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Old 02-04-2016, 11:52 AM   #126 (permalink)
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Great to see some progress!

Thank you for the updates. I am always excited to see what is next.
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Old 02-11-2016, 09:05 AM   #127 (permalink)
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8 February 2016

Chinese new year Holidays

Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.




Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.

2 hours later I had it all installed but need new gearbox mount bushes.



Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.

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Old 02-11-2016, 09:06 AM   #128 (permalink)
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9 February

Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.




Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.
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Old 02-11-2016, 09:08 AM   #129 (permalink)
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10 February

Morning starts with washing the dusty parts and yeah playing with the puppy.


And the finl result is washed parts eventually and a half washed puppy


Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.


Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub




At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.




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Old 02-11-2016, 09:13 AM   #130 (permalink)
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Love the progress!!
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Old 02-24-2016, 09:24 AM   #131 (permalink)
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19 February 2016

Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am

Idea was to run arround and get parts etc ready for Saturday and Sunday

After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.


So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).

We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.


All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.


Little Joe has some fun with the puppy after spending 2 days stripping paint.


Then we have a pile of parts to paint or electropaint and anodize.


Oh yeah then the 2 weekend helpers the stripper and the wire man.
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Old 02-24-2016, 04:24 PM   #132 (permalink)
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Look in great man, keep at it. I wanna see this beast done.
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Old 03-13-2016, 10:28 AM   #133 (permalink)
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Sunday 6 March 2016

A quick dash up to IPOH. 1hour 15 mins a new record time and the 190k slides by early in the morning air - go ISUZU.

Finally I have the pesky alternator installed after a couple of days effort


Then it's time to lower the cabin bottom onto the chassis after lunch.


And hey 2 hours later we have it sitting on the chassis


The junior driver Joe


OK so I'm happy is installed


Then we install the service ladder for fun


Monday 7 March 2016

I decide to cleanup the items I have been cleaning up at home and get them painted. Grill, Engine cover, PEdals, Air cleaner, front prop shaft etc


Es gives them a coat of axle undercoat black


Then the cabin had to be removed as the turbo cooling sill not worked out properly and the power steering hoses need to be installed.

I pack the doors to take them back to Kuala Lumpur to work on next weekend. Then it's time or the long haul back to KL.

Sunday 12 March 2016

Doors sitting in the ISUZU at home. I am in 2 minds strip the complete outside of the doors or and and add another coat off paint. I decide strip and reunderccoat and top coats as I don't want 6 layers of paint

Doors ready for stripping


A pair of doors now ready for final sanding and a minor repair and then painting.


Stripping the paint revealed 2 war wounds from it's days as a RIOT squad truck I assume from the grills. They will be further sanded down as part of the character being left on the truck.

I have a growing list of parts to get or deal with. Tomorrow is the dash parts to the powdercoaters.
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Old 03-23-2016, 05:42 PM   #134 (permalink)
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19 March 2016

Saturday morning finds me and an assistant Rob at the workshop before 8am collect the keys

greet the happy puppy an then go have breakfast and discuss the plan as Rob has to be back in

KL by 4pm.


Rob preparing the dimensions for the cutting out of the service hatch panels and the

surprise. They are to be laser cut and prepare in the coming weeks.


By lunchtime I have quite a bit of the soundproofing done in the cabin.


It's too hot for the workshop puppy he just lies around stealing stuff and breaking it. 39c

is very hot lol.


Then it's time to take Rob back to KL and then dinner refuel and the nite drive back up. End

of the day 570k travelled.

20 March 016 (Sunday)

I also apply paint stripper to the one door I have to work on and commence to get rid of the

body filler. The black is the rust converter.


More soundproofing work continued.


I gotta get rid of these holes. ooks like the welder has to come out and I have one more to

fix and the roof needs a repaint we found a istake which needs fixing.


Even the front of the window is being soundproofed.


The dogs collection of damaged kit.


Then I mounted the doors and checked alignment - opps some bending required.


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Old 03-23-2016, 05:43 PM   #135 (permalink)
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Then I install the front windows again and try and find the seal rubbers cannot.


21 March 2016 Monday

The overhead instrument console is layed out getting it ready to take to Rob to get measured

up to get laser cut.


Then it's time to do the console instrument layout check with the new steering wheel. The

console will be remade its not right.


I move onto the overhead console and lay it out until im happy with it. It's also to be

laser cut.






Then the afternoons progress is slowed by the arrival of Nazir who has come to collect the

Volvo's old engine for his C303 restore project. Happy restoring Nazir I will come and visit

you in Taiping soon. That is a cool old Chev pickup he has.


Then the final task for the day is to swap the sneakers and empty more junk from the

workshop wow 7 pieces removed in one day.
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Old 03-27-2016, 12:30 AM   #136 (permalink)
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26 March 2016

First task connect the Powersteering inspection reveals the banjo bolt is missing hmmmmmmmmmm I
know just the shop. A quick run down to the parts street gets me the parts I need 8mm 12mm and
10mm hoses and connectors etc


Then the task of fitting the turbo water inlet. Since we had to chop the top of the thermostat
housing off which contained the turbo cooling inlet and outlet taps. We have a donor location
from the left side of the engine unfortunately. Worked it all out another trip to the hydraulic
shop and the same assistant lol.


On the way back I drop into a chop shop collect 12 military boxes and 6 special ones. Reveal on
these later and also pickup a diesel filter and housing as this was missing from the engine
when I bought it.


More puppy damage a new scraper destroyed before I even used it.


Then the arduous task of removing the broken sump bolt. Drill it out then try and find the
eaziouts I bought in the morning. Searched for ages could not find. In frustration I climb the
office stairs and then spy a pile of rubbish near the Landrover and investigate yes the eazi
out packaging destroyed along with the plastic case.


Recover the eazi outs and finally have the errant bolt out. Victory finally. Now sump can have
the oil temp sender fitted and fit it back.


Turbo cooling hoses connected. The turbo shielding needs work. Will install this one and build
another fancier one out of alloy in coming weeks as this one has transport damage.




The left side of the engine almost completed change al of the vacccum hoses to new blue silicon
until I ran out more needed. Only 2 pipes need sorting out still. Power teering pump hoses all
connected - mounts to cabin but that may change soon as engine needs to drop out as a complete
unit from the cabin.



Hometime 7.15pm and long horrid drive home ensures in the dark. The brakes stink by the time I
get to the restaurant in KL by 9pm from the heavy braking from 150-170kph constantly.

Next visit we will be changing the wiring loom to split it with a military plug at the cabin
and hopefully filling the engine with oil and starting it. Well it's the goal.
The consoles may also be cut and ready for test fit. The dash's will also be fitted and the air cond parts.

Last edited by geckoadventure; 03-27-2016 at 11:24 PM.
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Old 03-27-2016, 08:37 AM   #137 (permalink)
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Great to see some progress this thing is going to be a work of art
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Old 04-01-2016, 09:56 PM   #138 (permalink)
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Love the progress! I know how a long-term project feels as mine took about four years to be 95%.
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Old 04-15-2016, 09:15 AM   #139 (permalink)
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3 April 2016

Quick trip up Sunday morning to Ipoh 190k whizzes past quite fast.

Today's goal is to finish the soundproofing in the cabin and then move on to whatever is left.

First install the last turbo cooling pipe adapter for the 10mm to 8mm tubes.

My helper today is little Jo.

We both tackle the soundproofing until we realise we are out with 1-2 sheets needed. The little cabin has consumed 8 sheets. So we move onto the doors and remove the door handles ready for powdercoating.










Then the puppy decides he wants lots of attention from Joe


Seats are fixed up after we realise a base is not screwed in corretly.

Then the doorhandles are stripped with the wire wheel.


End of the day we have 90% of the soundproofing done.


Suddenly it's hometime.

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Old 04-15-2016, 12:15 PM   #140 (permalink)
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Thanks for posting. Very interesting build !
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Old 04-19-2016, 06:52 PM   #141 (permalink)
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9 April 2016 - Saturday

3 day to IPO starts with a late Friday night trip to Ipoh as it'ss last weekend of Cheng Meng (chinese grave cleaning). Traffic is shit.


Fit the powdercoated left side of the dash but the bolt holes don't line up looks like I gottaa make another an oversight it's 30 mm too low so there is a gap between the dash and the window frame.

Then I fit the centre console for a fit before putting in the fuse box and wiring.

I also need to go get 5mm button bolts we have none in the shop.





Then it's time to put the new power steering together for a dry fit as I try to round up the parts. Takes me a while to figure it out. Then I have 3 parts still to find. Find them when Brett turn up later on Saturday evening in a box I would have not looked in lol. Dry fit completed.


Then I pull out of the parts boxes a much needed bonus a 180degree bend and it fits the turbo bonus.



10 April 2016 - SUnday

Remaking panel time. The errant panel being recut.


Fit the fuse box's and wiring to the centre console.


After lunch its fitted to the cabin


Then I look at the right side of the dash and decide mods are needed fo the warning lights.


Remaking time 20 minutes later I have the rough shape ready.


A few spare minutes gives me time to remove the rest of the body filler from the door to expose the reason for the body filler. Pop rivets from the police screens just body filler over. They will now be drilled out and filled with lead over the coming weeks a home.
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Old 04-19-2016, 06:53 PM   #142 (permalink)
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11 April 2016 - Monday

By lunchtime I have the air cond blower holes ready and working and the bolt holes drilled to match this time.


Power steering fit test damn the 90deg fittings have to go and be replaced by straight ones.


Then the big mistake - someone left the top panel of the centre console on the floor for a couple of years its ruined with moisture. I have to remake and out of 2mm alloy this time not 1mm.



The truck looks a lot more complete.

Then it's hometime its 6pm.
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Old 04-19-2016, 07:32 PM   #143 (permalink)
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Old 04-20-2016, 08:37 AM   #144 (permalink)
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16 April 2016 - Saturday

Everything goes bad wake up late, on road late by 75 min and hit the 7am traffic 2.5 hours later one frustrated KIWI with a ISUZU with hot brakes pulls up at the workshop with a happy puppy delighted to see me. Oh yeah and the wife came along to visit her mum in IPOH also bitched the whole way about my driving.

After the morning Mum greetings etc. Down to the worksop. First parts collection go fix the power steering hoses and swap the elbow bends for straights and get them relamped and purchase gasket glue for fitting the sump. Then the air conditioning hose needs to be found and purchased that turns into nightmare 2 shops dissappear into dead ends with WAZE and then I fluke a 4x4/air cond shop however since my car is not being serviced by them the service guy starts yelling at the shop lady in cantonese and I stand there lisening to strings of cantonese being rattled off like a machine gun. Eventually she rings someone I assume the shop owner and I get 8 feet for an outrageous price. Then need bolts over to the bolt shop for a minor success. it's now pm when I arrive at workshop again so straight to lunch instead. Actually it's LUNCH from FRIDAY and DINNER and SATURDAYS breakfast. Yeah yesterday was a bitch in the office.

First job create a J bracket to hold the blower as curently it HANGS by 2 brackets. Yeah
someone did not finish the blower stuff off properly. Takes me all arvo to create this as I not want to drill a hole in the front of the CABIN as that was the easy way to create a rust hole later. So it take 4 hours of stuffing around just after 5pm I have a nasty bracket made up ready to paint.



Painted and drill 2 holes up under the dash mount the 2 RIVNUTs and then it all bolts together and the blower hoses also fit however we will need to put the window wiper arms in there is no room. So I will have to make up 2 Y joints for the drivers side to provide more space for the wiper kit. The blower doen't shake so the design holds up.

The hoses in place ready for the air conditioning contractor to finish off.





The clutchmaster cylinder and the master brake booster etc have also been fitted and still needs a little finishing.

6pm time fed the puppy etc now to find a hotel and food. Now that's a bad idea 4 beers and a nice chinese later I literaly stagger upstairs for a well eaned proper sleep. Wife went home in the train.

Tomorrow is the air conditioning condenser fit.

17 April 2016 - Sunday

Morning no breakfast woke up too late. Faactory is opened for me 8.30am 9.00am I come back from breakfast to start.

Todays task make these 4 pieces into one joined unit and bolted to the service hatch. Intercooler, Air cond condenser and the shroud and the fan.


The fan has nothing its bare. So 10 brackets (and 10 round down bolts made up) need to be made and fit the shroud to the air cond condenser and the condenser to the intercooler.

I finish about 5pm and bolting it down the FAN Breaks damn, falling off a few months back and hitting Pete on the head then the floor cracked it. Now I gotta order a new one.


Then it's time to fit the sump after sitting on the shop floor for 3 years. I can fill it with oil next trip.

Next trip is on 7th May. I have charity work next weekend and then 4x4 driver training the May long weekend. I take the doors home with me for leading at home.

Parts ordered for clutch slave cylinder and copper piping to connect it all up. I will also start the brakes and next trip finish the gearbox mounts and all the small things needing to be done. Next round of Tanaka parts will have been ordered and shipped. Oh yeah the fan is ordered and ready to pickup.

Centre console will be ready and as also will the speaker brackets along with the service hatch panels all of the above being lazer cut.

7pm hometime its a crawl 3 hours home.
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Old 05-16-2016, 06:00 PM   #145 (permalink)
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17 May 016

Not much to report

Attended a medical mission in the jungle so lost a weekend.

Then took a bunch of kids from the orphanage for May day weekend to the beach for camping so lost a weekend but the kids are more important.

Then I got sick turns out is the heart again (however this time I could not feel the irregular beat) so I have lost 2 weekends working on the truck however spending 3 days in hospital and then a week off work gave me time to work on stuff

doodled the fridge and campin kitchen slideouts all I need is a couple of dimensions to finish it and get it lazer cut and then construct it.

Then I managed to purchase the first batch of switches I need for the switch panel.


The doodled slide out panels plan. Test bearings etc have been obtained so I can test measurements and bolt/nut configurattions.



If i'm OK this weekend and the heart stops beating as irratically this week then I will go work on the truck. Else I will be doodling a final plan for the slide out drawers.
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Old 05-20-2016, 06:53 AM   #146 (permalink)
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Fantastic. Enjoying following along. Admire the features and integration of design,
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Old 05-25-2016, 05:57 PM   #147 (permalink)
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21 May 2016

After 2 weeks rest 3 days in hospital 6 days off work resting my heart and new medication i'm back in action.

First the sad news while I was typing in the last report I head a noise outside at 7am and thought thats a window smashing then I heard a car wheel spinning away I go to go to work and I see my ISUZU window lying on the road. new toll tag, GPS and card camera gonefark.

Late start up to IPoh 190K away and the 7am traffic is bad yeah I left an hour late and hit the idiot traffic. 9am arrive workshop to be greated by the ever growing happy puppy.

I work on mounting the diesel filter to a new location on the motor with a new alloy bracket and then fix up the hoses to the fuel pump, breather hose and fuel return connect the sender unit and we hunt down batteries to collect Monday.

For the last hour I pull the doors and start sanding them down and seeing how to pull the windows out and fill the engine with oil and top up the radiator.

22 May 2016

First job of the morning for my assistant is to fit the gas struts for the doors while I work on stripping the windows out of the doors and preparing the central locking bolt threads etc from the galvanising. Everyhing has to be drilled and retapped.

I spy a water leak in the radiator it needs to be removed and repaired next week. The engine is hand turned and seems to be ok.

Doors can finally stay open unassisted.



I lead filled 2 holes and still have about 8-10 more from the old riot squad grills on each door to fix.


My assistant getting lessons on how to wire wheel fine rust away. 400 grit and hen 600 and then 1000 grit sandpaper is next before painting.


The doors working by themselves. Now I gotta go get a new set of gas struts all with rose joints in them.


Then we put in the new gearbox rubber mounts.

Then its time to take the 1 day assistant back to KL and return.

23 May 2016

Monday first job run off to the battery shop and hydraulic shop. Come back 2pm witht he stuff I need and then realise I forgot battery terminals. The day is wasted when I return at 4.30pm only time to setup a a small amount of the work needed to get the engine started before the 6pm cutoff.

All I got done was to tighten the fuel tank fittings up and then get the batteries into place and started to connect them up. Now I gotta make square rubber gaskets for the fuel tank covers

Batteries connected except the posative wire.


So what was done. Doors attacked yet again, Fuel tank ready to go just fuel pump to weld in brackets and connect up. Gearbox mounts. Doors holding up by themselves.

Last edited by geckoadventure; 05-25-2016 at 06:04 PM.
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Old 05-31-2016, 11:18 AM   #148 (permalink)
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Impressive work - keep the updates coming!
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Old 06-01-2016, 05:20 AM   #149 (permalink)
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28 May 2016

I have an assistant this weekend. We are on time for the 190K drive to IPOH so I stop 40K up for DONUGHTS 40 minutes to go the last 45K to the workshop EASY.

Shit buying the doughnuts takes forever then on exit from the roadstop TRAFFIC JAM. WAZE states accident 570 metres away 30 minutes wait. NO NO NO NO !

So here is the reason I was 30 minutes late to the workshop. Takes a LOT of skill to hit the bridge and only put both front wheels over the edge. Stupid prick was out with the insense and on his knees praying frantically and rocking back and forth as we crawl by at 9.00am.


So first items trip to the Hydraulic shop for last minute stuff and the 12v battery is purchased. Back to workshop damn its lunchtime so lunch first.

Someone sends me pics HEY your on TV with the fishing video

Joy works on the doors sand first and we fill the separattion tubes full of WD40 so we can attempt door splitting later today.

Someone sends me pics HEY your on TV with the fishing video




So here it is
[URL="http://www.geckoadventure.net/Images30/5_Tourism_Malaysia_Angling_Paradise.wmv[/URL]

Stupid PLUG for the Injector pump.


We fill the tank with DIESEL. NO NO NO everyone forgot the bottom BUNG which is impossible to see is missing, 10 litres of diesel runs all over the floor and $50rm of KITTY litter needed to soak it up. Another item to get from the hydraulic shop next saturday.
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Old 06-01-2016, 05:21 AM   #150 (permalink)
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29 May 2016

We work on the doors by 10.15 we have one door split. It a lot of work. A Bar the right size to slip up inside the tube gentle tapping to push the inside tube up and we have to cut one tube out to get to the inside tube and lots of WD40.


Then I decide I need to cut the panel open to see how much rust is inside the panel. Sure enough my guess is correct. I will make a cover panel up later to replace the cut out panel. Anyone else with a VOlvo should look at doing this also. Rust converter and undercoat etc will be needed on rebuild to prevent a reocccurance.


The cutout panel hmmmmmmm perfect.


We go to lunch and cannot find the puppy to lock him out so leave him in the Factory. Bad move. Return to a bag of 500 ble ties all over the floor. New VOlvo Fan dragged on the floor. My tool box sponge ripped up on the floor. Damn a mess to cleanup.

The rust is revealed the rubber strip between the 2 door halves keeps moisture causing a lot of rust.


And more rust.


The naughty puppy.


The wiring of the fuel tank is completed as is the hose connecctions all ready to go with some minor wire protection needed to be installed next weekend.


Then time to connecct the front 12v battery up

Last edited by geckoadventure; 06-01-2016 at 05:54 AM.
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