Chris's 2004 Hilux 2wd Sas build- #CrawlMate - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 06-02-2016, 05:43 PM   #1 (permalink)
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Chris's 2004 Hilux 2wd Sas build- #CrawlMate

Some of you on here may know me from Facebook, recently deleted it, sick of the Bs. So thought I'd throw a build up thread on here of my Hilux. It was an old work ute from the family business I purchased for cheap and moved all of my parts out of my old unreliable crawler into.

Basic specs are:
2004 2wd Hilux Workmate
2.7 3rz with 200,000kms.
Currently g52 manual but plan to go R151 in the future.
Dual 2.28 transfers with Trailgear adaptor and Twin sticks.
Fj80 front diff, lock rite Auto locker, custom double shear steering setup, Braced housing, Psc 8" single ended ram.
2010 Hilux rear Diff with full spool. 4.88 gearsets.
Box front shaft, Pto tube rear shaft.
2wd rears up front Spring pack, 2010 Hilux rears, rear springs Inboarded 3" each side.
Tm Fabrications plate shock towers in the front, F250 towers drenched into the chassis in the rear.
Chassis had had 240mm taken out of the centre to shorten the wheelbase. Current wheelbase is 104".
Full hydraulic steering using 8" Psc ram, Psc resovoir, inline finned cooler, High flowed V6 commodore pump, Eaton orbital.
Front and rear winches and suck down winch in the rear. Most likely other stuff I've forgotten.

Basically built it to be a fairly capable but basic setup, reliability being the key. It runs the stock fuel setup, moved around to work with the shortened chassis, all accessories wired to a separate dual battery to keep the original wiring intact.
Engine is left Stock apart from the commodore steering pump.

37x12.5r17 Blue label Krawlers on 17x9-30 Dynamic steel wheels with DesignFab beadlocks.

All stock interior, still running the 3/4 bench seat and has working Air con.

Future plans are to Exo cage it and run a seamless internal cage.










Last edited by Aus_Mallcrlwr; 06-02-2016 at 05:51 PM.
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Old 06-02-2016, 05:50 PM   #2 (permalink)
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Will post some of the Sas/Build up pics tonight.
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Old 06-02-2016, 06:52 PM   #3 (permalink)
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The old crawler, had engine and wiring issues. Was parted out and kept all the axles, transfers and various other pieces for the new build.



After being stripped.

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Old 06-02-2016, 07:04 PM   #4 (permalink)
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The 2wd as I bought it.



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Old 06-02-2016, 07:08 PM   #5 (permalink)
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Chassis cut, shortened and fish plated back together.







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Old 06-02-2016, 07:48 PM   #6 (permalink)
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Boxed in the rear of the chassis using a towbar I had and added recovery points and a winch mount.





Rear tube work.



Standard fuel tank mounts reused with the stock tank.




Dimpled rear tray made for space case/toolbox and can also see the rear inboard Spring mounts on the inside of the frame. They bolt through a crush tube in the chassis and tie the whole lot together.





Tire mount added.



Rear all mocked up with axle under.


Rear ended welded off and painted.

[IMG]http://i1198.photobucket.com/albums/aa455/Chris_Yarrow/47222AF9-F5C1-4CDD-83F5-9DB87AAFA614_zpsrqpnb4sc.jpg[/IMG]

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Old 06-02-2016, 08:42 PM   #7 (permalink)
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Rear end all back together. 2010 Hilux rear axle installed, this matches an fj80 front for width and is also an 8" third member.

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Old 06-02-2016, 08:48 PM   #8 (permalink)
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2wd suspension all removed and frame cleaned up, shackle tubes installed.



Front shock towers modified to clear the steering column.



Shock towers installed.



Painted.

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Old 06-02-2016, 08:52 PM   #9 (permalink)
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Factory 3rz-w series bellhousing on the g52.



Dual transfers installed, unfortunately I didn't flat belly it. I didn't want to hack the body up to much. Will be building a solid belly pan on it to protect the transfers.



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Old 06-02-2016, 08:52 PM   #10 (permalink)
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You need new u bolts.
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Old 06-02-2016, 09:16 PM   #11 (permalink)
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Looking bad ass as always Chris!!!
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Old 06-02-2016, 10:12 PM   #12 (permalink)
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You need new u bolts.
Longer u bolts have been put in since the pics.
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Old 06-02-2016, 10:13 PM   #13 (permalink)
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Looking bad ass as always Chris!!!
Thanks Pepe!
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Old 06-06-2016, 06:01 PM   #14 (permalink)
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Thought I would throw some pics up of the FJ80 Axle and my double shear steering setup.

Housing was shaved and had leaf perches added, I made it a bolt on deal with one u bolt on the pumpkin side and a normal setup on the other.





Then the double shear was doing using a rhd lower arm and a lhd lower arm to have the tierod in the front. Made my own top arms with a press fit pin to locate the trunion bearing. The lower arms have been tig welded to the knuckles.



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Old 06-06-2016, 06:06 PM   #15 (permalink)
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Few pics of the Full hydro setup.

Orbital mounted above the frame so I could use the standard steering shaft and keep the orbital out of the interior.





Power steering pump mount on the 3rz, it uses a high flowed v6 Holden commodore pump, these are easy to find here in Aus and simple to high flow. I keep a spare in the toolbox. I also added a brace afterwards to stop the mount flexing under high revs.



With Psc Ressy mounted and brace added to pump.

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Old 06-11-2016, 03:26 AM   #16 (permalink)
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Knocked up some sliders before dinner this afternoon. Mini kick style with a dimpled sheet. Yet to weld off fully and make mounts.








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Old 06-11-2016, 09:49 AM   #17 (permalink)
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looks good.

what year range commodore are you snagging pumps off of?

looks like is/should be the same chassis as the chevy lumina here in the states
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Old 06-11-2016, 10:49 AM   #18 (permalink)
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Nice and low, I like it. Any plans on adding a third bolt in the abs hole.
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Old 06-11-2016, 04:05 PM   #19 (permalink)
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looks good.

what year range commodore are you snagging pumps off of?

looks like is/should be the same chassis as the chevy lumina here in the states
The one I'm using is off the 96-04 Ecotec V6's. They are an L36 I believe. Mainly just ran with it as they are so easy to find over here. All parts shops carry them in stock.
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Old 06-11-2016, 04:07 PM   #20 (permalink)
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Nice and low, I like it. Any plans on adding a third bolt in the abs hole.
Thanks, I was trying to keep it low but the front ended a little higher than i expected. Hoping it will sag an inch or two.

I've got the pre abs knuckles but was planning to tap another hole when I put Rcv's in the front.
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Old 06-11-2016, 04:35 PM   #21 (permalink)
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Very nice work. A lot of normal type mods but all done very cleanly with a twist of ingenuity.. I like it
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Old 06-12-2016, 12:45 AM   #22 (permalink)
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Chris's 2004 Hilux 2wd Sas build- #CrawlMate

Got the sliders tacked on to work out mounts. Welding fish plates to the chassis with tube and a gusset.






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Old 06-12-2016, 12:57 AM   #23 (permalink)
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Very nice work. A lot of normal type mods but all done very cleanly with a twist of ingenuity.. I like it
Plan was to just keep it a simple, reliable and capable crawler.
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Old 06-12-2016, 01:39 AM   #24 (permalink)
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It's a refreshing simplicity. If that makes sense.....
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Old 06-19-2016, 02:38 AM   #25 (permalink)
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Got one side finished tonight, other side is nearly done just need to paint it and weld them on.






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