Explorer I
For sale is a 1991 Toyota Land Cruiser HDJ80 expedition camper built around Toyota 80 Series running gear, fitted with a 79 Series cab and a Maltec carbon fiber living cabin.
This is an HDJ80-based expedition camper with Maltec-built carbon fiber living quarters and Maltec-performed cab/cabin/frame integration. Maltec built the camper living space, integrated the 79 Series cab and carbon fiber cabin with the 80 Series platform, and extended the frame to accommodate the conversion.
The mechanical build was completed separately after import and includes a Toyota 1HDT crate engine, rebuilt H151F manual transmission, triple lockers, long-range fuel, custom suspension, Maltec carbon fiber living space, lithium power, solar, Webasto diesel heat, onboard air, water, refrigeration, and a compact camper interior.
The result is a rare, mechanically serious diesel Land Cruiser expedition camper built for long-distance travel. It is best suited for someone who understands diesel Land Cruisers, expedition conversions, and the difference between a branded camper/chassis conversion and a bolt-on overland build.
This is not a pavement-only collectible, a generic camper van, or a cosmetic overland build. It is a purpose-built expedition truck. Turn-key and ready to take you around the world.
The mileage displayed on the dash is not representative of the completed vehicle. The odometer belongs to the donor 79 Series interior that Maltec used when building the truck. It currently reads 290,222 km / 180,335 mi. Since the camper was assembled, the vehicle has approximately 35,000 miles of use, with most major engine and drivetrain components having approximately 29,000 miles.
More Photos
Overview
Model: Toyota HDJ80 Land Cruiser
Year: 1991
Camper Builder / Chassis Conversion: Maltec
Cab: Toyota 79 Series cab
Camper: Maltec carbon fiber living cabin
Engine: Toyota 1HDT 4.2L turbo diesel crate engine
Transmission: Toyota H151F 5-speed manual
Drivetrain: Full-time 4WD
Lockers: Front, center, and rear electronic locking differentials
Seats: 2
Wheelbase: 128 inches
Weight: Approximately 6,000lbs empty with both fuel tanks full
Fuel Capacity: Approximately 50 gallons total
Color: Toyota Army Green, paint code 6V7
Build Provenance
Maltec was responsible for the living cabin and core conversion architecture. Their work included the carbon fiber camper living space, electrical support systems, 79 Series cab integration (2013), marrying the cab and camper structure to the 80 Series frame, and extending the frame for the final configuration.
The drivetrain and mechanical expedition systems were replaced after import. That work included the 1HDT crate engine, H151F transmission rebuild, suspension, fuel system, air system, and other mechanical components not directly related to the Maltec living cabin or chassis/cab integration.
Mechanical
The truck is powered by a Toyota 1HDT 4.2L turbo diesel crate engine, not a rebuild, with approximately 29,000 miles since installation. The H151F 5-speed manual transmission has approximately 29,000 miles since rebuild.
* Toyota 1HDT 4.2L turbo diesel crate engine, approximately 29,000 miles since new
* Toyota H151F 5-speed manual transmission, approximately 29,000 miles since rebuild
* Full-time 4WD
* Front, center, and rear electronic locking differentials
* Terrain Tamer front and rear lockers
* Rebuilt injection pump, approximately 29,000 miles ago, by Fred Holmes Fuel Injection
* Rebuilt injectors, approximately 29,000 miles ago, by Fred Holmes Fuel Injection
* HPD Australia air-to-air intercooler, model IK-801HZ-S2T
* GTurbo Grunter Vortex Green, Series II, boost set to 17 psi
* GM-compatible fuel filter for easier parts availability
* Long range fuel tank approx 25 gallons (total front and rear approx 50gal)
* Custom TorFab airbox using GM air filter for easier parts availability
* New A/C compressor installed approximately 29,000 miles ago
* Additional condenser/radiator fan with manual on/off control
* Condenser for power steering
* GlowShift EGT gauge
* Wilson switch for glow plugs
* Truck battery shutoff
Chassis, Suspension, and Brakes
The truck uses Toyota 80 Series running gear with factory solid axles front and rear. Maltec extended the frame as part of the cab and cabin conversion. Additional reinforcement has been performed where appropriate.
* Toyota 80 Series frame and running gear
* Frame extended by Maltec for the camper conversion
* Frame reinforced where extensions were made
* Steering box area reinforced to address the known 80 Series frame-cracking issue associated with lift and larger tires
* Rear frame cross member replaced with stronger piece
* Front and rear solid axles
* Custom-valved Radflo shocks
* OME coil springs
* Whiteline heavy-duty rear sway bar
* Factory 80 Series front disc brakes
* Factory 80 Series rear drum brakes
Wheels, Tires, Recovery, and Exterior Equipment
* Braid Winrace T wheels
* Falken Wildpeak A/T4W tires, 315/75R16, including spare
* Approximately 8,500 miles on the tires
* Tires installed at 277,404 km / 172,371 mi
* Black powder-coated aluminum front bumper
* Warn Zeon 10-S winch
* Factor 55 FlatLink MultiMount
* Aluminum skid plate
* L-track mount for Maxtrax or sand ladders
* 4x Action Tracks
* Fiberglass hood with locking latches
* Built-in ladder to access the roof
* OCAM 4x4 truck mirrors
* Philips X-treme Ultinon LED H4 headlight bulbs
* Front Runner Slimline roof rack
* Front Runner 40-inch LED flood/spot combo light bar
* Iron Man Fog Lights with amber covers
* Aluminum roof storage box
* Rear exterior storage boxes for fluids, tools, and hardware
* ARB 2500 Awning
* Deadman Recovery
* Safe Jack Bottle Jack baseplate for off-road use
* Shore power outlet
* Exterior shower outlet
* Back-up camera
* Maltec carbon fiber cabin covered in 3M paint protection film, except rear and roof
Cab Interior
The cab is simple, functional, and built around travel, comfort, and secure storage.
* Scheel-Mann Vario F heated seats
* Ceramic window tint on side windows and windshield
* One Stone Armrests
* Department of the Interior Australia ceiling storage console
* Tuffy locking center console
* ARB dual air compressor with air outlets on both passenger and driver side
* No radio or stereo system installed
* Former speaker locations repurposed as concealed storage compartments
Maltec Camper Interior
The Maltec carbon fiber cabin is compact, lightweight, and functional. It provides sleeping, cooking, refrigeration, heat, ventilation, water, power, and storage in a small expedition footprint.
* Seating area for four
* Seating converts into bed sleeping two
* Pop-top bed sleep 2
* Storage beneath seating area
* Additional concealed storage compartment beneath floor
* Two-burner Dometic propane stove with integrated sink
* Dometic CRX80 fridge, approximately 85 qt
* Webasto diesel heater with two cabin vents
* Walnut cabinet tops
* Lightweight sandwiched-aluminum cabinet fronts
* Soft-close drawers
* Dometic roof fan
* Simarine digital monitor for power usage, interior/exterior temperatures, and water level
* Pop-top canvas with removable bug screens on side windows for increased airflow
* Dometic cabin windows with integrated bug and privacy screen
* Back window opens completely (see photos)
* 3x 12v power ports and 2x regular outlets
* LED light strip for cabin lighting and 2 spot lights
Cabin Electrical System
The camper electrical system uses lithium storage, solar charging, shore-power charging, and Victron components.
* 300Ah LifeBlue low-temperature lithium battery
* 400W solar system using four SunWare panels
* Victron SmartSolar 30A MPPT charge controller
* Victron 25A shore-power battery charger
* Split-charge system between truck and camper battery management
* Victron 300W pure sine wave inverter
* Alternator charges house battery
Water System
The water system is designed for remote travel and cold-weather use.
* Approximately 33-gallon water tank
* 12V water pump
* Water filter
* Sink plumbing
* Exterior water hookup
* 12V Falcon heating pad mounted to bottom of water tank to reduce freezing risk
* Insulated water hoses
* Heat-Line Kompensator KHL125 self-regulating heating cable on water lines to reduce freezing risk
* Space and plumbing remain for a 3-gallon engine-heated hot water reservoir
The hot water reservoir has been removed. We rarely used hot water and preferred the additional storage.
Known Issues and Disclosures
This truck has been used as an expedition vehicle. It has cosmetic wear from real travel and off-road use.
* Small oil leak on lower front of engine block. So small it doesn't manage to drip onto the driveway.
* Pop-top roof hinges may need adjustment; roof currently sits slightly crooked
* Roof alignment has been mostly aesthetic and has not affected use
* Small tear in passenger-side roof-canvas bug screen
* Tear in front roof-canvas bug screen
* Small dent in passenger door from contact with a tree trunk off-road
* Forest pinstriping and cosmetic wear from trail use
* No radio or stereo system installed
* Hot water reservoir has been removed but part can be included in sale
* Paint on carbon fiber roof has checking. This is common on these carbon fiber Maltec trucks. Our Troopy from them had the same thing.
