1UZ-FE into my 93 Hilux

[trentmeyer23]

that thrustwasher looks like it was starved of oil

[v8toy]

previously i had managed to remove the factory steering setup and fit the hi steer arms and also fit the track rod and drag link in.

****ty pic but front view of mockup of steering setup

view from passenger side its paramount that both the steering rods are paralell so they dont hit on suspension flex

and view from drivers side

today got the fish plates for the ifs steering box in place, drilled holes, cut the crush tubes to suit, and tacked everything up ready for welding.

pic from inside chassis rail

outside pic of everything mocked up ready to tack

during the week im gonna grind up the old shock mounts i cut off then tack new shock hoops on and then next weekend ill hire a gas mig and weld the steering box, front shock hoops and rear inverted setup all done

missus picked up the rest of my gauges on for me, been mucking around tryin to fit them in a 4 runner dash gauge pod its been a tight fit but got them in.

i got a oil temp, oil pressure, water temp(all in degrees celcius) and the wideband gauge.

ill get the whole lot re upholstered similiar to the factory grey interior.

then made a .6mm ally mount for the gauges also folded 3 edges on it to give it a bit of strength and somewhere to put some screws.

i shaped the pod to fit the dash better with just enough room to get the the first gauge in

all thats left is to drill a hole for the wiring and acouple to mount it to the dash once all upholstered.

basically just finished welding the fish plates in for the ifs box cleaned up the chassis rails with the flap disc and welded and gusseted the shock hoops.

its all cleaned up and painted now, im a bit worried about the drag link clearing the sump but with a acouple of quick runs with the tape and my eyes i think i might be safe, full compression will figure that out tho.

wheel her forward tomorrow and weld the inverted rear shocks in there all tacked there just need some more glue on them.

and as of saturday 9th oct

IT RUUUUUNS AND BETTER THAN BEFORE

even took her for a fang around the block and im hard lol

small oil leak to sort out and try and attach some shocks this week

ok so the engines all good i thought the small oil leak was from the sump not being sealed quite right, so after doing a whole 1 hrs work at work this morning i was sent home (as theres not a scareck of thing to do there), i pulled the sump of and resealed it only to notice it was leaking from the input shaft seal on the gearbox ( spose i gotta expect that its been sitting idle for 3 yrs).

not to worry tho i gotta take the gearbox x-member in to be powder coated so i might as well slip the box out and fix it all at the same time.

no.2 injector isnt doin its thing properly either, according to the lappy its intermittent checked it out and its getting full voltage all the time at the plug but the injector itself is prob toast so gonna rip them out tomorrow and and get them sorted atleast then ill know its got good injectors when it hits the dyno.

other than that the engine runs really smooth for a rich map thats loaded in the ecu and its has a really nice crackle when i snap the throttle. (ill get another vid tomorrow).

also parked her on the lawn this arvo and give her a bath and got really carried away and cut and polish the whole rig shes lookin all shiny again

cheers

stewy

Edited October 11, 2010 by v8toy

[ELEGNT]

oh dude thats awesome!!

great work on it hey!

[v8toy]

lux has had a full wheel alignment during the week, it had 4 degree wedges put under the leaf packs to correct the caster and it had 1 degree shim in the passenger king pin to correct the camber of that wheel, plus the toe in/out and spoke position since the new steering arms have been fitted.

i had a fella machine me some shock bushes for it and then fitted up all the shocks last night

and he did a sweet job too and i also made a cardboard airbox and templates up and most probally if not tomorrow or sometime next week will cut/fold and weld that up

the airfilter its a unifilter and has a outerwear cover for it

sitting in the box itll obviously sit off the bottom and closer to the top incase i fill it with water and mud and also has room for a drain valve in the bottom

with the outerwear which will only be used for offroadin so it will prob be in there 99% of the time 8O

and in the car in the ome battery spot

so then i just took it for a run down the bottle shop to ummmm test the new shocks and they work a treat on both full soft and full hard settings

got a fair few looks not sure if it was cause of its shear awesomeness or the lack of no. plates lol

stewy

[v8toy]

took it out for its maiden offroad voyage on sunday

i had it tiltrayed there and back because of no rego and is cheap really.

i had my mate in his duallocked and front and rear winched 75 series as my helper/recovery vehicle.it normally runs a set of 34" simex's with staun internal beadlocks but took the rd tyres for the day haha

i had no front tailshaft so today was more of give the engine a good run and try tune it a fair bit more and also just a general test to make sure most things were working before it does go for rego.

also had no snorkel so deep water crossings were a no no

all in all i am 100% happy with the lux and the only troules i had was the crappy ac delco igniter/coil pack failing and arcing on its bracket a quick adjustment away from the bracket and its was running smooth again.knew i shoulda kept the ***** gm crap of it.

and the crappy exhaust system i had someone make up originally failed on the bracket side as they only used crappy rubber for the hangers and it melted of.

and a small power steering leak that developed during the day

oh and a staked front tyre

as for the engine man its fast i would put it up to being not the same but close to the power of my v6 aurion it would pull second gear power skids,

me and d1 also had it running really smooth the engine wasnt moving at all at idle if it wasnt for the exhaust note u wouldnt know it was running

took it down the long sand straight acouple of times for power runs and to load her up and my mate can vouch for this its friggin fast i had it 4th gear flatout across the sand and the suspension took it sweet

we went to get a video of this but had quite a recovery emergency to deal with and ran outa time before the tilttray rolled up.

just acouple of pics

mate dan settin up for a pose

dan gettin ready to snatch the transit van lol

and these fellas we recovered were the same young dudes from a mareeba 4wd fun run day that were stuck down the back of the property, again no recovery gear and no idea if i new it was them straight away we wouldve kept goin

so the things that need attention are the igniter pack, a bit more adjustment for the gearbox x-member, reroute the extended brake lines so they dont rub on tyres at full lock, power steering leak, and another small sump leak which i allready knew about, and try figure out something with the stupid exhaust dont know wether to build my own stainless one now or after rego.

all small things which dont stop me wheeling it

also shut down a fella in a 75 ute tryin a hill climb i did it in 2wd lol

cheers

stewy

Edited March 31, 2011 by v8toy

[v8toy]

acouple of poser pics after a wash from yesterday next to the aurion

stewy

[v8toy]

this is a quick vid from about 3 weeks ago i had a inj output issue on the ecu but got it sorted with a change of a value in the injector sequencing folder

mind the fuel smoke lol but its much clearer after the sunday run

not this weekend but the weekend after itll be back out for another run with the said problems sorted fingers crossed.

stewy

[Zeinheiger]

Wow mate, that scares me a little bit, nice work on it though, good to see you actually using it for what it's built for as well

[01 VEY]

I must say that I am no 4by fan but that Hi-Lux is sensational. Obviously it’s built for offroad excursions where no man dares go.

Your ingenuity seems to have no bounds though I’m sure it would have been handy having such a workshop to do things in. Love what you have done for the steering system. Also the ....everything. What’s not to like. My goodness that looks fearsome - WOW

This saga has been a story with triumph and tragedy all rolled in. I nearly cried when you told about the cam seizing. That really would have hurt.

Take it steady up there on the wet roads. That beast will be a thrill a minute.

[v8toy]

cheers fellas it sure is built to go far offroad but that could get me in the ***** next investment is a 9500lb winch for the front, then lockers front and rear.

it has been a super slow and painful journey but i can now see the light

i was shaking when i took it for its first offroad/onroad test in so long, really nervous

and as for the wet rds yeah thats gonna be a mission lol except when its flooded

i got my front tailshaft back lastnight and bolted her in also fixed tghe powersteering leak with a nice new return hose.

so couldnt resist i wanted to see it flex in 4by, i ran outa aurion wheels to drive up but its got miles left in the front and not much in the back going to leave it for a few runs and see how its goes if not might do some work to the leaf packs.

its got crap loads of rear shock left and the springs are quite tight still should be able to get at least anotehr 150-200mm of downtravel yet

if only i had another set of genuine sportive aurion wheels :P it could of gone way more

[v8toy]

not much been happen to the lux mainly cause of lack of funds and the monumental amount of bills lately but good news is i got a mammoth tax return happenin

i have been building a new zorst system for it and sometimes i hate myself for being so perdantic with things but it will be a really nice zorst once done only in mild steel tho.

i got airbox pretty much set i just need to get motivated and tig it up and ive got some 88mm stainless pipe and ally tube lined up for the snorkel and intake do these items then its out for another play

tax will also pay for my rego and engineers crap so ill say it again fingers crossed itll be drivin soon

i also swapped my aftermarket mags of my aurion for a 9500lb warn winch for the front its a good deal as one mag is smashed from a big ***** far north qld pothole and a new winch is 2g hehe

i also was navi for a local 4by comp last month so that took a lot of time getting our comp rig ready for action

comp pics

our truck just a 2.8D powered 85 lux runnin front and rear lockers winch and about 5-6 inch lift

rollover no.1 we had 2 for the weekend

and a vid

http://vimeo.com/25742909

cheers

stewy

[v8toy]

this was our damage list

bent doors

bent roof

broken mirrors

bent pillars

bent and cracked exo(tree on stage 10)

cracked chassis

cracked bullbar

snaped superior toque rod

striped some bolts off the steering box

burnt out winch

and when i un loaded it and put it out the back it poped a CV we took 4 spare set with us and didnt bust one during the weekend hehe

[v8toy]

been rebuildin the winch since sunday

stripped it down and the grease was pretty shagged probally never had a freshin up ever, cleaned all that up in the parts washer then got onto the motor side and it was lookin worse wear but believe it or not still worked fine

so on order is acouple new gaskets, some new mounting bolts (these are a special square style nut to stop them spinning while doin them up), and a new 500amp new warn style solenoid and a new hand controller.

the motors at the lecky fella and he's freshining that up and put some sort of marine lecky coating on it so im told.

the housings are also been bead blasted tomorrow and once back i will give them a lick of paint

other than that its in good order ive also got some new winch switches coming they look exact same as arb airlocker ones but are for winch in and out and winch power this will allow me to operate the winch from the cab if my winch bitch is to far from the hand controller

it gonna cost far less than a new one at around the $300 mark rather than $2000 for a newby

new old winch

the old grease and gearbox

the armature believe me it still spooled in and out

and most of it in bits

hopefully more updates on that this week

also gettin myself a new tig this month told its a 3-4 week wait for it.

its a unitig 200A ac/dc machine been told they arent to bad for a home w/shop fella so we will give that a wizz see how we go

[01 VEY]

I would recommend a decent tacky gear grease that will 'string up' as the gears work with each other.. A multi-purpose grease is just not good enough for winch gears.

Maybe all someone like Shell, BP or Caltex 1300 tech advice lines for the best recommendation.

I must say you don't do anything by halves.

[v8toy]

cheers mate

ive had enough time to hopefully perfect what im trying to achieve so no excuse for failure lol

hearing ya there, me and my mates up here use a sticky horrible orange grease that my mate can get hold of where he works the ***** is worse than sika lol

its a heavy machinary grease and the amount of mud and water we wheel thru it doesnt let nothing in

that cruiser on the other posts runs it in his front and rear winches wheel bearings springs the lot and we buried that thing up to its winches in mud at the start of the year (middle of the wet season here lol)and when we pulled the winches down the water hadnt got past the grease pulled the wheel bearings out and same story. i try get the name of it when he delivers me some.

bought my cat convertor last night and 3m's of 3" pipe so besides some geniune toyota exhaust rubbers i have everything to finish my exhaust

best i go make a start now.

cheers

stewy

[v8toy]

more updates

first up this is the grease we use in all our stuff

http://www.moreyoil.co.nz/details.php?&name=MOREYS+BIGFOOT+EP+GREASEcatID=12&productID=8

youll see it in the fotos coming up

i got the new gaskets for the winch today they ordered 4 in for stock i needed 2 so i bought the 4, seen as i had to wait a week for these ones and they only $2.70 each anyway

i got my new winch solenoid this is the new version for the warn winches and it replaces the four they normally run with one unit which is much smaller and waterproof, made a bracket for it outa 3mm ally plate and put in ally rivnuts to hold it all in place in the engine bay

new vs old

this is it

http://www.ebay.com.au/itm/12V-Winch-Solenoid-DC-Contactor-ARB-Warn-Tigerz-Ironman-/300587671985?pt=AU_Car_Parts_Accessories&hash=item45fc6be1b1

cleaned up all the drivetrain ready for reassembly the parts washer made this much easier lol

my mate delivered my blasted and etched gear train bits to reassemble it all

1 stage planetarys all greased up and fitted back in

2nd stage back in

itermediate housing back on

and all reassembled bar the brake shaft and brake setup thatll go back in the drum when i get the motor back plus i give it a lick of dark grey paint

also got some 5/8" staino solid to spin some new drum tie rods up to replace the ally ones

those dirty scabby ones above the drum

which will be shiny and strong using this

[v8toy]

also went on a bit more of a spending spree today and got a new cat convertor, some 3'' flanges and some 3'' pipe to finish of the zorst

i then got real carried away and found some 3" stainless tube and bends to have ready for my snorkel and then got distracted and found some 88.9mm od and 6mm wall ally tube for my intake under the bonnet.

Now i know ya thinking why the hell 6mm well theres a reason once i have got my lengths i need sorted ill put it in the lathe at work and machine it down to about 3mm thick while leaving a nice little 6mm lump/ridge all the way round at each end to make it look all the more factory and help retain the rubber joiners on over kill yes cool i think yes too

some pics

the 3" bends were more exspensive than the 2m's of staino tube and ally tube put together

88.9x6.3 something ally tube

76.2 staino snorkel tube

and boring 75mm zorst pipe

not much will happen on the weekend goin away for 2 days may get something done sunday arvo

[01 VEY]

You won't find too many better products than Moreys. I have only used the heavy oil stabilizer as engine assembly lube but will always recommend their stuff.

Looking great.

[v8toy]

agree, heard alot of good things about moreys and only just started using it since being in cairns not cheap tho

had a minor setback with the winch turns out the brushholder has cracked brush springs

thought it would be an easy fix so went to arb to check out a newy and oldmate turns around and says "u cant buy brush holders for warn winches you have to buy whole new motor for $350" 8O 8O

rang ateco down south and its all pretty much sorted now, answer is you can get brush holders and olemate doesnt know ***** lol. :roll:

other than that got acouple of switches delivered today 1 for the winch in and out and another for all the spotties, also got the warn mounting bolts and square nuts

switches

mounting bolts

also got on the lathe at work today and spun the 5/8" staino rod for the winches tierods to length and drilled the holes ready for tapping

started tapping the first one when i got home and broke the tap 3/4 the way thru doing the first hole, new it would happen i was using the wrong type of tap for stainless blind holes. :(

heres where i got too

old one in the middles

tomorrow after work should consist of more zorst work

[v8toy]

got the brush springs sorted

ateco equipment told me to go to tjm cairns so i did but they didnt have one in stock or any brush springs and the new brush housing is $230 and there are for types for the xd9000 mine just so happens to be the most exspensive.

so with more investigation i rang a contact in melbourne who does alot with winches and found some springs, so they are on there way and winch will be near complete to be fitted up.

did some more zorst work tonight, i have the 2-1 section all fabricated, i have the cat convertor bolted in place, gonna see if my old muffler will work with my new plans if not ill buy a newbie but otherwise only have the 3" section of pipe to finish which is straight forward then weld it out.

whole exhaust will use the factory chassis mounting points

so more zorst work tomorrow

stewy

[JDM-GTFour]

I've got a 92 Hilux with the slug 2.8d still in it.. after seeing all the work you went thru with yours, mine will be staying with the slug motor! Very impressive.

[v8toy]

really its not that much work im just to perdantic on things for instance theres not one tech screw holding anything on if somethings been moved or somethings been added ive either made a bracket to suit or put a rivnut in.

and ive gone to alot of other extremes others havent in there conversions wiring for one

plus ive done absolutely everything myself now

i reckon if i was to do another one knowing what i know now and what works i could knock one out exactly the same in about 3 weeks working on it solid

[v8toy]

getting closer now

so exhaust is all fabricated just needs welding up

winch is all done just needs fitting and some wiring

and i recieved my new toy today to complete the rest of the lux, its allready had a workout and its worth every cent of the sub 2g there going for.

so airbox is all welded up now, finish fabbing lid soon and fab some mounting tabs and its good to move onto the rest of the intake.

new toy

its a 200 amp AC/DC TIG with all the bells and whistles, ive been waiting 4 weeks for it and apparntly so im told its the first to be sold/used in qld of the new facelift models.

its a sweet machine and exedes my expectations of a so called cheaper machine.

about the 4th run

TIG all dialed in and performing well

so with a house move coming up in about 4 weeks i do HAVE to have the lux in a driveable/moveable state buy then

lets see how i go with this deadline

cheers

stewy

[ben yip]

good to see your tank with many cannons..

[v8toy]

tiny update

since gettin my tig i finshed or nearly finished the airbox pretty have the lid sorted just need to make some mounting tabs on the outside of the box then i can plumb it up and start on snorkel

i learnt a trick while working for custom works in darwin so i thought id see if i could apply it to this airbox

this is the lid after i welded it up and sanded it smooth

and one of the edges u can see the uneven edge that needs to be tidied up

and afterwards all tidied up and a constant radius all the way along

the tool for the job a simple wood router using a 1/4" radius bit

now my secrets out, some tips, using such a tool on ally doesnt hurt the the router bit at all, i even use a tiny bit of wax to help it but aslong as you go slow and not jerky it leaves a smooth consistant radius just as you would on timber.

next time id use the next size down in radius to match the other sections that i folded on the panbrake but still this size looks and turns out good

cheers

stewy