The Super-Single cab

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Unreal K-ZN
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Real Name: Gareth

Hi guys and girlsImage
Being a newby to this forum I would like to just start by saying thanks to all of you that have helped me with many answers on this forum before I joined. You guys are awesome.

My title, “Super-single cab” should say it all. I have a single cab, I want the super cab space for camping but I don’t wanna sell my Moose and have to go through all the mods again just for some extra cab space.
After much Captain and many brainstorming nights, as well as some crazy you tube time, I figured the only way to get the extra space would be to do what they do in Aus, build a new “bak” and add a canopy section.
The thing is, I don’t like the tray idea for my lifestyle and this seemed to be a critical elementImage so once again it was back to the Captain and the drawing board.
About half way to the bottom of my last dop, I came up with an idea that was almost too good to be trueImage so straight to google, Hilux forum, other forums, you tube, wiki, freakin anywhere I could think to find out if anyone, anywhere ImageImageImageImageImageImageImagehad undergone such a move before? There were many questions I had, and I could not find a single answer online. Maybe I searched the wrong things but I gave it my all until I just couldn’t be bothered searching anymore. I just had to dive in and try.

My idea is as follows. Step 1, remove single cab bin. 2, fit double cab bin. 3, fill the gap with the ultimate camping setup. 4, still look like a Hilux Image

Step 1 was easy of course, couple bolts and some wiring and Moose lost some weightImage
Step 2 was a bit more tricky due to only 4 of the 6 bolts lining up from the double cab bin to single cab chassis, but that’s easily remedied in step 3.
Step 3 is where I am at the moment in the build and I think I should mention that everything so far and to the end will be a bolt on application. I have not cut or welded anything on the chassis side of the build and nor will I. The idea is that if I wish, I can put the single cab bin back on at any given time with no mods needed.

Some pics so far for you guys, hope you enjoy them and I will post more on this thread as I go. Today I am planning to finish the “super” cab’s welding and grinding and maybe even get a coat of paint on itImage


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FIRSTGEER
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Very brilliant idea. I like your way of thinking. Please keep us posted as your build progresses. I cannot wait to see the finished job
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Mud Dog
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Awesome idea! :thumbup:
Keep us posted.
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.
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Mud Dog
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Maybe some gull-wing doors and a sliding tray on each side? :think:
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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Unreal K-ZN
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Mud Dog wrote:Maybe some gull-wing doors and a sliding tray on each side? :think:
Without a doubt the full wings, one for the fridge slide on one side and the shower rose on the other one. Image



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Unreal K-ZN
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FIRSTGEER wrote:Very brilliant idea. I like your way of thinking. Please keep us posted as your build progresses. I cannot wait to see the finished job
Thanks a mill. It’s been quite a jol so far, looking forward to bolting it on Image


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pieta.swanepoel
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Creative thinking. Like the idea and would not be as heavy as a fill tray style canopy
Groot berge en lang grondpaaie
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Bear
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Hi Gareth

I see the guys giving you credit for a job well done.

I was going say great stuff, very original. That is what engineering is!

And as I continued reading and you stated - “After much Captain” … “About half way to the bottom of my last dop”
I’m not sure if you deserve the credit for this work anymore.

Be a gentleman, give the credit to "CAPTAIN"
Travel is not really about leaving our homes, but leaving our habits.
Adventure tends to magnify all human emotions.
It's only in adventure that some people succeed in knowing themselves - in finding themselves.
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FIRSTGEER
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Gareth another very important aspect of your project which I fully agree with,is to use the origonal mounting points on the chassis without welding and cutting anything on the chassis.
I have completed many projects over the years, including engine conversions and campers etc and have always applied this golden rule of keeping mounting points etc standard so one can always revert back to the standard vehicle setup should the need arise for whatever reason.
We are waiting in anticipation for further updates. :thumbup:
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Unreal K-ZN
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Bear wrote:Hi Gareth

I see the guys giving you credit for a job well done.

I was going say great stuff, very original. That is what engineering is!

And as I continued reading and you stated - “After much Captain” … “About half way to the bottom of my last dop”
I’m not sure if you deserve the credit for this work anymore.

Be a gentleman, give the credit to "CAPTAIN"
All due respect to Captain Henry Morgan. Image


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Unreal K-ZN
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FIRSTGEER wrote:Gareth another very important aspect of your project which I fully agree with,is to use the origonal mounting points on the chassis without welding and cutting anything on the chassis.
I have completed many projects over the years, including engine conversions and campers etc and have always applied this golden rule of keeping mounting points etc standard so one can always revert back to the standard vehicle setup should the need arise for whatever reason.
We are waiting in anticipation for further updates. :thumbup:
I agree, if this mission turns out to be a lemon, I can always drop my long bin back on and not have to worry about anything except for my loading bars which will just be lengthened again to suitImage


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Unreal K-ZN
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Some work in progress pics. Please don’t judge my weldingImageImageImageImageImage[IMG]//uploads.tapatalk-cdn.com/201910 ... d9a507.jpg[/IMG]ImageImageImageImageImageI am a carpenter by trade, not a welder, this job has taught me a lot about welding thoughImage


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Unreal K-ZN
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Sorry about the random order. They appear to load in reverse Image

ImageImageImageImageImageImageImageImageImage


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Mud Dog
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Looking good Gareth! :thumbup:

We can't all be professional welders, but with the will to give it a go and a little practise we can all make a go of it,. So what if you have to do a bit of grinding to smooth it off afterwards. :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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I agree with Mud Dog not all pretty welds is strong. Well done at least you can be proud you are doing it yourself. Nothing trumps that 💪🏼
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Dowe Koos
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Hi Gareth. I'm very keen to see your end product. So far, it's looking interesting on how you progress. I am going show you some photos to give you some ideas about basic welding. I mean it good, not in negative way.
First of all, I never grind off my welding for it is weakened the structure, ALWAYS. I will only grind off the weld where something flat must fit on and only that. Only weld where I will grind off is when I had V weld joint.
Top one is a gap of 1 mm, middle is normal joint and the bottom one is where the V is prepared.
001 three plate.jpg
This is show you how the weld had penetrate through the plates.
002 penetrating of weld.jpg
002 penetrating of weld.jpg (33.71 KiB) Viewed 5777 times
I haven't grind of the weld of all three plates.
Bending the V weld joint
003 bend v.jpg
004 bend v 2 gap.jpg
Bending the normal joint weld
005 bend no  gap.jpg
006 bend no gap 2.jpg
Bending the gap joint weld
007 bend with gap.jpg
008 bend with gap 2.jpg
I had bend all three plates a few times.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Dowe Koos
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Now I had grind off the weld.
009 grind off weld.jpg
Bend the one with V joint
010 bend v gap.jpg
011 bend v 2 gap.jpg
011 bend v 2 gap.jpg (27.75 KiB) Viewed 5775 times
Bend the one of normal joint
012 bend no gap .jpg
013 bend no gap 2 .jpg
Bend the one with gap joint
014 bend with gap.jpg
014 bend with gap.jpg (32.38 KiB) Viewed 5775 times
014 bend with gap 2.jpg
014 bend with gap 2.jpg (33.69 KiB) Viewed 5775 times
015 bend.jpg
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Dowe Koos
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Bend the one with the V joint weld a few more times
016 v bend few times.jpg
Bend the one with normal joint weld one more
017 bend no gap one more.jpg
017 bend no gap one more.jpg (33.83 KiB) Viewed 5772 times
018 bend no gap one more.jpg
Bend the one with the V joint weld extra few more times
019 bend v few more tine.jpg
Here you can see how important is your preparations.
Other important thing about arc weld is the heat. If you weld over and over the weld to fix it, it is weakened the metal composite and can give you problem when you do some over landing where it is getting rough. I understand that you are a carpenter and is not a welder. I would suggest to you to practice more on your weld so that your project is well done and will not give you problem later on.
Hoop nie ek is windgat nie, wil maar net help.
Sterkte met jou projek.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Nee, Oom Hennie is nie windgat nie - hy weet darem so iets meer van welding as die gemiddelde ou op straat!
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Dowe Koos
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Dankie Thabo.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Unreal K-ZN
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Hi guys. Thanks for all your input and positive feedback. Progress a bit slow at the mo, work getting in the way of fun againImage

I have managed to paint the frame and fit the floor panel ally in, this let’s me get an idea of fridge slide positioning and batteries spacing. Gotta get some templates made so I can take the rest of the ally for bending.
Would love to get the skins on before December creeps up in low rangeImage

ImageImageImage


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Mud Dog
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Still looking good and slowly getting there, Gareth. Well done so far. :thumbup:
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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Unreal K-ZN
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A few pics. Progress been slow while waiting for the skins to arrive. Picked them up yesterday so I’m keen to get some action in the shop this weekend Image

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Last edited by Mud Dog on Sat Nov 16, 2019 1:23 pm, edited 1 time in total.
Reason: Images re-sized
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Mud Dog
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Real Name: Andy
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Beautifully neat! Keep it up! :thumbup:
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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That is a great idea, I love it. Looking forward to see the end result.
Only Dead Fish Go With The Flow!
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FIRSTGEER
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Nice project so far Gareth.Classy workmanship.
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Unreal K-ZN
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A few more pics after a few more evenings


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Unreal K-ZN
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Image Link BrokenImage Link BrokenImage Link BrokenImage Link Broken

I’m pushing to have it ready for the Xmas toy run through the valley of 1000 hills this December Image


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FIRSTGEER
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You are almost there.Although the small finishing touches are the things that take time to complete.Great job.
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Mud Dog
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Real Name: Andy
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Looking good! :thumbup:
Waiting to see what it all looks like together. :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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Unreal K-ZN
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Been a busy weekend so far. Managed to get the dog box on the chassis and get the bin back on yesterday. Today is the task of reconnecting all wiring, fuel etc.
but for the first time I get to see what she is going to look likeImage

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Mud Dog
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Real Name: Andy
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Love it ! :thumbup:

What are your intentions with this space?
bcc1d9e1bbda5bc81e27e43e9f098f13.jpg
You could build a couple of boxes that bolt on from underneath to be used for tools or whatever. Can have separate door flaps or your main gull-wing doors can cover them. :winkx:
When your road comes to an end ...... you need a HILUX!.

Image
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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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Unreal K-ZN
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Mud Dog wrote:Love it ! :thumbup:

What are your intentions with this space?
bcc1d9e1bbda5bc81e27e43e9f098f13.jpg
You could build a couple of boxes that bolt on from underneath to be used for tools or whatever. Can have separate door flaps or your main gull-wing doors can cover them. :winkx:
Shot Mud DogImage
I had thought of putting two boxes in there for wet stuff and or dirty stuff like wetsuits or recovery straps so the mess won’t interfere with the clean space inside.
The other option is to put a recessed step into that space for swambo, she’s a bit shorter than me and the truck Image
Will just have to see what’s going to be best


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Mud Dog
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Real Name: Andy
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Got the same problem with my wife, Gareth ... a real shorty. Problem with a step so far back it's an impractical off-set, and then also it's gonna look a bit odd if you drop it below the sill height. I would rather fit boxes and then do some sliders / side steps (full length) which are in any event below the sill height and so is more helpful as a step.
When your road comes to an end ...... you need a HILUX!.

Image
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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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FIRSTGEER
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I agree with you and Andy. Good place for even storing the potjie pot and recovery gear. I would also look and see if your second battery could possibly be mounted to free up space above it. Look at my camper build thread and so how I tried to utilize every possible hook and cranny.
Yours is a very unique and practical build. You'll see that after each outing you will possibly change and fine tune aspects of the build to suit your needs. I congratulate you on a job well done.👏👍
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Unreal K-ZN
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Hi guys.
Nearing the end of phase 1. The dog-box is built and fitted.
Next up I need to test everything before doing all final coverings and touch ups and wiring.
After that it’s onto the bin mods next yearImage
And some boxes under the box
A few pics taken yesterday afternoon

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Mud Dog
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Town: East London
Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy
Club VHF Licence: HC103

Looking very good! Nice Job! :thumbup:

I hope you're still going to seal all the composite material to protect it from moisture. :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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Family_Dog
Moderator
Moderator
Posts: 12969
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:

Nicely done, Gareth. This truck will be something to really be proud of once you are done. :thumbup:


-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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Dowe Koos
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1054
Joined: Fri Oct 10, 2014 6:44 pm
Town: Pretoria
Vehicle: Toyota Buschwagen 2.7 4x4
Real Name: Hennie

Very cool, love your idea Gareth.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Unreal K-ZN
High Range 2WD
High Range 2WD
Posts: 17
Joined: Mon Sep 09, 2019 4:32 pm
Town: Ballito
Vehicle: 2013 Single Cab
Real Name: Gareth

Thanks guys.
Final day today to get her ready for the 1000 hills Xmas toy run tomorrow.
90% done with 90% to go pretty much sums up my day ahead


Keep it Unreal
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FIRSTGEER
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1540
Joined: Thu Sep 30, 2010 6:00 am
Town: King WilliamsTown
Vehicle: 2,5 D4D Singlr Cab 4X4 Full OME suspension. snorkel.GMA aftermarket bullbar.
Real Name: Tony Geer
Club VHF Licence: HC 109

Enjoy your holiday and you can proudly display that superb and unique build of yours.Well done indeed :thumbup:
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FIRSTGEER
LR4WD, Lockers, Crawler Gears
LR4WD, Lockers, Crawler Gears
Posts: 1540
Joined: Thu Sep 30, 2010 6:00 am
Town: King WilliamsTown
Vehicle: 2,5 D4D Singlr Cab 4X4 Full OME suspension. snorkel.GMA aftermarket bullbar.
Real Name: Tony Geer
Club VHF Licence: HC 109

Howzit Gareth. I have been waiting to hear how your conversion build to your hilux performed during your December travels. Kindly post an update on your creation
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