dont you try upgrade the brakes.... put on KZTE disc's calipers and brake booster!! (i could be corrected!)
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dustbuster
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Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Still want to design an ARB style bumper and get one made just no time at the moment that is cosmetic stuff want to get the Hilux running then start on the interior, then exterior. Was thinking of upgrading the brakes as well but just to much on my hands think the standard breaks will be fine for now if they are fixed up and working properly, can be a project for the future also cant splash out to much with the bucks every thing adds up quickly especially getting tools to do the job. Back doors are at mboza so they can use them to line up the glass ones, once the project is finish will post up all the left over parts and see who wants what
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dustbuster
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My first big ooopppps and surely not the last, the galv wash did not work :dash: :dash: and the primer is not sticking to the chassis :evil: :evil: so have to take it all off and try something else. What a waist of time now it is going to take another 2 nights to clean it up………… :cry: :cry: Toyota doesn’t have a gasket in stock for the back axle :thumbdown: :thumbdown: so going to have use gasket maker.
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Musselcracker
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oh no dude..... not ideal pal!!
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Mud Dog
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To paint, one should use an etch primer first (preferably not a water based one) like red oxide or otherwise a zinc chromate or calcium plumbate primer.
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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dustbuster
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Mud Dog wrote:To paint, one should use an etch primer first (preferably not a water based one) like red oxide or otherwise a zinc chromate or calcium plumbate primer.
used the galv wash and washed the chassis and used a balck etch primer still did not stick :crazy: :crazy:

going to try a little section with stone chip leave it over night and see if that works.
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dustbuster
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Took the diff off last night looks in good nik :thumbup: cleaned the flanges going to go see if I can get new studs, washers and nuts later the one stud has been hit by a rock so cant reuse it luckily I could get it out. Got the side shafts back with the new bearings pressed on so tonight I will start putting it all back together.
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dustbuster
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IT’S GOT WHEELS…………….. :yahoo: :yahoo: :yahoo: :yahoo:

I put the new OME suspension on had some issues look here if u haven’t read it viewtopic.php?f=3&t=19883" onclick="window.open(this.href);return false;

Sorry for jumping all over the place, still need to make a plan with the back shocks as they are the wrong ones :evil: :evil: and will have no luck with SA4x4 store.

The chassis is really high as there is no weight on it cant even get the front shocks into the mounts will have to get the engine in place to bolt them on.

The paint is still a mess up used a galvanizer primer and then painted chassis black over it and it has nearly been a week and it is still tacky when u touch it and it scrapes off. :evil: :evil: :evil:

Next on the list is the steering started cleaning all the ball joints and tie rod ends
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Musselcracker
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Nice work ...

Thanks for the pics of your steering arm... now I know what the inside of the thing looks like!

Mine is pretty shot! let me know where you get new parts like the rubber and springs
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CasKru
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Musselcracker wrote:Nice work ...

Thanks for the pics of your steering arm... now I know what the inside of the thing looks like!

Mine is pretty shot! let me know where you get new parts like the rubber and springs
Have you tried tightening yours?
To God be the glory
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dustbuster
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Musselcracker wrote:Nice work ...

Thanks for the pics of your steering arm... now I know what the inside of the thing looks like!

Mine is pretty shot! let me know where you get new parts like the rubber and springs
Chris I am just cleaning mine up the rubber boots are still good, just going to get new grease nipples have painted it with hammerite will have more photos next week cant work this weekend going hunting with some mates
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dustbuster
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steering (Medium).JPG
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Musselcracker
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i have tightened by adjusting screw on the steering box... well i was a bit nervous to tighten it too tight! whats a good gauge as to it being tight enough? i do not have a big jack or jackstands so the car has to sit on the ground!

i loosened the nut until the a bit of steering fluid leaked out and then tighten the screw!! and tightened the nut back again
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CasKru
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Musselcracker wrote:i have tightened by adjusting screw on the steering box... well i was a bit nervous to tighten it too tight! whats a good gauge as to it being tight enough? i do not have a big jack or jackstands so the car has to sit on the ground!

i loosened the nut until the a bit of steering fluid leaked out and then tighten the screw!! and tightened the nut back again
I'm not refering to your steering box :shock: :shock: :shock:

I'm referring to the drag link in this picture...
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Mud Dog
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Chris, what Cassie means is that you can tighten up the end screws on the drag link ... that compresses the spring and puts more pressure on the little cups, taking up the excessive play in the link itself. :winkx:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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CasKru
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Mud Dog wrote:Chris, what Cassie means is that you can tighten up the end screws on the drag link ... that compresses the spring and puts more pressure on the little cups, taking up the excessive play in the link itself. :winkx:
Yebo yes
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Musselcracker
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shot okes....

Should have read this on the weekend and could have fixed it! I know the screw you are talking about there is a split pin in there you have to pull off first!

Sorry did not mean to highjack your thread Dean!
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dustbuster
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Update time, have put the drive chain on……………….. did some work on the engine replace the gaskets on the sump and tappet covers painted them as well also replaced the sparkplug tubes still lots to do now I am waiting for the bodie to be made.........
ball joints
ball joints
ball joints finished
ball joints finished
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NardusJVR
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dean............ Wel done. Stil some work left but she will look Gr8
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Musselcracker
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put a seat on and drive it just like that!!

WOOOHOOO
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Musselcracker
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OKay whats been happening??

GIVE US AN UPDATE
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dustbuster
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The waiting game have paid for my body over 9 months ago and still waiting :evil: :evil: :evil: :evil:

Mboza is been taking there time hope it is worth the wait……………………

everything is ready for the body want to start putting it back together!!!!!!!!
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519franco
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go take a turn there when i was there i saw one hilux but wasnt getting worked on.. but i could be mistaken
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HAPPILY BUILD 3L V6 1987 TOYOTA HILUX
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dustbuster
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519franco wrote:go take a turn there when i was there i saw one hilux but wasnt getting worked on.. but i could be mistaken
they have started on the cab waititng for some pics to be sent to see the progress am going to go down next weekend and have a look.
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dustbuster
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So on Saturday went to Mboza and had a chat with Steve and showed me the new way he is putting the body together as to make it line up better, He is assembling the floor on the chassis and then putting the cab on top and lining it up and glassing in position.

I am going to cut my old cab up and reuse the front section and mounting plates/gusset which he will acid clean and glass into the new body.

Here are the pics of the my cab in the mold and some pic’s of Marks CAB getting fitted to the chassis
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here is Marks cab
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pampoen
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Aaarg!!! Drool drool, My cab's starting to look more like that, about 10% being fiberglass and the rest... painted rust :evil: .Hopefully as i add more and more fiberglass one day ill eventually have an Mboza body.
With each replacement of parts, a car slowly becomes Chinese.
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This is a gr8 thread........

:beg: Can we have an update????
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Any updates?
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dustbuster
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The body is coming together slowly, here some pics I took a two weeks ago when I was in Durban, The doors still need to be glassed onto the frames and the bonnet put together the inside skin and bar for the dash, also the floor needs to be reinforced.

Still lots to do :crazy: :crazy: :crazy: :crazy: :crazy: :crazy: :crazy: :crazy:

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Quintin
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This is a very cool project keep sending those pics I am very interested in the progress as I am considering the same. If I may ask what is the cost of the cab.
Toyota Fortuner 3.0 D 4 D 4X4 A/T (4 play). Hilux DC 4x4, Lexus 4Lt V8, Mikhem suspension met 50mm lift, 50 mm body lift, Bilstein Shocks extra length, 33" tyre, 8 J rims, 2 x Lockers, Snorkel. (Blou Job) en dan n Peugeot 107 (Quickie).
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Are those inner door frames metal? They don't appear to be F/G...


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dustbuster
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Ya they are trying out a new way on the doors Steve is reusing the inner panel he plasma cuts the old outer skin off then acid cleans and electroplates the old inner panel (that is what you see) he is then bonding the fibreglass outside shell onto the inner.

Steve always says he has had trouble with the doors sealing and the windows ect. Now everything lines up and you can reuse all the bolt holes. He also does the same in the front for the lights and radiator that panel is steel as well.

We tried a new system with my cab as well where I cut all the brackets that mount the cab onto the chassis and he glassed them into the cab so it mounts better onto the chassis.

Here some pics of the parts i cut off my old body
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dustbuster
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Quintin wrote:This is a very cool project keep sending those pics I am very interested in the progress as I am considering the same. If I may ask what is the cost of the cab.
quintin best to call steve at mboza and ask him is number is zero84548637seven
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Quintin
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Thanks That is what I will do. Your project looks very nice.
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MariusF
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Any updates mate?? :beg:
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dustbuster
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was at MBOZA on SAT morning and got a few pics they are finished all the glass work
and now just the fulling and sanding left the a coat or two of primer and the shell should be ready for me to take.
so hopefully if all goes to plan i should get it by the end of next week :beg: :beg: :beg: :beg: :beg:
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The Legend
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MariusF
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I think it is time to show us the progress.

Feels like the waiting game is on us....Why are we waiting ? :tongue:
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dustbuster
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eish just no time!!!!! to busy with work CAB is ready just have to get from durban to richards bay will start work on it in the new year......
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dustbuster
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So this weekend I got my birthday present!!!!! :yahoo: :yahoo: :yahoo: :yahoo: :yahoo:
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next year is going to be a busy one!!!!!!! :alvarin: :alvarin: :alvarin: :alvarin:
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Family_Dog
Moderator
Moderator
Posts: 13020
Joined: Tue May 22, 2007 10:09 am
Town: Klerksdorp
Vehicle: Hilux DC SFA, Hilux 2.7 DC, Hilux 2.7 SC, Prado 95 VX
Real Name: Eric
Club VHF Licence: HC101
Location: Klerksdorp, NW
Contact:

This is going to be a worthwhile read! Please keep your camera fully charged. ;)


-F_D
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White Fang: 1999 2.7i DC Raider 4x4
Bull Dog: 1987 4Y-EFI 2.2 DC 4x4
Pra Dog: 1998 Prado VX 3.4
Hound Dog: 2000 2.7i SC 4x4


One Staffie, One Jack Russell, One Ring Neck Screecher, 17 Fish of questionable heritage


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User avatar
Baasvark
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1375
Joined: Mon Aug 01, 2011 7:45 pm
Town: Virginia
Vehicle: '97 D/C with all the trimmings & 2011 Troopy
Real Name: Shane

You definately have"Beeg Cohones" to tackle a job like that!!!
I have had a similar itch once or twice but decided to play it safe and save up for another hilux ;)
Aint it ironic that "Common Sense" aint so common after all...
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dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Eish have to get back into this project :aggresive: :aggresive: :aggresive: :aggresive:
just bought a house so been spending time sorting that out gardens are a mission :dash:
want to take the body home so I can work on it there but only got a single garage so will be a squeeze
will start this weekend so Monday will post some more pics of the Mbosa body
User avatar
dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

So the project has taken a turn :crazy: :crazy: :crazy: :crazy: , think I am just going to get frustrated keeping the 4Y even if I EFI it :aggresive: :aggresive: :aggresive: . Just want the power to cruise to Transkei and places not battle up hills fully loaded. Also might get a boat in the future so want to tow as well.

So going to take the 4y out and do a Mazda/Ford WL2.5 TDI conversion with 33’ tyres and 50mm body lift, this seems to be the best motor option sucks that it is not a Toyota engine :cry: :cry: :cry: but fit’s as easily and not break the bank.

I like the fact the WL2.5 is a simple mechanical engine as well so no ECU needed so will be more reliable once set up, and double the torque than the 4y.

Started work on the CAB lot's of finishing off needed tiding up the glass few air pockets under gel coat and cracks on some of the joins noting to major, else looking good. :thumbup: :thumbup:

sorry didn’t get time to take some decent pics


under cab
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glassed in steel rib from cab
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crack in door pillar
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Froll
Monster Truck
Monster Truck
Posts: 3312
Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 2010 4.0 V6 Fortuner 4x4
Real Name: Roger
Club VHF Licence: N/A

Massive job you are doing there Dean. I am reading the post with interest and was wondering if you have got any further? :thumbup:
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MOFASA
Monster Truck
Monster Truck
Posts: 3123
Joined: Sun Mar 04, 2012 7:27 pm
Town: Kempton Park
Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
Real Name: Johno
Club VHF Licence: X119
Location: Kempton Park

An update would be awsum..... :thumbup: :thumbup:
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP :yahoo: ..... You wouldn't understand....
ImageImageImage[rimg=206x128]
User avatar
dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Engine is ready Hoppy should courier it up this week :thumbup: :thumbup: :thumbup: , so need to take the 4Y out,

The body is not lining up nicely on the chassis so bit of work needs to be done there
and the mounts are going to have to be custom heights to get the body level.

Then I want to spray in the engine bay and under before mounting to chassis

Very busy with work at the moment so have not spent enough time on it......
:thumbdown: :thumbdown: :thumbdown:
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Baasvark
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1375
Joined: Mon Aug 01, 2011 7:45 pm
Town: Virginia
Vehicle: '97 D/C with all the trimmings & 2011 Troopy
Real Name: Shane

Hey Dean,

How's the project going?

Long time no pics?
Aint it ironic that "Common Sense" aint so common after all...
User avatar
dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Going slowly :crazy: :crazy: , have taken the 4Y out, have revived the 2.5TD from Hoppy :thumbup: :thumbup: :thumbup: :thumbup: and should get the new bell housing next week.

will try to get the engine in next weekend.
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MOFASA
Monster Truck
Monster Truck
Posts: 3123
Joined: Sun Mar 04, 2012 7:27 pm
Town: Kempton Park
Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
Real Name: Johno
Club VHF Licence: X119
Location: Kempton Park

Must be VERY :frustrated: to see how far you have come since Jan 2011 and still cant drive her....
It should ALL be worth it in the end......
AWSUM build so far.....
Dont loose faith SHE will drive soon.... :thumbup: :thumbup: :thumbup:
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP :yahoo: ..... You wouldn't understand....
ImageImageImage[rimg=206x128]
User avatar
dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Still going slowly, have been tinkering in the garage during my spare time!!!!

Got the body on the chassis and all lined up had to make different size spacers to get the cab as level, so front has 75mm going down to nothing at the back, what I think happened is the mboza glassed the existing rib on the outside of the cab which gave a body lift at the back.

Have the new 2.5 TD engine in place :clap: :clap: :clap: :clap: now trying to sort out water piping and intercooler, next is to sort out steering rack and brakes want to mount everything temporally then take off and spray the cab.

Will get some photos this weekend if I can
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4x4BEES
Monster Truck
Monster Truck
Posts: 3477
Joined: Wed Nov 20, 2013 10:13 am
Town: Brackenfell
Vehicle: Hilux 4.0V6
Real Name: Kevin

Awesome build boet :clap: :clap: :clap:

You have a lot of patience and determination to keep on going for so long, you must really enjoy it.
Good luck, hope it all works out okay with no further hassels.
User avatar
dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

So in my spare time I have started on the project again :mrgreen: :mrgreen: :mrgreen: , have started designing my bumper and making a mock up one :celebrate: so radiator is in and piping sorted and intercooler is integrated into new bumper and piping is also sorted.

Next is the steering rack fuel system and brakes.
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ThysdJ
Moderator
Moderator
Posts: 16730
Joined: Wed Oct 24, 2007 7:31 am
Town: Brackenfell
Vehicle: 2010 Hilux D4D 3.0 D/C 4x4
Real Name: Thys
Club VHF Licence: HC102
Location: Brackenfell
Contact:

Looking good, but you're not doing your approach angle any favours with the I/C in that position.... Can you not lift it, tuck it in closer or even angle it? The WL will perform verry verry nicely with that big IC!!! :thumbup: :thumbup: :thumbup:
Thys de Jager
CEO and Refreshments Manager at Team Offroad.

2010 Hilux 3.0 D4D D/C 4x4 with GOMAD "Brood" Canopy. Tripod.
1997 Jeep Wrangler TJ 4.0 Sport. The original SFA. AGA... Gooi kole
email: thys@teamoffroad.co.za

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dustbuster
LR 4WD Rear Locker
LR 4WD Rear Locker
Posts: 445
Joined: Wed Jul 28, 2010 9:42 am
Town: Richards Bay
Vehicle: Rebuilding 91 D/C Hilux Mboza Body, OME 4Y EFI, & 91 S/C 4Y Hilux
Real Name: Dean
Location: KZN

Good point will have a look, tricky with trying to get space with the winch and also do not want to restrict the airflow over the radiator.
Will do a side view and see what angle I get with 33” tires on looks a bit funny with the small tires
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ThysdJ
Moderator
Moderator
Posts: 16730
Joined: Wed Oct 24, 2007 7:31 am
Town: Brackenfell
Vehicle: 2010 Hilux D4D 3.0 D/C 4x4
Real Name: Thys
Club VHF Licence: HC102
Location: Brackenfell
Contact:

If you just angle the bottom in towards the back it will already help a lot.

Airflow wont be restrigted too much if you put it in front of the radiator either, but you might have to mod the grille somewhat. On my 2.5 Ford we put a similar sized I/C in front of the radiator with no ill effects..
Thys de Jager
CEO and Refreshments Manager at Team Offroad.

2010 Hilux 3.0 D4D D/C 4x4 with GOMAD "Brood" Canopy. Tripod.
1997 Jeep Wrangler TJ 4.0 Sport. The original SFA. AGA... Gooi kole
email: thys@teamoffroad.co.za

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MariusF
High Range 4WD
High Range 4WD
Posts: 51
Joined: Mon Mar 12, 2012 10:14 pm
Town: Pretoria
Vehicle: Toyota Fortuner 3.0
Real Name: Marius

Hi Dean...any progress?
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