[tmarx]

Thanks but before people get the wrong idea, I made that comment in jest. When I started this crazy project I had absolutely no mechanical experience whatsoever and Keith(tlc-4play) has been one of my main guiding mentors

[uted]

Awesome stuff mate, looking real good.
My 82 troopie had a rubber around the vent cover similar to what you have done from factory

[tmarx]

Some progress ...










But eventually I could no longer avoid the wiring looms - easily my biggest fear on this project. I decided to start with the rear part and it was not a pretty sight...
















The leftovers ...







The wiring itself was fortunately still in perfect condition so after a good clean I could tape it up with some high quality tapes that a good friend sent me






Thanks Keith, you da man !


















And then installing it back in place ...

[tmarx]

Which brought me to the rear lights.







My old ones were not good and I knowingly bought some chinese(?) replacements from N1 4x4.







In some respects the quality was not good but that was not the only problem ...











So I decided to use the 5 pin OEM wiring and contact-points with the new housing, which needed some serious rust-proofing.











Spot the earthing solution







I was also not entirely happy with the rubber gasket. The front was OK but the back not so i decided to beef it up a bit with some HD fibre rubber...







I also changed the flimsy mounting screws with nuts and bolts which will bne used as the new earth contact



















All done ...







They do stand out about 4mm more than before but I am happy that the sealing and shock absorbing is better than before :wink:



Next nightmare the Main Loom !

[Fernando69]

Oh god.

you are sick and I envy you.

keep up the great work !!!

[Ron B]

Super job!!! I hope to get mine looking half as decent one day but right now Im having to much fun just driving it. Keep up he great work!!

[M5driver]

Absolutely super work, Theo. I love it!

And I second this sentiment: "Thanks Keith, you da man ! " Keith comes through in the pinch, eh?


Dan

[Roberto]

looking good Theo, looking good, got my glow plug insulators in, thanks again. That tape you are using, that is non adhesive or adhesive? I know the old stuff i pulled off my wiring (all still in a big box and marked) was not adhesive but every store i go to to find does not know what I am talking about?

R

[tmarx]

Thanks guys, much appreciated !

Rob, the Plymouth tape is not adhesive as such. During application you have to stretch it out to about 2/3rds of it's original width and then wind it bit by bit. It then sticks and in that state "amalgamates" itself around the wires. Lovely stuff to work with but the entire job is a PITA and worse than watching paint dry

[Roberto]

LOL, I bet it was, just taking all that stuff off the wires was a pain. I will start my search for this elusive plymouth tape for I am ready to do my wiring cleanup now. Get my body back this weekend.

R

[tmarx]

Visible progress has been very slow as I am getting to the stage where you find out how much time it actually takes ....
The wiring and all aspects of it was my biggest fear from the start of this project














But bit by bit I managed to wrestle myself through it ...






As allways the self-amalgamating HV tape first and then the other stuff ..

















Along the way I found that main loom and some relays etc had been incorrectly fitted and that some stuff was completely out of place :?







Some of the relays had some surface rust on the outside.Instead of normal paint I chose to go with a clearcote rust coverter primer combination so as to retain the OEM look.It may not be as pretty as new silver paint but troubleshooting should be easier if I can read the inscriptions clearly and besides, they are all hidden out of sight anyway. I also made rubber "washers" for all areas of contact, just to add a bit of cushioning etc









I have taken some flack for putting back the ugly old OEM heat and sound matting, seeing that I covered the entire firewall in stick-on matting already. However when I am finished, very little of theo ugly matting will be visible but it will still be functional ...





I didn't like those sharp edges on the sides of the cubbyhole especially since some wiring runs in those areas ..




and fixed it with some moulded rubber

[tmarx]

During stripdown I found that my gearlever "bushes" were shot.













The flat black levers also came out real stealthy looking







Which brought me to the skinny pedal and the hand throttle ..










Not all my YP stuff came out as expected and it seems as if areas which had rust do not come out shiny. Maybe I should have sanded it all before the time ? At least the rust is gone ...

[Roberto]

Lookin great Theo, the wire harness is a bear to tackle. I only found 1/2" non adhesive tape so took me a little longer then if I would have 1". But I am glad I copied you in doing it. I still have to put my looms on once I work out all bugs. Keep er goin, I continue to copy pics of yours to help me with mine.

R

[dkroth]

Originally Posted by tmarx

During stripdown I found that my gearlever "bushes" were shot.

Theo, where does that white bushing go? Do you happen to have part numbers for those bushings? Thanks.

[tmarx]

Originally Posted by dkroth

Theo, where does that white bushing go? Do you happen to have part numbers for those bushings? Thanks.

It goes on the tip of the shift lever. If you look at the pic above you will see that my old one was so worn out it stayed behind when I removed the lever. I subsequently dropped it into the box but we found it when we stripped the box and it now has a permanent spot in my 105 ser .

The part no for that one is

BUSH, NO.1, SHIFT LEVER (FOR FLOOR SHIFT) # 33548-60020

and the other

SEAT, TRANSMISSION SHIFT LEVER BALL # 33505-60010

[dkroth]

Thank you, sir.

[tmarx]

Got a bit more done ...

[1Fine40]

That's just too pretty!!! Gotta coat that exhaust manifold so it feels at home in the engine bay!!

Outstanding build and quality work...drop dead gorgeous!

Cheers!

[tmarx]

Thank you, much appreciated !


Time for an update ...

















My heater was in a bad state of disrepair.





The vents were glued to the bottom of the dash for obvious reasons ....




It needed a total rebuild as the foam rubber was shot.





Fortunately the core was only dirty but very good :wink:















It is advisable to bake the UHT paint but you do so entirely at your own risk !








When you only have 2 hands you have to make a plan to drill & poprivet the unwilling broken parts ..

[tmarx]

New foam




















Then the other bits ...













Cab light door activators from a box shape Hilux- a perfect match

[tmarx]

Yug, who wants old flaky and dirty knobs.













all done and ready for install ...






To go with the other freshly painted & rebuilt bits


















Now it is back to the engine side of things

[Roberto]

looking very good Theo, very good, can you send me pics of your factory jack and its holder. Mine was under the 2 seater rear seat, just wondering if yours looks the same as mine and the jack, for my jack is an Isuzu jack? also, your heater top vent does not look factory? Do you need or want one sent to you? I only say that becuase I have never seen one like that at all? I did the same with my knobs but was a pain in the butt to get excess paint off. I used oil paint markers.

R

[tmarx]

Only have these Rob, shout if you need more

[tmarx]

Originally Posted by Roberto

. I did the same with my knobs but was a pain in the butt to get excess paint off. I used oil paint markers.

R

I used 1000 grit sand paper for the excess and it was easy peasy and the knobs even got a polish for free

[tmarx]

With my Fuel Control Relay woes threatening to halt my project for 2.5 months, it got some other positive injection today ..






















Man I love the tall and skinny look

[JackRabbit Slim]

just read through your whole thread and only now noticed that you put your steering wheel on the wrong side! Eeek... Hope that doesn't cause too many problems!

Aside from that though, she looks awesome! Keep the posts coming.

[Roberto]

looking great Theo, keep rolling with it. question for you. Is yours a 5 speed? Did you refurbish your old transfer boots? specifically the outside one that you see from inside cab? Reason I ask is becuase I bought a new late model OEM one and it is smaller than mine and does not even come close to aligining with bolt holes? My buddy has an 82 BJ42 LX and is bringin by tommorrow night, his is pretty good condition he bought last year and is of course from AUS.

Rob

[tmarx]

Originally Posted by Roberto

. question for you. Is yours a 5 speed? Did you refurbish your old transfer boots? specifically the outside one that you see from inside cab? Reason I ask is becuase I bought a new late model OEM one and it is smaller than mine and does not even come close to aligining with bolt holes? ..

Mine is 5 speed and I re-used my original boots etc. They were just to good to replace

[Roberto]

cool, my 5 speed boot is perfect but my transfer boot is not so pretty and is a diff part number on Toyodiy.com than the 4 speed models for it is larger.

Thanks
Rob

[tmarx]

With the Fuel Control Relay woes over I could move forward again ...

















































Tonight I started alignment of the panels which is proving to be difficult if attempted without help !