T-Ones Hilux upgrade thread

[T-One]

Hi Guys,

i have quite a todo list before our next long distance journy starts.
Regarding the car itself it's the same every time for most parts, but because my better half upgraded her standards quite a bit i have to do a lot of stuff with the camper.

I will keep you guys updated on the process in this thread and share some insights with you.

Todo Car:

• Changing all liquids and lubrications
• timing belt
• alternator belts
• glowplugs
• differential seals
• cardan shaft seals
• leaf springs
• Tires
• rust prevention
• fixing the front bumper

Todo Camper:

• fixed solar panels
• Two new AGM batteries
• b2b charger
• solar charger
• larger roof hoods
• new insulation
• switching from LED illuminants to all LED low profile lamps.
• new kitchen area/fridge cabinet
• under floor water tanks (100L) (+60L to the previous tank)
• under floor diesel tank (60L) (back from a 180l spare tank in the camper to a smaller 60l under the car, 120L should be enough) switched to a 134 Long Ranger Tank that replaces the old one
• complete new water system (with hot water)
• fixed water filtration system (portables are way to slow)
• new vehicle-heater (old one was a extremly loud)
• new outside shower (needs a hot water mixer now)
• new awning (270°)
• new tent fabric (wont do, just fixed the old one)
• rear spare wheel carrier (need the room where the spare wheel is placed for the 60L diesel tank)
• outside attachment points (have to get as much stuff attached on the outside as possible, it's getting cramped inside)
• info system (battery, water)
• backup camera

So here it all begins:

 

[Low594]

Great restoration project!

 

[T-One]

So yesterday we did some stuff.

At first we removed the lights, panels and insulation of of the roof.



We also removed the old roof hoods



Extended the cutout 7,5 cm on both sides to get a 50x50cm for the new larger roof hoods.
Because of the square steel tubing that supports the roof we did the cutout with an angle grinder.
If you ever use an angle grinder on your car be very cautious about the flying sparks, they tent to do all kinds of nasty stuff with glass and the paint, so cover up all vulnerable parts on the inside and outside.



Perfect fit of the new hoods



In the next days a rectangular 52x52 cm steel frame will be welded to surround the roof hoods, this frame will be welded on to the existing square tubing to give the roof enough support to walk on it again.

We also removed the old kitchen block:



And discoverd a bit of mold, yikes!



We checked some other parts for mold and we found a lot of it under the boarding of the pull-out bed.
Looks like a fundamental redesign of this part is necessary.




After this discovery i was a bit pissed and had to do something different to get a sense of achievement for this day, so i fixed the bumper:



YEAH, FIXED BUMPER!


Thats all for today.

 

[T-One]

We welded some support frames for the windows:



to hold the windows in the correct spot while marking the cutouts for the new frame we created a simple retainer


Both frames in position


a little bit of sanding, taping and zinc spray



and some colour


Next we will add the windows and the solar panels.

 

[T-One]

Long time no post, here is what happened:

Sealed all seams on the roof and installed new window frames: (every time i glue or seal i use stuff from Sika (dont now if this is available in the US)



Fixed some rust issues on the bed seams and redone all seals



More rust related fixing



added solar panels


cooked some delicious roast pork


added lights (and windows)



build a new rack for the fridge


removed the interior and fixed some rust on the bed


glued felt on the old walls


redone the whole insulation and looked at my new gorgeous walls (also inserted a new floor and some of the old interior)


added a snorkel and lashing rails (also changed the windshild)



installed a new awning (eezi awn batwing)


and a long range tank (also a a new undercoating)


that's it for now, last thing we have to do on the outside is relocating the spare wheel carrier to the back door, install a new water tank under the bed also all the interior stuff and electrics are next.

 

[Ob1]

Love what you have done to the truck. It’s very fulfilling being on the trail knowing that you were the one who put the vehicle together. Also helps when it breaks. :) What kind of range do you get with the new tank?

I also spent some time building/fabricating a vehicle. Wrote a blog about it in this thread.

Building a home in a 80 series Landcruiser

About 25 years ago we bought a family car. A 1993 Toyota FZJ80 Landcruiser. It served us for 20 years for family camping, and car pooling around town. Now that the 4 kids have left the house, we have no use for it. Looking at the low resale value, we decided instead to invest and convert it...

www.overlandbound.com

I wish I had the space you have in the truck.