[gilghana]

Guys,
never done a thread like this - always tended to be more a Q&A type. Anyway, I am currently in the process of a total interior re-modeling of my troopy so thought I would start with what has been done to the vehicle so far, and then document the interior stuff which is being done over the next weeks as I build it and as parts arrive in from South Africa - which could take a while.

Firstly the interior on the day I got it (getting on two years now)



Living in Africa good driving lights were first on the list, in fact I bought them in Europe in readiness of getting the car. Output is fantastic, seem pretty damn tough. Only thing is the beams are a bit narrow which a filter on one will cure.



As the vehicle was going to be carrying some weight the next thing was some firestone airbags for the rear - nice easy solution pending heavier springs. Dead easy to inflate. Fitting was not the easiest, ended up cutting the exhaust out as a side exit pipe was in the near future. Around the same time a longranger (from Oz) 180L rear tank was fitted which was located where the spare used to hang. Fitting was fine although blanking plug for the sender took a bit of messing around


and so it goes... The spare had to be relocated so I got IEF Engineering (South Africa) to supply a double spare bumper replacement - very solidly made, but measurements were a bit off and it took a bit of bending and shimming. Routed the valves for the airbags to the bumper and recently installed a 12v CAT flood light for camp set up



I was lucky enough that we had 6 steel wheels from 105 series cruisers lying around - vehicle originally came with splits and sand tyres, so 4 MTs and 2 Dunlops (OEM 105 series) as spares. CAT worklight has outstanding brilliance!

[gilghana]

Then came a need for power! The 1HZ is a sweet motor as you all know, but for relaxed travel a turbo was really wanted. Got it from All American Imports in Holland who really know their stuff - all genuine toyota stuff too. Fitted a boost compensator and pyro/boost gauges at the same time.


I had experimented with a home made side exit exhaust, but to be honest the noise was too much - GF couldn't open her window any more on boost! I had planned a side exit so as to fit a water tank in all the wasted space, so Tourfactory of Germany supplied a beautiful SS piece which sounds JUST right and seemed to make it pull even harder!



It's not cheap, but Helmut from Tourfactory makes some really great kit for 78/79s



At the same time I got him to supply a 100L SS water tank - really his version of another fuel tank. Not such a clear picture but you can see how it makes use of all the dead space where the huge muffler was and under the prop shaft. Only thing is I now need a 79 handbrake cable as the 78 one is too short with the tank.

[gilghana]

To fill and draw water from the tank I fitted a glind (again Oz) shower heat exchanger and flojet pump - fantastic! Hot water on demand, and with the help of two ball valves and by using push fittings on the bumper (which you can see on the lightforce snap) I can either draw from the tank, fill the tank or just shower from a bucket. Contemplating making it so that I could also recirculate water while driving and heat the tank - why not! Will probably get a General Ecology Filter so as I have no problems with the water being completely potable. The heat exchanger hose routing was not entirely finished when this one was taken:



Then the cheap SAGA EGT gauge packed in, so Thermoguard from Oz shipped a digital EGT which just happens to fit exactly under the radio in the spare DIN slot. Below the dash you can see another temp gauge which is going to probably check the water tank temp, but is currently bolted to the head. Again an Oz device designed to protect against overheating. On one of the blanks above and to the left of the temp gauge you can just see an LED warning light, which is a low water alarm plumbed into the radiator top hose. This I fitted after a head gasket failure on my old Defender 300Tdi, and because I wanted to be safe rather than sorry after cooling system modifications... If coolant level drops the LED comes on and a LOUD buzzer. These Ozzies really think about this stuff! The headunit I replaced with a Blaupunkt plus amp, speakers and sub. The factory unit has to be probably the worst OEM sound system fitted to a modern production vehicle!

[lshobie]

Looks awsome!

[gilghana]

At first my thinking was that the interior I would do so that everything could be put back to 13 seater standard. National Luna SS fridge I got from a mate in South Africa and it is the biz! To run it and various accessories I installed a home made battery box with a CAT 100ah calcium cranker connected to a Sterling Battery to Battery Charger (very clever device) and a Clipper Battery monitor. These all work very well, but is not really space saving:



The battery monitor is great - designed for boats, big backlit display showing current battery voltage and charge as a bargraph at the side, as well as A/hrs used and time remaining on the battery at current use. Would really recommend this.



Anyway, space is at a premium as we don't really do this packing lightly thing:



And I never intend to be putting the vehicle back to 13 seats. Right now we only need two seats and maybe later a small bench behind the front seats. So everything came out and the interior lining was ripped out. Amazing how much space is in these panels:



The beginning is to replace the panels with 8mm custom pressed marine plywood (Mahogany) with the Battery stuff, amp, subwoofer, compressor and some hatches for recovery gear etc. Here's last night cutting up the custom ply (there are a few advantages to working in timber...). The wood stuff I leave to Julia as she is way better with power tools than me!



The plan now is to semi finish the panels, fit all the stuff behind them and a milford cargo barrier, then wait (impatiently) for the African outback drawers that are in a container as of tonight in Durban. Ghana customs permiting there should be a set of Dobinsons heavy duty rears and lighter duty fronts (no bar and no winch and no intention of fitting) in our store this weekend.

Here's our other two - 105 series company car and GFs company Golf:



Will update with the springs soon,
Cheers
Gil

[gilghana]

Thanks Louis, here's one for you guys in Canada getting out your snowmobiles! This is in Mali, awesome place.

[roscoFJ73]

Nice build up. Was the National Luna fridge expensive? For some reason they are nearly double the Weaco/Engals in Oz

[gilghana]

Oh yeah, I forgot to mention that I live in the wilds of Western Ghana in the forest. Now Yotas are common here - we have 4x 75/79 work trucks and 8x 105 series. But modifications other than bush repairs are totally unknown, and parts supply is a nightmare. The tank was fitted 6 months after being bought! Luckily we regularly have containers from EU and ZA being shipped, but even simple stuff like a small ratchet strap needs some forward planning. Of course the 'pro' to the cons is that tomorrow I can jump in the 105 and go check a forest Op in the rainforest, 4x4 for 6 hours and get paid for it!
Gil

[gilghana]

Ross, the NL was a good price as I got it from ZA. At the time it was quite a bit cheaper than a waeco or Engel in Europe. I heard they were pricey in Oz but in their home country they are okay. Saw loads of them in Namibia recently - they do a really good double door fridge/freezer.
G

[Radd Cruisers]

Koooool build, keep those pics comin..


Does the 105 have a solid front axle?

Rob

[crushers]

if you have air bags why do you want heavy version rear springs?

well thought out ride, there M8...congrates..

and thanks for posting this up.

[roscoFJ73]

Originally Posted by gilghana

Ross, the NL was a good price as I got it from ZA. At the time it was quite a bit cheaper than a waeco or Engel in Europe. I heard they were pricey in Oz but in their home country they are okay. Saw loads of them in Namibia recently - they do a really good double door fridge/freezer.
G

One more question. Is your battery gauge like this one ?

BATTERY MONITOR ABR 'SIDEWINDER' 4WD 12V POWER, CARAVAN - eBay 4x4 Accessories, Exterior, Car Parts, Accessories, Cars, Bikes, Boats. (end time 02-Nov-08 19:30:00 AEDST)

Ive been looking at the Arrid range of gauges at the 12V Shop but they are all more or less the same,only one very small digital unit

[gilghana]

Cheers guys! Yup the 105 is solid front axle. The airbags, well they are great but IMHO they are a helper rather than a solution - on one trip I almost lost a bag due to chaffing (okay was really my fault as I hadn't fully checked clearances). Without the support of the bags the whole rear sags BADLY. We run airbags on a few logging trucks, and to be honest they have all been replaced with std springs. I am not knocking 'em , but for long term remote travel I just have a few nagging doubts. When I bought them (again cheap from ZA) I always sort of planned that they were a stop gap for a while until HD suspension. On a weighbridge (45L diesel and no water) the troopy was on 2700kgs. The bat monitor is the exact same one - very useful esp running a cranking bat for a fridge (first cheap cranker didn't last long!)

[Coyote808]

Nice troopy. My main question is, do you think 100L of water is enough for two people? I would personally want more, but you can't have everything I guess. I guess it depends on the available space.

[crushers]

okay, understand about the airbag situation... good call then.

[xtfritz]

Nice troopy. Where in Ghana are you living? I had the chance to visit Tarkwa several times and loved seeing all of the 70 series worktrucks.

Cheers

[gilghana]

I am about 2.5hrs west of Tarkwa, 120kms.... Yeah, the mines down there have some very cool 79s. Ghana Toyota have opened a branch just to cater for the miners!
Re the water, I think 100L is quite a bit - if somewhere where water is plentiful then obviously it's not an issue, and if somewhere very dry, then 100L under the car is quite a supply - even 2 people consuming 10L a day (obviously not showering etc but still a high personal consumption) means 5 days. A couple of plastic jerries and that becomes a week!

Last night I finished the prep of the plywood panels, so tomorrow hopefully start fitting stuff behind them and mounting. Will get some more pics up then.
G

[lshobie]

Do what the Aussies do and drink more beer = less water needed

[UK4x4]

Nice truck, here's a site that apreciates expo type builds, nice friendly folk..

Expedition Portal Forums - Powered by vBulletin

You'll make them all jealous...8-)

[gilghana]

Originally Posted by lshobie

Do what the Aussies do and drink more beer = less water needed

That (and cheese) is the prime reason for the Nat. Luna!

[gilghana]

Well, like so many things it often takes longer than planned, and I don't have much spare time, 12hr days and half days Sat&Sun doesn't leave much time for Toyota stuff... However I got the first two panels done with everything placed behind. The right hand one has the amp (sticking out for cooling) and the subwoofer behind a lot of holes. Sounds great and I am really happy to get all this stuff tucked away:



Behind the left hand one is the Sterling battery to battery charger and the serious duty wiring prepared and ready for the second battery(s). The next left hand panel will have the shunt and battery monitor plus a couple of 12v sockets, the fridge connection and my compressor. There will still be space for the jack, wheel brace, air hose. On the right hand side I will leave it free for a few lesser used tools, ropes and straps.



I will need to wait for the African outback drawers to arrive so I can be sure of final second battery location and then the cargo barrier. Speaking of batteries, some advice would be good...

Okay, I have a CAT cranker and a Deltec deep cycle on the way. The CAT cranker I bought as a second battery simply because there was no locally available deep cycles. Looking at the Deltec battery BushPower - Products it looks even like the same casing as the CAT (both are same A/hrs). Now if I wire them both in then it gives me a pretty serious power supply. I also "found" (in the store, gathering dust.....liberated!) a couple of solar panels. But back to batteries: I am a bit concerned that the fact that the batteries are not completely identical might have an adverse effect over time? The sterlings charge program matches both batteries (sealed lead acid) so I can't imagine too big an issue?

Dobinsons heavy duty springs, shackles and bushings arrived over the weekend as well, Koni shocks are in an airfreight consignment tomorrow, so I have plenty to be getting on with for a good while! Funnily enough I couldn't see the Dobinsons leafs 'handed' in any way like stamping etc. Compared them side by side though and one is higher, so marked it ready for the drivers side. Heavy bloody things. Happy to have some lifts and willing helpers in our workshop for those!
Gil

[roscoFJ73]

Originally Posted by gilghana

Well, like so many things it often takes longer than planned, and I don't have much spare time, 12hr days and half days Sat&Sun doesn't leave much time for Toyota stuff... However I got the first two panels done with everything placed behind. The right hand one has the amp (sticking out for cooling) and the subwoofer behind a lot of holes. Sounds great and I am really happy to get all this stuff tucked away:



Behind the left hand one is the Sterling battery to battery charger and the serious duty wiring prepared and ready for the second battery(s). The next left hand panel will have the shunt and battery monitor plus a couple of 12v sockets, the fridge connection and my compressor. There will still be space for the jack, wheel brace, air hose. On the right hand side I will leave it free for a few lesser used tools, ropes and straps.



I will need to wait for the African outback drawers to arrive so I can be sure of final second battery location and then the cargo barrier. Speaking of batteries, some advice would be good...

Okay, I have a CAT cranker and a Deltec deep cycle on the way. The CAT cranker I bought as a second battery simply because there was no locally available deep cycles. Looking at the Deltec battery BushPower - Products it looks even like the same casing as the CAT (both are same A/hrs). Now if I wire them both in then it gives me a pretty serious power supply. I also "found" (in the store, gathering dust.....liberated!) a couple of solar panels. But back to batteries: I am a bit concerned that the fact that the batteries are not completely identical might have an adverse effect over time? The sterlings charge program matches both batteries (sealed lead acid) so I can't imagine too big an issue?

Over a period of time they will take on each others characteristics. If the internal construction is the same (the thickness of the plates) it shoudnt be too much of a problem.


Im using a Delkor Calcium 100 amp deep cycle and Ive had my weaco 80 litre running for 4 days+ on low
Im thinking of buying another.

Dobinsons heavy duty springs, shackles and bushings arrived over the weekend as well, Koni shocks are in an airfreight consignment tomorrow, so I have plenty to be getting on with for a good while! Funnily enough I couldn't see the Dobinsons leafs 'handed' in any way like stamping etc. Compared them side by side though and one is higher, so marked it ready for the drivers side. Heavy bloody things. Happy to have some lifts and willing helpers in our workshop for those!
Gil

I remember the weight of my Dobinsons and having one roll onto my foot
I thought mine had a A and B stamp where the U bolt goes on the smallest leaf.
Mine was about the thickness of a leaf higher on one of the rears. The fronts were the same but that was a long time ago.

[gilghana]

Well not going as fast as planned (of course)! We were away for three days at the coast - Ghana has some great beaches, so the battery and fridge got thrown in again and tied down. Then got back and had a dose of malaria (like flu here....). Anyway, back to business!!!

Well obviously with all this not much got done to the troopy. However all sorts of goodies arrived over the last two weeks. Firstly the Dobinsons stuff:





Will get cracking on it tomorrow afternoon. I will use the workshop and a couple of our mechanics.

But the real PORN is the Koni Heavy Track "Raid" shock absorbers.... These arrived today What can I say. They are bigger than the shocks on our trucks
When I saw them I just had to whip off a front wheel and take a picture for MUD:




I knew they were larger than stock, but not that large!




Only problem is the stupid 'no language' picture type instructions - can I figure out the adjustment of rebound damping? Can I hell! If anyone knows would be great... Will go and google it now. You would think they could at least provide a 2 cent instruction page... Will get some install pictures tomorrow I hope.

[gilghana]

Well today things went a LOT faster. I asked a couple of our mechanics (Vincent and Simon) if they wanted to help out so we got cracking in the workshop. These guys are doing leaf springs every day, but I was surprised at their speed... Believe me they don't work like this when it is company stuff! We met at 2pm.

First we basically stuffed a 2 post lift (it is pretty much on the way out, but we didn't help) bolts are coming out of the floor! But we managed to get it high enough to pack it safely and get full droop and more...


The front springs and shocks were done within the hour:




Vincent was pretty pleased with getting pictures taken of his work - first time! It's not often a camera is seen in the workshop




Just behind him on the wall is a home made safety sign. Very cool - shows a guy sort of exploding under a pick-up as he didn't use proper packing!



So these are the rears before:




We had to drop the 180L rear tank slightly to get the old shackles off. When fitting the tank Longranger recomend turning the shackles so the pins can be withdrawn from the outside in the case of future suspension upgrades. Glad I didn't bother as it is way less hassle to drop the tank a bit then turning the shackle!



And that was us done by 5pm. I was pretty happy at 3 hours for complete suspension change. I have kept the air bags on and will see if they are needed. For sure they would seem to limit rear axle articulation, but I am not too bothered as the car is not a mud or rock beast but a tourer as the title says. Will get some pictures of flex this week at some stage.




Now the drive home is all of about 10 minutes, but it is corrugations and a sprinkling of potholes... The ride felt fantastic - major improvement. To be honest one of my fears was that the heavy duty Dobinsons (they don't make heavier!) would be too stiff, but I was really pleased. Okay about 80 litres of water and twin wheel bumper is on, but the Dobinsons felt great. Cliche I know but I felt it rides better than the coil sprung 105 GX (which I have actually never liked compared to a std 105 that I had before. No idea why!?!). So next one is fitting a handbrake cable from a 79 series as mine was too short when the water tank was fitted. Lift is not much (also happy as I did not want big height) 2 inches max. Didn't measure before or after, as I say the objective is not clearance but load carrying - and this it can do!
Gil

[Hltoppr]

This thread makes me drool....

-H-

[mot]

Originally Posted by Hltoppr

This thread makes me drool....

-H-

x 2.

I'm jealous that you guys have "really" cool places you can travel to in your cruisers!!

[gilghana]

Hey thanks for drooling guys! Glad you like it. Okay, well I learned today that my African Outback drawers, deep cycle battery and roof tent are in a container, sitting on our truck down at the port - was loaded last night, but customs won't allow it to move until Monday morning ggggrrrrrrrrr! Oh and our MD has flown in for one of his rare visits, which means several weeks of meetings now leaving sod all time for cruiser tinkering Anyway the cool thing is that I told him our decision to hit the road in six months with no real plan other than see more of Africa for a good long while. We see where we end up. I have been here 13 years and worked up to GM from a junior manager out of college, so it is a big step to jack it but my girlfriend and I are getting very little satisfaction from long hours/high pressure jobs with little reward (apart from financial) in a place where there is zero free time, bugger all social life and a whole bunch of new expatriate asian managers targeting me and my job....... they are f*****g welcome to it in six months. We see, and if things go pear shaped I can always come back. Not in current position but probably in a more fun one! Okay, rant over.

Back to Cruisers. To keep the interest levels up! Well I mentioned that I never really liked the GX 105 series. I always felt it heavier, looser and more "unsolid" than my previous 105 Std wagon. I really don't know why - checked everything. The previous Std however ended up with a tree being felled on it And African hardwoods tend to be big (no pics unfortunately due to a hard drive issue). So, as I am the boss (well for six more months) and we have a very nice 105 Std that we use for managers/customers traveling to the airport airport etc . So executive decision made - swap!!!

Took the TJM 13 bar and the winch (comeup and mine not company) off the GX and put some spacers (hacked up conveyor belting) in the front coils to compensate for the weight. Stuck on a new set of General AT2s and result!
- wind up windows
- manual mirrors
- 'hose out' interior
- no side steps
- sub tank
- not even free wheeling hubs!
- part time 4by

Now the asian managers can fight over who gets to travel in the GX with the chrome and I get to play with a stripped out bush wagon that matches my troopy.
Gil

[roscoFJ73]

I had a a 400klm race this weekend with a 105 vs my 75 He had an almost empty trailer and I had my camper on the back.
It was close,I would lose him on the hills, but on the corners the 105 just hung in there. My 75 series leaf springs make you pucker your ass cheeks on long bends

[gilghana]

Rosco,
know what you mean! 1996 I got given a 75 pickup company car, got it brand new with an identical one given to another young forest manager and we used to do some very puckering cornering!!! The 105 is no sports car thats for sure! Both utes still going to this day after no small amounts of abuse.

As of this morning drawers, tent and battery are sitting in our store - excited as a dog with two tails... Pictures this weekend and if we are lucky maybe Sat night try out the new roof tent (and see how the Dobs and Konis deal with roof generated oscillations ).
Gil

[gilghana]

Well, two massive boxes were pulled out of a container a few days ago... and I didn't even get to open them until tonight. What would you rather be doing - meetings about world Mahogany markets or rooftents and drawers? Exactly! So we got the boxes home and started unpacking this evening.

Firstly the drawers. African outback, 1.3m long, full steel construction. Damn solid. The AO system is such that on top of the right hand drawer is a full length sliding top for mounting the fridge (pictured here on the right).



The only parts not sheet steel are the fronts of the drawers and the tops. Yes I have access to some amazing timber and machine shop etc but when I see these and bearing in mind I got a GREAT deal thanks to a plummeting Rand, I don't regret it at all! I paid the same amount of cash for the tent and drawers and battery as I would for only the tent back home in UK.



Here is the frame:



And some frame detail: