2001 Montero Sport ES 3.0L

I bought it new, and it did daily driver duty till 2006, at which point it got 4.90 gears, a rear ARB locker, 2"rear coils/2" body lift, and 33's.

http://i128.photobucket.com/albums/p166/sthsdr/badlands07032.jpg
http://i128.photobucket.com/albums/p166/sthsdr/3days004.jpg
http://i128.photobucket.com/albums/p166/sthsdr/devilshead06051.jpg

I wheeled it for a year like that, then the SAS started.

http://i128.photobucket.com/albums/p166/sthsdr/sas002.jpg
http://i128.photobucket.com/albums/p166/sthsdr/sas001.jpg

Got my Dana44 from a 79 F150 and installed 4.88 gears and another ARB.

http://i128.photobucket.com/albums/p166/sthsdr/sas004.jpg

Used the wedge parts of the Ford radius arms, and spliced them to 2"x.250"DOM with some .250 gussets and 1" heims on the end. These arms ended up being 6" longer than stock. I located the axle an inch forward from the IFS centerline.

http://i128.photobucket.com/albums/p166/sthsdr/b1009.jpg
http://i128.photobucket.com/albums/p166/sthsdr/b1010.jpg

Had to modify the trans xmember to clear the arms. Now it bolts to the inside of the framerail instead of under it.

http://i128.photobucket.com/albums/p166/sthsdr/sas013.jpg
http://i128.photobucket.com/albums/p166/sthsdr/sas011.jpg

I went with Wild Horse 5.5" EB coils and Ballistic adjustable buckets, Pro-Comp 14" travel shocks and Ballistic towers.

http://i128.photobucket.com/albums/p166/sthsdr/b002.jpg
http://i128.photobucket.com/albums/p166/sthsdr/b2008.jpg

The trackbar and draglink are 1.5"x.250"DOM with Poly's on the trackbar and 7/8" heims for the draglink. The steering gear was moved forward about an inch and down a little.(Can't find pics right now.)

For the rear I swapped the stock trailing arms from the bottom to the top of the axle, kind of like a SOA. Then I raised the trackbar mount, reused the stock trackbar, and went with Tuff Country Easy Ride 3.5" XJ front coils, and two more 14"Pro-Comp shocks.
Before
http://i128.photobucket.com/albums/p166/sthsdr/b2001.jpg
After
http://i128.photobucket.com/albums/p166/sthsdr/b2006.jpg
http://i128.photobucket.com/albums/p166/sthsdr/b3005.jpg

The xmember that holds the front of the gastank got in the way of the rear driveshaft droop so I replaced it with some leftover 2"x.250"DOM.

http://i128.photobucket.com/albums/p166/sthsdr/xmem003.jpg
http://i128.photobucket.com/albums/p166/sthsdr/z10010.jpg

On to the doubler. The stock Mitsu t-case had a ratio of 1.90:1 and no other gears are available.
So, in order to get an Np231/D300 into my Sport I had to swap in a different trans. Luckily the 97-99 Sports came with the Aisin 30-43LE, Same as the AW4 except for a bellhousing that will bolt to my Mitsu 3.0. Got one of these transmissions out of a 99 and bolted on a tail housing from a 01 XJ, and the NP231 from the same XJ. I shift it with Bretts Controller, in manual mode only, since I don't have a TCU. Twin sticks and doubler kit from DDMachine.

http://i128.photobucket.com/albums/p166/sthsdr/sas017.jpg
http://i128.photobucket.com/albums/p166/sthsdr/dblr001.jpg
http://i128.photobucket.com/albums/p166/sthsdr/a002.jpg

Lastly Exhaust, RPW headers(ceramic coated), 2.5" high flow cat, magnaflow muffler, wheel well exit.

http://i128.photobucket.com/albums/p166/sthsdr/z10023.jpg
http://i128.photobucket.com/albums/p166/sthsdr/z10016.jpg
http://i128.photobucket.com/albums/p166/sthsdr/z10019.jpg
http://i128.photobucket.com/albums/p166/sthsdr/z10020.jpg


http://i128.photobucket.com/albums/p166/sthsdr/z9019.jpg

There have been a few changes this year, like PSC hydro assist, and high steer(not installed yet). I'll get some more pics up after I put the high steer knuckle on. :beer:

So does Marks4wd.com not make gears for your monty?

So does Marks4wd.com not make gears for your monty?

That's correct. I emailed them to check and was told that they won't work in the 3.0 auto Sports. Also they're $1,395AU.

They made the low range gears for my truck but the ujoints on the front driveline would have bound, so didn't even bother. I figured, if I am going to spend that much I might as well spend a bit more and get the Atlas.

That is a very cool rig. Good job

I think if you're going to run 18s you better have some nice big brakes to fill the hole...:flipoff2: Got any video of it?

Found a pic of my current steering link setup with hydro assist.

http://i128.photobucket.com/albums/p166/sthsdr/Picture014.jpg

Still have to install my reid racing high steer knuckle on the passenger side to eliminate the misalignment spacers on the draglink, reposition the tierod to the top of the knuckles, and get a little better turning radius.

That looks much better.

He gets by... :lmao: Super nice setup. Pulled me back to the parking lot.:(

http://i132.photobucket.com/albums/q34/Trishka523/104_0002.jpg

Good to see ya here. How's the case replacement coming?

I got the new one in Sunday. Tested it on monday in the driveway. No go. :mad3: It pops and jumps out of gear. Taking it back tomorrow morning before work. :shaking:

Those 18's need 40's :flipoff2:

Welcome to Pirate4x4 good to see you here :)

did you need to swap out the tail shaft from the Jeep AW4 or just the tail housing?

did you need to swap out the tail shaft from the Jeep AW4 or just the tail housing?

Just the housing. The tailshaft speed sensor and sensor wheel need to be swapped with the jeep housing, but I didn't have to worry about this because I'm using Bretts controller to shift my AW4(manual mode only), and not a TCU.

High steer in the house.
Looks like I'll have to relocate the steering gear, assist cylinder, and track bar, and possibly bend the draglink and track bar. I'll get some more done tomorrow.

http://i128.photobucket.com/albums/p166/sthsdr/Pic006.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic007.jpg

He gets by... :lmao: Super nice setup. Pulled me back to the parking lot.:(

http://i132.photobucket.com/albums/q34/Trishka523/104_0002.jpg

that red raider is the shit!

Like they say, once you go high steer, you don't go back. I added high steer to my rig and I love it.

any chance youll have it fixed by sunday? i think i might head out to haspin for the day. i wouldnt mind someone to ride with, and check out that thing in person.

ive got a soft spot for that style montero. i almost bought one instead of the grand..... but it was out of my price range. yours looks killer.

does it feel too stiff with bronco coils? im not sure how much more a v8 bronco front end weighs in comparison. just curious

I went with Wild Horse 5.5" EB coils and Ballistic adjustable buckets, Pro-Comp 14" travel shocks and Ballistic towers.

http://i128.photobucket.com/albums/p166/sthsdr/b002.jpg
http://i128.photobucket.com/albums/p166/sthsdr/b2008.jpg

does it feel too stiff with bronco coils? im not sure how much more a v8 bronco front end weighs in comparison. just curious

I was worried when I ordered them, but they are the "Rock Crawler" type of Wild Horses coils, designed to be more flexy. I'm very happy with the spring rate, even with my aluminum headed v6.

Sorry, can't make it to Haspin this weekend, I had to order tube adapters, and tie rod ends to replace my worn out heims. :shaking:

Got my T.R.E.'s. Moved the trackbar up a couple inches, new bracket.
Just had to bend the trackbar a little to clear the diff cover. Looks like the draglink will have to be bent also, to clear the oil pan. Still waiting on tube adapters.

http://i128.photobucket.com/albums/p166/sthsdr/Pic009.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic011.jpg

props to ya for building something totally different. came out killa !

Time to start the cage. First I'm going to eliminate the body lift. Planning on tieing the cage into the shock towers and coil buckets(which have started to bend inward). Going to try to shorten the nose a little too, for better approach angle. Not yet sure how I'm going to land the cage onto the frame yet, suggestions and tips would be cool, since this will be my first cage. Got Bend Tech SE to make it easier.:smokin:

http://i128.photobucket.com/albums/p166/sthsdr/Pic026.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic031.jpg

hey do you have any more pics of the front 231 box shifter? i was planning on having to reuse the original shifter but your cable shifter looks pretty nice. did you buy it? or fab it?

wow. did the montero have a full interior before? if not do you plan on putting it all back afterwards?

Poly performance makes a roll cage tie in to the cage "kit" if you will. basically tubing in a T with bushing at the part that attaches to body. it attaches brackets to mount the T that sandwiches cage to body.

hope this makes sense.

hey do you have any more pics of the front 231 box shifter? i was planning on having to reuse the original shifter but your cable shifter looks pretty nice. did you buy it? or fab it?

Don't have any other pics of the shifter. It's a 1990 Eclipse manual trans shifter modified to move in only one direction, and with one of the two cables removed. I had it in my garage so I used it. I mounted it under the seat.

wow. did the montero have a full interior before? if not do you plan on putting it all back afterwards?

Poly performance makes a roll cage tie in to the cage "kit" if you will. basically tubing in a T with bushing at the part that attaches to body. it attaches brackets to mount the T that sandwiches cage to body.

hope this makes sense.

Yeah, I still have all the interior but don't know if it will go back in or not. I'll check on that Poly Performance thing and yes, it makes sense. Isolating the body from the cage is how I want to do it. Thanks:D

Some progress on the cage.
The main hoop.
http://i128.photobucket.com/albums/p166/sthsdr/Pic042.jpg

In.
http://i128.photobucket.com/albums/p166/sthsdr/Pic045.jpg

Going to mount next to body mount bracket.
http://i128.photobucket.com/albums/p166/sthsdr/Pic046.jpg

Front down tube
http://i128.photobucket.com/albums/p166/sthsdr/Pic044.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic047.jpg

Then this build went a little off-track

http://i128.photobucket.com/albums/p166/sthsdr/Pic053.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic055.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic057.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic086.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic088.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic089.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic093.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic091.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic092.jpg

:p

NICE!!!!!! Ive been waiting to see the cage get built since you played with your bender for a bumper on the ranger.

And I'm really interested in seeing what a chopped sports gonna look like. Waiting for a chopped gen II

Holy fucking hell that looks amazing!!!

i've considered doing that so many times to mine but i have practically zero body damage and cant talk myself into it :D

What are your plans for the back seats? Looks like they will be sticking through the rear?

Looks awesome!

When bolted in, the back seat can be in the middle or uprightmost positions. With the window open it might go back to the pimpmost position.:grinpimp:

That thing looks awesome. I've been watching your build since the start, you're the reason I went radius arms and coils instead of leafs. Keep up the good work.

Thanks, glad you guys like it. Got most of the cage pieces done and test fitted.

http://i128.photobucket.com/albums/p166/sthsdr/Pic106.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic105.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic107.jpg

http://i128.photobucket.com/albums/p166/sthsdr/Pic109.jpg

Nothing is tacked but so far it all fits pretty good, thanks to Bend-Tech Pro.:smokin:

Any new progress on the cage?

Little progress has been made. Work's been so busy.

All the tops are welded ready to lift the cage to the cieling for the last time.

http://i128.photobucket.com/albums/p166/sthsdr/pic123.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic129.jpg

I am really following this thread,, as I have thought about cutting the back off mine ever since I saw a cherokee with it.

looking good. im in the middle of my cage too right now.

cant wait to see a finished outside shot:smokin:

Picking up a ford 9 inch tomorrow, time to link the rear.
Anyone need a Mitsu 9" 4.90 ARB third?

:smokin:

Whats the price tag on it?

And Ill say this before toasty shows up and says it, the mitsu 9in is designed after the ford 9in and is a better design overall it just doesnt have the unending aftermarket support.

Nice work!, any updated pics?

it’s the RD46? Any damage? Can you put some pics of it?

This is a great build,,, I have been eyeing my 98 montero sport thinking on the same thing. Is this a unibody construction, hence the heavy emphasis on the roll cage, or is your cage for hard core offroading? I know with jeep cherokees if you do a "bob job" on them you have to reinforce everywhere you cut, because of the unibody construction.

Yeah stick the mitsi 9", or better yet buy a mitsi 9.5 out of an SR and swap in some 4.90's you'll be set and you can make that radius arm setup flex like a jerk. Also the way those axles bolt up makes it super easy to link up with heims, for reference check out the jabber resistance project on outerlimits4x4.
Anyway you knew i was gonna post this up :D and keep up the good work this is purely badass and puts my beater chop to shame:smokin:

Picking up a ford 9 inch tomorrow, time to link the rear.
Anyone need a Mitsu 9" 4.90 ARB third?

:smokin:
Whats wrong with the mitsu9? It already has the right gears and a locker...

This is a great build,,, I have been eyeing my 98 montero sport thinking on the same thing. Is this a unibody construction, hence the heavy emphasis on the roll cage, or is your cage for hard core offroading? I know with jeep cherokees if you do a "bob job" on them you have to reinforce everywhere you cut, because of the unibody construction.
He doesn't wheel his rig, obviously. He said he was going to powder coat the cage to look cool and drink energy drinks, and wear flatbill hats and high blacks socks to go with his 18" rims brahhhh:rolleyes:


:flipoff2:

It needs a cage because:
-so if he rolls it the cab might fold over and smash his brain
-its got a choptop, less strength for the roof
-place to hook up a safety harness
-if he does roll it, the truck isn't a complete waste after

Unibodies are for fags with jeeps.:flipoff2:

Any one knows if the ARB RD46 will fit my sport?:confused: it has rear disc brakes, I think I read somewhere that the locker works only with drum brakes...

:grinpimp:sorry for hi jack the thread.

Pics or it didn't happen, right?

http://i128.photobucket.com/albums/p166/sthsdr/pic131.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic130.jpg

Went with the Ford 9 for the width and bolt pattern(and, of course the aftermkt support). WMS width is 67" compared to the 59" of the Mitsu. Now I can eliminate a very weak link in my Mitsu rear, the wheel spacers/adapters. The Ford has 31spline shafts that are thicker than the Mitsus 28 spliners. As far as the housings, the Mitsu looks better made, though it has smaller tubes. I should put up a comparison thread about the two axles. :flipoff2:

Decided to go 3 link instead of 4, gas tank is in the way of a fourth link, and the frame already has the stock trackbar mount. Oh, and going to 5.13 gears too.

The ARB locker is an RD25, and yes it will work on the disc brake 3.0L Montero Sports(which is the 2000-2004 models, I think). It has about 7500 miles on it and worked flawlessly for me every time. I'm thinkin $500 obo

nice. looks like the same one as mine.

I'm doing a 3 link to my thing as well, I don't have much room with my gas tank being above my rear driveshaft :shaking:. An axle comparison thread would be cool, i was going to do one when i had my bronco 9" laying out on the garage floor but i'm lazy. From what i hear is that the Ford 9" is really close to the Mitsi 8" and that the splines match, there is a guy on Outerlimits4x4 who did a hybrid axle using the ford 3rd on the mitsu axle. sorry for the semi hijack

Keep up the good work!

Got some work done in the last couple days.

http://i128.photobucket.com/albums/p166/sthsdr/pic141.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic142.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic143.jpg

Any progress on the 3 link? I want to see how it turns out. I want to run the same set up when I tear into my monty.

Just have a couple fone pics, for now.

http://i128.photobucket.com/albums/p166/sthsdr/pic158.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic161.jpg

typical MSport guys trying to tuck big rims yo
:flipoff2:


How much rear steer are you going to get with that much droop??:eek:

Probably have to trim the rear quarters, the axle had more up to go.

The axle won't drop quite that far when the springs are attached.

Looks awesome!! Did you have any problems with clearance for the links any where?

I like the use of ramps and boards to get the jack stands high enough too!!:D

Another poser shot for the build thread

http://i128.photobucket.com/albums/p166/sthsdr/pic168.jpg

I thought about attaching the coils to the axle and running a pin on the frameside for the coil to slide down, but now I'm leaning towards attaching the spring to the frame as well, at least for now.

In this angle the left coil has come off the frame about an inch, behind that emissions b.s., but the right rear isn't really fully stuffed.

http://i128.photobucket.com/albums/p166/sthsdr/pic169.jpg

Rock sliders/cage mounts.

http://i128.photobucket.com/albums/p166/sthsdr/pic173.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic172.jpg

I think I'll move onto the engine compartment tubing next. Work is slow again so it's full-time garage now.:grinpimp:

Raole, how are you dealing with the the original ABS on your SAS?

Edward

Raole, how are you dealing with the the original ABS on your SAS?

Edward

ABS is long gone. In it's place is a Summit adjustible proportioning valve mounted under the dash, so I can tweak on it from the drivers seat.

I appologize. Let me rephrase that. I assume you only removed the wheel sensors when you did the axle swap. How is the rest of the ABS system behaving? The ECU? I got the impression that if the ECU detected a problem with the ABS it's start popping trouble codes and screwing with the computer. I don't know if there's any major differences between ABS on an 01 vs. an 03.

Edward

I appologize. Let me rephrase that. I assume you only removed the wheel sensors when you did the axle swap. How is the rest of the ABS system behaving? The ECU? I got the impression that if the ECU detected a problem with the ABS it's start popping trouble codes and screwing with the computer. I don't know if there's any major differences between ABS on an 01 vs. an 03.

Edward

I just drove it with the abs light on. Now that my old Illinois plates have expired, and I'll have to pass Indiana emissions testing before I can register it at my new address, I'll have to figure out how not to have any lights on the dash. Where I live(both states) I think they just check for engine codes, not ABS(different test anyway). The problem there, is that my trans swap causes about five trouble codes. So my plan is to run a 97-99 Sport harness/ecu, and not use the wire that powers the ABS light, and not use the tcu, (pcm/one unit in the 00-04's, tcu-ecu/seperate in the 97-99's) since I already have Brents controller, and i don't mind shifting all the time.

If you need the ABS part of the computer to not have trouble codes where you live you'd have to run wheel sensors. And no, I don't think there are any ABS differences between the 01 and 03.

nice build, just might have to pimp the wifes 00 mits. sport.

how bad is your rear steer?
looks good, i love cruisin the lesser popular brand builds

I just drove it with the abs light on. Now that my old Illinois plates have expired, and I'll have to pass Indiana emissions testing before I can register it at my new address, I'll have to figure out how not to have any lights on the dash. Where I live(both states) I think they just check for engine codes, not ABS(different test anyway). The problem there, is that my trans swap causes about five trouble codes. So my plan is to run a 97-99 Sport harness/ecu, and not use the wire that powers the ABS light, and not use the tcu, (pcm/one unit in the 00-04's, tcu-ecu/seperate in the 97-99's) since I already have Brents controller, and i don't mind shifting all the time.

If you need the ABS part of the computer to not have trouble codes where you live you'd have to run wheel sensors. And no, I don't think there are any ABS differences between the 01 and 03.

Ok. That sucks. Can't have trouble codes up here either.:shaking: I'll have to do more digging into the ABS, I guess. I need to get off my lazy butt and figure out exactly how the wheel sensors are configured. I spoke to the guys at the shop and they've done conversions on D44s, 60s and the Ford 9s so theoretically it shouldn't be an issue.

Thanks for the info on the tranny, though. That I didn't consider. I'd prefer to stick to the AW5 to minimize the electronics conversion BS but not if I can't bolt an NP to it. I need to get a hold of Duffy and get the details of running the doubler into an NP242 rather than a 231. Think I'm going to try to keep AWD on this one just for the hell of it.

Edward

Hello, Nice project

I just want to know what coils did you use for the rear ? I currently have the GenII rear coils with upper spacers, but i need longer coils spring now, I been looking some old man emu but they're just 1.75 lift.

also i'm in a project of my over knuckle steering, how did you deal with the pitman arm ?

once again nice truck

Hey, thanks. The rear coils are Tuff Country Easy Ride 3.5" XJ fronts. I drilled the stock pitman arm and used a Ballistic tapered insert to accept GM one ton TRE's.

?

when you added the PSC hydro assist did you use the stock steering box and tap into it? If so do you have the info on where too drill and tap? Thanks
When will the montero be back in action? Would like to see some videos

Check this thread for pics and explanation of the assist.
http://www.4x4wire.com/forums/showflat.php?Cat=0&Number=1160512&page=0&fpart=1&vc=1

Still have a long list of things to wrap up on the Sport. I haven't touched it all summer, been too hot outside. Now that its cooling off I don't have alot of free time with a newborn son. :D Still, I hope to have it done before spring.

Thanks!

Some tube for the engine compartment. The shock towers, coil buckets, and steering gear tie into this tubework. More pics soon.

http://i128.photobucket.com/albums/p166/sthsdr/CageFront005.jpg

love this build ! when was the last time you saw a heavily modded montero on the trail..

love this build ! when was the last time you saw a heavily modded montero on the trail..

all the time if you wheel with me and my friends. we all own Montero's:)

all the time if you wheel with me and my friends. we all own Montero's:)

cool!
I always liked wheeling something different.

I remember when Samurais and 80 series landcruisers were rare to see on the trails.

Not anymore..

I see Montero's from time to time, but I have never seen another Montero Sport in the trails. On the street, I've never seen another lifted Sport.

We're a rare breed:homer:

all the time if you wheel with me and my friends. we all own Montero's:)

Raole Duke Did say heavily modded montero and there's no ? that his is heavily modded! Never seen any in the woods around here!

I see Montero's from time to time, but I have never seen another Montero Sport in the trails. On the street, I've never seen another lifted Sport.

We're a rare breed:homer:

Yep!
why is that?
is it any harder to lift or work on it?
The all glass rear window is sort of different. but that's about it.
I see a white sport zipping up and down my street most everyday.:)

Got the steering gear bracket done today. You can kinda see where the tube ties into the coilbucket and shock tower, too.

http://i128.photobucket.com/albums/p166/sthsdr/pic001.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic002.jpg

Upper radiator mounts and hood latch bracket got made today. The plan is to squeeze a winch under/behind the radiator. I wanted to have the winch hidden behind the bumper skin. That's why the radiator is tilted back, not too many other options.

http://i128.photobucket.com/albums/p166/sthsdr/pic005-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic004-1.jpg

Looks awesome man! Your doing some great work.

Either I'm blind or you havn't got to it yet but where are you going to put your shocks?

Looks awesome man! Your doing some great work.

Either I'm blind or you havn't got to it yet but where are you going to put your shocks?

look through the coil in the last pic

look through the coil in the last pic

This. ^^^


Unless you're talking about the rear, those aren't mounted yet.

Got the lower radiator brackets made today, also two small tabs for the hood pads to land on. Then I mocked the headlights, grill, and bumper in place. The hood ended up closing about an inch lower than factory(I was shooting for 1/2"), and the fenders will need some creative twisting and bending to line up better, but I think the new lower nose works.

http://i128.photobucket.com/albums/p166/sthsdr/pic010.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic012.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic015.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic014.jpg

any Plans to apply your skills to a killer front bumper?

any Plans to apply your skills to a killer front bumper?

I have one drawn up in Bend-Tech.:smokin:

I have one drawn up in Bend-Tech.:smokin:

do tell!

do tell!

Not sure how to do screenshots.

Awesome build project and even better it's all in house build. Loving some of the poser pictures too.

In the UK thats called a Shogun Sport, ive been toying with the idea of fitting the rear axle of one as they have coils as standard over my L200 leaf springs, the rear end need drastic work to get some travel on it, you've give me some new idea's to toy with, :D

Finally got some garage time in the last couple days. The headlight/fender brackets are done, front end is bolted on. The only other fab work to do in front is the winch plate, and I have to bring that steel to a friends house for plasma cutting.

So then it was back to the rear axle for some shock mounts. Got the brackets made then ran out of time, nothings tacked yet. There's no good spot between the framerails, so they go outboard, should clear the tire.

http://i128.photobucket.com/albums/p166/sthsdr/pic019-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic017.jpg

that doesn't look like a whole lot of up travel

that doesn't look like a whole lot of up travel

Yeah, I still need to tack them in and stuff a tire to see where I'm at, but it worked in my head as I was measuring things yesterday.:homer: Probably get back to it this weekend.
Getting parts together for the rear disc swap too. Caddy calipers are more $ then I thought so for now I might look into making the mitsu caliper work with d44 front rotors. Which means no parking brake.(the stock axle had an internal drum park brake)

Could you not adapt a prop shaft brake like on land rovers or the X-ENG kit supllied in the uk ?

Could you not adapt a prop shaft brake like on land rovers or the X-ENG kit supllied in the uk ?

I'd like to do independent right and left brakes, two handles, one for each wheel. So I definetly need two calipers with p-brake. Land Rover stuff is pretty hard to come by at the junkyards around here, anyway. I'll have to go see what I can scape up, something maybe from a newer truck without the drum/disc rear axle.

Kinda like a fiddle brake set-up then ?

Kinda like a fiddle brake set-up then ?

I've never heard of it called that but it sounds right.:laughing: The stock rear calipers don't open enough to accept a front rotor, the stock rotors were not vented.



Rear shock mounts are done, 88 was right, not enough up travel. I decided to lower the lower mount a couple inches. Now it's in front of the axle tube.

http://i128.photobucket.com/albums/p166/sthsdr/pic026-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic025-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic028.jpg

Over here they are called fiddle brakes, very handy to have and very effective.

Take it the wheel does not foul the shock then like you possibly thought ? ?

Gonna see how this setup works on the wheels. I read good and bad experiences here on pirate. I lost air a few times on the trail due to the beads burping, thought I'd ghetto-rig a fix today.:homer:

http://i128.photobucket.com/albums/p166/sthsdr/pic029-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic030-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic031-1.jpg

Let me know how that goes, I have a tire on my beater car than goes flat in 30 mins leaking from the bead.

Raole I think your tires burp on the trail because you have those perrrty 18's........:flipoff2:

Good luck to whoever has to dismount those tires next :laughing:

Let me know how that goes, I have a tire on my beater car than goes flat in 30 mins leaking from the bead.

Most of the time bead leaks like that are caused by corosion or rust on the lip of the wheel. If you can get the tire dismounted and buff the wheel the problem will most likely go away. Unless you got your car stuck in deep sand before :laughing: then theres probably sand in between the bead and the wheel.

You can request tire shops to glue your tires on the wheel, I had a wheel with a bad ding in it and they just glued over that area with there tire glue shit and it held like a champ. So i asked if they´d glue all my tires and they said they would, I didn´t do it though:D

Yea I worked at a discount tire for a little over a year so I got to do all of that fun stuff. We called it bead sealer but I wouldn't say its a substitute for bead locks.

Yea I worked at a discount tire for a little over a year so I go to do all of that fun stuff. We called it bead sealer but I wouldn't say its a substitute for bead locks.

That's what I read in another thread, Liquid Nails or marine adhesive, are used to secure the bead(and reportedly work great), and that bead sealer is just for sealing purposes(corroded rim/damaged bead).

So Have you tried it yet! How low can you go and still keep them on?

So Have you tried it yet! How low can you go and still keep them on?

Hasn't left the garage in over a year. Hoping to have it running by April, for a wheeling trip. A couple guys are running 5 psi or less.

Time for an update, there has been good progress. The final cage tubes are welded in, the "x" in the b-hoop. A wheelin buddy and professional welder-boilermaker came over tonight to weld all the up-side-down cage welds for me(I can't weld up-side-down fer shit).

http://i128.photobucket.com/albums/p166/sthsdr/pic034.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic035.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic045-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic046-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic047-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic048.jpg

Oh and he brought over his Miller plasma cutter so I cut out this for the winch to mount to. It's 3/16 and will be doubled up where the winch mounts.

http://i128.photobucket.com/albums/p166/sthsdr/pic050-1.jpg

Did another rear flex test now that the tires are glued and filled, and shocks are mounted.

http://i128.photobucket.com/albums/p166/sthsdr/pic033.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic032.jpg

Bucked up for the loaded caddy calipers from TSM, D44 front rotors. For the 9".

http://i128.photobucket.com/albums/p166/sthsdr/pic051.jpg

The chop is 95% done. Just have to paint, and finish off the liftgate and tailgate. I didn't get pics tonight but body welds are finished, grinded, and a coat of bondo has been applied. These pics are a couple weeks old but they show all the final filler panels in place. The cardboard is a mock slide-out panel I still have to make, where my dirtbike should roll in, when removed.

http://i128.photobucket.com/albums/p166/sthsdr/pic040-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic041-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic038-1.jpg

The plan is to have it running by the third weekend in April, I got a spot on a trailer to Haspin Acres(Laurel, IN) for a real test(don't have to worry about driving it 4 hours home). Should be fun, of course all are welcome to join us. :homer:

Great news can't wait to see it all finished and WASHED ! ; )

I might not have time to wash it:D

Took a couple more pics

http://i128.photobucket.com/albums/p166/sthsdr/pic052.jpg

The front crossmember has been cut out to make room for the 3/16 plate, and the framerail ends capped around the tube.

http://i128.photobucket.com/albums/p166/sthsdr/pic053-1.jpg

You can see how far the steering column support on the firewall had to be raised so the shaft doesn't hit the coil bucket or shock tower, now that the body lift is gone.

http://i128.photobucket.com/albums/p166/sthsdr/pic054.jpg

The front tubework from above. After I weld in that winch plate, It'll be time to paint.

http://i128.photobucket.com/albums/p166/sthsdr/pic055-1.jpg

No wonder its taking so long, you tore that thing apart! :flipoff2:

Cage looks great! I digging the front tube work, you're running fenders still?

No wonder its taking so long, you tore that thing apart! :flipoff2:

Cage looks great! I digging the front tube work, you're running fenders still?

Thanks, yup fenders are going back on.

Took a couple pics of how the Sport sits today. Tubework is painted, engine, trans, cases, and axles are back in. Yesterday evening I got a good start on reinstalling the wire harness. Still have to make brake brackets for the 9", and a tail support bushing for the doubler, and the exhaust will have to be routed around the upper link bracket in the rear(may just run a dump for now).

http://i128.photobucket.com/albums/p166/sthsdr/pic001-1.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic002-1.jpg

What a wiring mess. i hate doing that shit.

Looks great so far!

That's just awsome:smokin:

your truck is awesome. and what improvements you've done to the engine to gain a few hp? the exhaust manifold is custom made​​?

Thanks guys.

Update, The Sport did great last weekend at Haspin Acres. Only had a few minor issues, had to re-secure the rear springs, lost a couple D44 u-joint caps on the last day. They will be getting 6 tack welds each from now on. I'm very happy with how the 3-link did, huge improvement over the trailing arms.

Just a couple pics for now, working on rounding up more pics and video.

http://i128.photobucket.com/albums/p166/sthsdr/pic.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic2.jpg

http://i128.photobucket.com/albums/p166/sthsdr/pic1.jpg

It's still dirty!

Just kidding . Glad it's back on the trail where it belongs !

Need to get some pics of it flexing !
Looks good man!

Looking well fella, need to pics of the flex in the suspension, ;)

Thanks guys.
Still waiting on friends to send me pics, it's like pullin teeth. I know someone got some flex pics. Here's some video, nothing spectacular.

YouTube - Montero tearin it up at haspin acres. (http://www.youtube.com/watch?v=GHzqxj4rAoY&NR=1)

YouTube - Haspin42911 (http://www.youtube.com/watch?v=sc10jhRwZvo)


Edit: Another that picks up where the last one left off YouTube - Haspin2 (http://www.youtube.com/watch?v=odfQbeGuVTk)


It's still dirty!

I actually did wash it when I got home.:D

Just Awesome! I Would love to do that to a sport and put the L200 fenders and headlamps on but i love L200's.

Thanks.
I love the L's too.
The left side headlight and fender did get a little roughed up the last time out. Gonna have to get a new headlight for sure. Now that I think about it the grill is cracked too, from a couple years ago. I might look into that swap.:smokin: I'm sure the shipping alone would be more than my budget could handle.

Hi Raole Duke,

Just read your build thread. Your Montero build is awesome! Thanks for sharing!

/John

Thanks John. Looking forward to seeing your build.

Thanks John. Looking forward to seeing your build.

Looking forward to posting it. I'm not a fan of daily forum updates, I'm one of those that wants to try it out before posting. So sadly its gonna be some waiting. :smokin:

Hey, just noticed, you're from St.John? Thats quite close to Chicago, is it not?
I'm (obviously) from the other side of the "big pond" but I have lots of IRL friends in the Detroit area. Visiting every year. Perhaps taking a detour next time if I'm welcome :D
Got a few questions on your rig by the way. Perhaps better taking that in pm?


/John

Any updates...progress??? I need some more motivation to buy some shit! :flipoff2:

Any updates...progress??? I need some more motivation to buy some shit! :flipoff2:

Nothing major. Two biggest things on the list for this winter, a winch and second battery, and tube bumpers.

Here's a vid from a few months ago, I put it on the Wire but it should go in here too.:D

Badlands - July 2011 - Scott, Quarry - YouTube (http://www.youtube.com/watch?v=LNo47MLdCJw)

And a flex pic.

http://i128.photobucket.com/albums/p166/sthsdr/wis.jpg

Seems like since the rear lost the trailing arms, and got links, now the front doesn't flex as much. Thinking about going with xj springs in the front and ditching the EB's.

What size xj springs do you have to use to match the 5.5" EBs?

Not sure yet. I still havta look into that.