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Old 08-06-2013, 05:07 PM   #26 (permalink)
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A customer view of my world.


Run through the Jungle - Kuala Lumpur - YouTube


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Old 08-06-2013, 05:08 PM   #27 (permalink)
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3 September 2012

Yay progress

The external cage/roofrack is taking shape.

The front view still not complete.


Side view


The rear tray floor frame is also taking shape.


The Radiator on the left and the intercooler hanging in place on the right will be the exhaust.
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Old 08-06-2013, 05:12 PM   #28 (permalink)
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New shocks purchased AMADA's new PIGGY back shocks.

Valved for a 80 Series Landcruiser they should almost be correct we will correct once its on its feet and driving.

FYI $2800rm or $913USD for the set of 4 shocks.



Still no estimate of completion date may be end of February 2013.
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Old 08-06-2013, 05:13 PM   #29 (permalink)
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28 December 2012

Spoke to the builder last night he is saying end of February to complete it he wants to get it out of the workshop as he knows I have 3 more rollcages for him to build into my Landcruisers. It's also costing me business to have the Volvo off the road.

Now I gotta give him the VHF radio, new stereo and speakers, the remaining new VDO gauges, the side and rear LED lights and then the new switches for the interior.

I am taking the shocks up this weekend for a test fitting and let my wife see the truck.

Last week I was in the jungle for 6 days 2 days real corporate team building with 30 pax and straight out home repack and a 5 hour drive that night to pickup a discovery channel film crew (12 Pax and 2 stats) with 3 of my trucks and 6 others for another 4 days of filming 4x4's in the jungle. The Volvo was needed lucky I took my TOYOTA troopy along it took nearly 50% of the kit. Discovery channel said they would be back for more jungle filming. Volvo has to be finished . THe only casualty for the 6 days as a BLOWN up 8274 winch motor (blew spectacularly )

Discovered to my surprise the Toyota BJ75 TROOPY can take 34 camp BEDS and 5 passengers and a crap load of camping kit and still recover vehicles.

will do some pics sunday nite.
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Old 08-06-2013, 05:14 PM   #30 (permalink)
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30 December 2012

Visited the Volvo in the hospital yesterday no pics the light at 5pm in the workshop through the skylight just made taking pics impossible.

1. Shocks fitted for a test and removed the REAR piggyback will hit the Springs and the other way too round too easy for bamboo or a vine to wrap around the wheel and tear the piggy back off. Piggy back down also impossible things will hit and tear them off. A quick call to the AMADA shock shop and they will convert the rears to REMOTE for me in a few weeks. Wonderful
2. Put the wife in the passenger seat realised the floor needs to have a 50mm platform as her feet not touching the floor resulting in loss of circulation
3. Fuel tank inspected after builder consesses to making it 1.5mm ALLOY and not 2 or 3mm so its now an experiment we will 1/2 fill it when the truck is finished and drive and see if it bursts open - oooooooooppps.
4. Wife inspected the proposed composite material for the outside and gave it the thumbs up
5. Work resumes on 15/1/2013 when the builder finishes the order of 15+ military trailers
6. CHecked everything else on the truck all seems to be progressing ok. Cabin rollcage is complete.
7. More pics in 3 weeks time when I visit the hospital again.
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Old 08-06-2013, 05:15 PM   #31 (permalink)
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24 April 2013

Work is progressing

Intercooler mounted and pipes made fan on intercooler to go



All tack welds now permanent on the cage the ROOF CRoss steel is being recut due to some "errors"






Radiator final fitting next week

Cooler for engine oil to now be added not sure where it is being mounted yet.

Muffler and exhaust to also be mounted this week.

Old rear body weighed 440kg and is now a Chinese body part for a jeep I hope as it was sent to the scrap heap

Rear floor will be 3mm alloy sheet it was decided
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Old 08-06-2013, 05:16 PM   #32 (permalink)
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14 May 2013

OK quick visit Saturday on the way to mothers day dinner.

The Volvo radiator and fan connected along with piping - we will work our during testing if the 14B-T water pump will pump the water up the extra 3 feet during testing.



Only a bracket left to hold the pipes


The side view I loose another 6" from the rear cabin rats.




The front rollcage is almost complete


I have to find a Toyota 80 series AIRFILTER (4.2 Diesel) - easy ordered I have to deliver it this week and then it and the exhaust can be installed.

The air filter will fit in the hole behind the drivers seat.

Not long before the thump of a 14B-T diesel splits the air.
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Old 08-06-2013, 05:18 PM   #33 (permalink)
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24 June 2013

Progress

two weeks into the full time worker on the Volvo progress is being made.






Looks like the Exhaust is mounted but the air intake is not. However the 4 wall frames are up and so is the roof frame and the floor frame is done

I expect better pics this week with the Alloy roof or the rear wall completed.

Also found this last week after sending 3+ hours to find stuff - finally I have a starter and kill switch. But I need to find a 12v to 24v RELAY to kick the starter solenoid with it.

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Old 08-06-2013, 05:20 PM   #34 (permalink)
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Progress progress progress

This mornings 2.5 hour visit and discussion in seating position and lights.

My drivers seat needs to go back 3" or 75mm so the corner of the engine compartment will be moved back leaving the existing shape.

We then pretended I was strapped into the harness and organised all the DIFF LOCKS etc to be moved to above the driver on the roof, Winch controllers etc will be there. Being 188cm its amazing how far I can reach.

Console will now be constructed.

Then we discussed rear lighting and switch position.

Then the progress. Wow 2 weeks and a lot done.

The rear frame looks strong with only the air filter to be fitted


The rear right and left front doors are complete and swings out gull wing style as shown here.


The middle post is hand made c-channel and a bent flare for the door seal you cannot see the quality in the pic.


The new front floor and my foot well widened for my size 11 boots


The roof will be 3mm alloy and can walk on it and a side top rail will be added to tie stuff too. The floor will be bolton/off 3mm alloy so the complete floor can be lifted for maintenance work. The rear "door" will be cross braced up next week and the "DOOR" will not open side entry only.




The angles look wonderful.


The left side is impressive with the angles back frame. The "middle" work area (the radiator and exhaist area etc) will be two parts bottom half will fold out as a LADDER and the top half will be bolted in.




Brett talking to the workers telling them to finishe it by next friday
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Old 08-06-2013, 05:20 PM   #35 (permalink)
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Front view - still a few bars to add to the front to make it tougher.






The final product - the DAKAR class winner from 1983.


Colour scheme is done

Completion date discussed RFC time 2013 so mid-late November 2013.
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Old 08-06-2013, 05:22 PM   #36 (permalink)
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20 July 2013

a long visit today

First the tour

The doors all fitted and all with gas struts to hold open - wow gull wing style.



Right side






Top view






Then upstairs to the Wiring diagram


Yup its all wayed out in red and blue red is 24v and blue 12v then as we go thru it with my switch diagram vs bretts count we have a discrepency I have more in the end we agree looks like my 42 is very very close and bretts 36 could be short..



Back downstairs 1.5 hours later

we have decided

1 month to paint everything except the alloy skin - second paint round

then the fitting of everything including the proposed 6 seats (we are talking 6 high quality customer seats) in the rear and the removal of the doors to be replaced with side rails

The winches and yes he is installing a 30 litre water tank and with our simplicity motto its going to be gravity fed.

THe new target date of mid November is looking good.

Many surprises on vehicle launch to be revealed

Next visit I gotta hand over the newly sponsored LED lights - The stereo - the rest of the instruments and the OFFROAD controls switches for the winches and a new albright controller sigh the other one is on a comp truck now lying in the workshop after its rollover in Ride N Seek TV program which im sure you all saw and two wheels.

Next visit should see the floor cut and fitted the water tank completed the dash started the winch wiring etc all layed out and ready to install.

The rear rollbar.
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Old 08-07-2013, 07:40 AM   #37 (permalink)
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Holy Crap this is sweet!
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1989 Toyota Landcruiser FJ62
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Old 08-08-2013, 11:06 PM   #38 (permalink)
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8 August 2013

A long drive to IPOH due to the public holiday traffic. Handed over the 35" Maxxis sneakers, the 4 small LEDS and the 50" LED and the stereo and a strip of LEDs.

Inspection revealed Hi-lift jack holder almost finished. Shovel holder next. Hammock loops being prepared, handgrabs for all ladders done.
Roof for the Radiator and intercooler etc ready locking mechanism to be designed. My seat area has been pushed back allowing my seat to move back 75mm which is huge when you are 6'2".

Inspection of the new AMADA shocks reveals 3" too much travel so looks like the shocks will never work hard.

New sneaker and the removeable entry ladder in place




The positioning of the Aquafilta (M) Sdn Bhd 20 litre water containers roughly in place we will allow for 3 to be stored and removed.
Due to keeping with simplicity no fixed internal tank or pumps to fill it.


The front wall frame is now finished and the hi-lift jack holder is tacked into place. nExt is shovel holder and air filter.


Over all the frame is now finished.


What's left to do well the DASH and Console and the wiring, power steering, fitting of seats, air cond (fitted just needs to be connected How to start and stop the 14B-T donk. 6 seats for customers in the rear and a removeable side rails so that the 4 rear doors can be removed when necessary. Floor to be cut out and boltdown points welded in. Roof to be cut out. The middle doors and panels to be cut and punched out, the mesh for the radiator roof to be fitted

We have divided DASH into Driving needs - OIL/WATER TEMP/Speedo/TACHO/Fuel Volts/AMPS to the right and recovery DASH. Air pressure and vaccum will be above on the roof along with the lockers and 4wd vaccum switches.

Next week I have to deliver ICOM V8000 VHF radio, the remaining gauges and the fridge slides.

and we discovered the 2 200 AMP batteries were dead oh dear there goes $1500rm.

and the final issue - where oh where is the ground ANCHOR going to go.
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Old 08-18-2013, 05:24 PM   #39 (permalink)
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Subscribed , love this rig . Keep up updated please
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Old 08-21-2013, 08:06 AM   #40 (permalink)
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with the water tanks arranged like that it would make a nice gravity fed water filter. use the top one for "dirty water" and the bottom for the clean. just plumb in one of the many gravity fed filters in the middle.

Love the build. cant wait to see the finished product.
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Old 11-02-2013, 04:50 AM   #41 (permalink)
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1 November visit.

The 50" LED light frame is built on top of the cabin.



The T-MAX 18,500 (yellow) and the WANR 12,000 tot he left all mounted in their mounting point


The winch controller box is also ready


The top view of the winches and winch controller box.


The crane to lift the spare tires up and down ready to connect to the warn winch is ready


The top hatch is ready witht he hole for the exhaust.


The doors now back on



The seats are mounted.




Next visit the dash sould be completed then its painting time.
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Old 11-02-2013, 06:46 AM   #42 (permalink)
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The water tank is to be built next a size of 150w x 400d * 1700l cm should give us 102 liters it will bolt to the rear panel.

The floor and walls alloy panels are all cut out and bolted down and has been removed so they can continue to work on the steel bits.
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Old 11-02-2013, 10:41 AM   #43 (permalink)
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Pretty freaking cool!
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Old 11-28-2013, 04:52 AM   #44 (permalink)
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The builder off to the rainforest challenge (RFC2013) tonight so I got a quick update and worse the worker doing all the welding resigned.

Dash is built and console - overhead console not done but all gauges will be up on the console except the speedo (Garmin colorado GPS) and the tacho - tiny tach.

So work has stopped for 2 weeks until the 15th at least. My goal is just after Feb - ideally for my birthday on 5th March I want it on the road.







Once the dash is built and the overhead console done its sand blasting and painting time.

Last edited by geckoadventure; 11-28-2013 at 04:54 AM.
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Old 11-28-2013, 07:27 AM   #45 (permalink)
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Amazing build.
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Old 11-30-2013, 06:36 PM   #46 (permalink)
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Cool build.
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Old 12-03-2013, 02:50 PM   #47 (permalink)
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The to do list to get to 1 March 2013 completion date
01. Order Tiny Tacho
02. Buy Garmin Colorado
03. Order Digital Fuel Gauge from US
04. Order Air and Vaccumm gauges
05. Design Overhead Console
06. Build Overhead console
07. Position for Inverters and USB chargers
08. Design Rear Side bars and access to replaced removeable doors
09. Wiring
10. Sandblast and undercoat and paint chassis and body
11. Fit Alloy body panels
12. REfit every part.
13. Sound proofing fit (after back in Kuala Lumpur)
14. Collect shcks from Malacca
15. Buy leaf springs (after back in Kuala Lumpur)
16. Power STeering do (Ford F5000 tractor kit)
17. Buy 3+3 seats for rear $600rm each) and harnesses
18. Fit rear seats
19. Tie Down points identify and fit/create
20. Hammock connect points fit
21. 100liter Water Tank Make (Anivsah to supply 3 filters)
22. Roller slides purchase 4 - delivery January from Australia
23. Buy 4 MAxxis Bighorn 762's
24. Buy 200' of 11mm winch wire for the PTO and 125' of 9mm for the M12000 winch
25. Design PTO winch lock (Lever by vaccum) to replace canvas strap
26. Oil leak in DIFFS fix
27. Electric pump for engine radiator
28. REplace CV booties
29. Buy 2 200 amp batteries
30. Buy Reversing camera
31. Buy Icom VHF radio speaker
32. Buy driving camera.
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Old 12-24-2013, 02:33 PM   #48 (permalink)
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Nice project
How it's going???
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Old 12-26-2013, 02:54 PM   #49 (permalink)
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Long (5 hour+) visit to the workshop on Boxing Day since the mechanic was working on the truck XMAS day I had no issue having a vist. Arrived 11.30am time for chit chat and then lunch and then the serious stuff. First the office we started with a blank sheet for the control panel and worked our way through switched 1-26 which need to be on the control panel

Then the discussion on 12v vs 24v everything discussed and reviewed again.

The empty switch box ready for me to reach when harnessed in.


Slowly the switch location emerged till we had this on the full size drawing.


The wiring diagram revisited all red is 24v all blue is 12v.


After 60+ minute time to go to downstairs and discuss Bretts list then mine.

Whats been done - all the ALLOY panels are cut out and now waiting for the rear seats and Drawer system to be installed.






There will be a raised platform at front 1/2 of the rear to sit fridge on (no it will not slide) and underneath will be a sliding table to be used as a cooking bench it will slide out approximately 600-800mm and will be 39" wide (1 meter).

The exhaust is now in place along with the hilift jack (6ft) and the shovel and chungko will also go here. The air intake will also fit up beside the exhaust.




I now have the depth of the fuel tank the matching gauge and sender from VDO can be ordered.

Then onto the rear seats 6 of these to be fitted they are 22" wide each we have 68.5" to fit them in. See our wonderful crash test dummy not smiling as we get the seat height correct. Once fitted then we can strip the rear sandblast it and undercoat it for the panels to be fitted. The seats are to only be fitted when the doors are removed and fixable sides designed along with harness seatbelts. So it will be a 8 seater when taking passengers.


Underneath the winches are all ready with new guides welded to the axles for the T-Max 18,500lb winch. Guides on springs to hold up the t-max and Volvo PTO winch cables to be fitted.

The seats have been removed ready to get the wiring done now it will be started this week.


Starting to look complete.

Last edited by geckoadventure; 12-29-2013 at 03:08 PM.
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Old 12-26-2013, 02:55 PM   #50 (permalink)
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Water tank relocated and redesigned its either now 94liters (24 gallons) or 104 liters (26 gallons) and will be on the front wall of the rear cabin.

It's first real trip will be 26-28 April when we have a 3 day trip to Cengal Besar (big tree) everything has to work as this track is now really cut up.

New steering wheel to be obtained possibly toyota hilux or similar and after market power steering to be added to the steering column. Steering column etc will be shrouded in alloy to replace the newer plastic which looks tacky on a Volvo.

2 months to go till d-day.

I have to deliver in next 2 weeks fuel gauge and sender, digital tacho, Water, 3 seats and harnesses.

Last edited by geckoadventure; 12-29-2013 at 03:05 PM.
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