My Montero Sport Build

[Raole Duke]

And a flex pic.



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.

[88mitsu]

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

[Raole Duke]

Not sure yet. I still havta look into that.

[Raole Duke]

Been workin on the rear bumper for the last few weekends.

First, some of the body got cut out. Shooting for a good departure angle so I wanted everything to tuck in as much as possible.



Some 4"x4"x1/8"(it was free), some 1.75x.120dom(cage leftovers), and a HF hitch tube.



Some more dom for the ends. Tried to fill the recess in the body for the plastic factory bumper.



Skinned the ends with some 11ga.(another freebie)





Painted it today. I'll get some pics outside soon.

[88mitsu]

Bumper looks sweet

[Raole Duke]

Originally Posted by 88mitsu

Bumper looks sweet

Thanks!

Here's a couple new videos from this past weekend.

Montero Sport @ Haspin Acres - YouTube

Montero Sport Climbs Devil's Backbone - YouTube

[Raole Duke]

A couple new things.
Military take-off 37x12.50/16.5 Goodyears on recentered H1's with PVC inserts.



5.43 ring and pinion, pinion guard, and a Yukon locker for the nine inch.



I put about 150 miles on the new setup this weekend. Mostly highway miles, the Sport finally has plates again. The 5.43 ratio is much more friendly to my tired ol 3.0, especially now with a 125lb wheel. Ran just under 2250rpm at 55mph Still have to install the 5.38 gear set in the D44, before I can hit the trail.

[nissancam]

I know you don't have ABS, but are you running the stock booster and master cylinder?

[Raole Duke]

Originally Posted by nissancam

I know you don't have ABS, but are you running the stock booster and master cylinder?

Still have the stock master and booster. The master goes to a Summit adjustable proportioning valve, instead of the ABS pump. The brakes work good but could be a lil better.

[sneakyninja]

You can swap on an 80's dodge fullsize pickup master cylinder with some line adapters from NAPA, that will give you more braking power to feed the bigger calipers.

[Raole Duke]

Originally Posted by sneakyninja

You can swap on an 80's dodge fullsize pickup master cylinder with some line adapters from NAPA, that will give you more braking power to feed the bigger calipers.

I will remember that, thanks. About a week ago I took the front calipers off and re-bled them by tapping them with a rubber mallet in many different positions and got a couple bubbles from one side, so the brakes have gotten better but could still use help.



Took the Sport to a Cat scale the other day.
4,840lbs with: me, 3/4tank of gas, spare tire, tools, and extra fluids.



I was expecting well over 5,000, so was pleased.

[lenross1]

What did it weigh before?

[Raole Duke]

Originally Posted by lenross1

What did it weigh before?

I've never weighed it, but curb weight for a 2001 Montero Sport is 4,205, so not that much gain, all things considered.

The 5.43 r+p have been a huge help getting that weight moving on the street. The 3.0 is over 100k, all hard miles, too. It is tired and runs hot. I've been on the lookout for a 3.5 to swap in.

[lordtrunks]

looking good man btw welcome to the H1 wheel club

[Raole Duke]

Originally Posted by lordtrunks

looking good man btw welcome to the H1 wheel club

Thanks, been a while since i've seen pics from you, post some up. So far I have not had luck with the h1's at highway speeds. That might just be the military Goodyears. Still have yet to off-road this setup, but I did have to see what zero psi looked like.





Here's what i did to the rims after i got them.

rebar rock rings in and out.



lightened the PVC inserts, 10 lbs total.



Golf ball balance.

[MudRaider]

Originally Posted by lordtrunks

looking good man btw welcome to the H1 wheel club

Really LT? Did I miss this somewhere? Pics?

[lordtrunks]

i'll have to get out and take some pics of the setup i've got the military bfg's on the 8 bolt rims i machine balanced 3 of them and did the airsoft bb's in one to check it out worked pretty good i need to put a little more weight in its got a some shake at 60 then smooths out after that i've been lazy and just havn't wanted to take the rim apart hahaha

[Guns_and_Roses]

damm...you are just a frickin' mitsubishi pimp!

well done.

[RocketScientist86]

Great build like the do it you self in the garage thing!
I,am new here but i was thinking is the d44 you put in the front match up with the original mitsu in the rear are they in same length?

I have a 98 pajero 2,8 diesel that i,am building in "my mind" right now but it would be nice to know for the future.

sry for my english am from iceland and my wrighting english is not perfect!

[Raole Duke]

Originally Posted by RocketScientist86

Great build like the do it you self in the garage thing!
I,am new here but i was thinking is the d44 you put in the front match up with the original mitsu in the rear are they in same length?

I have a 98 pajero 2,8 diesel that i,am building in "my mind" right now but it would be nice to know for the future.

sry for my english am from iceland and my wrighting english is not perfect!

Thanks.
Originally I had 2" wheel spacers to get the Mitsu rear axle closer to the width of the D44. But then I replaced the mitsu rear with a Ford 9 inch rear that matches the D44.

[crawldaddy]

Let see some picture updates!

[Raole Duke]

Couple updates to share.

Got these LED under cabinet lights from a friend for free so i mounted one on each corner. Well one month later and two of them are inoperative and another has gotten dim





Front bumper is done for now. I'm planning on taking a piece of tube from the side of the bumper, around the wheel well and landing it on the slider, but that will be a winter project.









Shaved the v shaped crossmember after getting hung up on some rocks.

before



after



Shaved the pinion guard, too

[Raole Duke]

Trail pic



Some video.
Taking Scott's Line - Badlands Quarry - YouTube
Montero Sport @ Badlands Quarry - YouTube
Montero Sport @ Badlands Quarry Pt.2 - YouTube
Badlands Quarry Ledge In Reverse - YouTube

[Raole Duke]

I put this one in other threads but I'll put it here, too.