200 Series 1VD into Prado/ converted to 79 Double Cab build, 40

[BiffS]

First of all, I'm crap at keeping up to date on the forums, but i thought that this might be something interesting to read on Christmas day, so I'll culminate the total progress from the last year into this single thread.

The background:

My 77 series with 1HD-T was written off, and I wanted to build something more "modern" and evolve the capabilites for my now much older family.

- The super-built HD-T from the 77 was the original choice, along with a later 79 series R151 (which is 1.5" longer than earlier R151's)
- Genuine double cab frame form a 2022 HZ79 double cab
- 3rd generation wide nose front end
- LJ78 body as a donor cab, chopped at factory locations and factory double cab back panels, quarters, etc to make it the real deal double cab
- linked rear suspension with coilovers and 80 series axle, but with the 79 series 14mm axle lugs, rear disc, electric park brake
- 79 front axle, new brackets, turned for caster, and coilovers front
- interior LHD swapped with the early style steel dash (i dont like the later plastic dash), and lots of modern upgrades.
- Center console electric fridge
- suspension seat bases with Corbeau or similar seats
- dual stainless exhaust
- strengthened frame braces from my mining truck world builds for heavy weight.
- Summit Expedition rear tray and removable canopy with hard shell RTT on top.
- Huge all Electric camping setup sponsored by Renogy: 14x Renogy 104A Solid State lithium batteries running 24V house. Renogy 4000Watt custom 24V inverter, 2x Renogy Rego Core and Core7 screens, 3x Renogy IP68 50A DC-DC converters, full electric cooking setup including two induction cook tops and air frier oven
- upgrade electrics: 320A alternator with 2/0 wiring, 1200W solar including foldouts and permanent flexible panels
- hard shell RTT with Solar onboard
- Truma diesel air and water heaters, including heated, pressurised canopy and RTT; for dust ingress prevention and heated water for camp cooking and cleanups/ showers
- Eaton E- Locked, RCV shafts, etc.
- Bosch iBooster electric master/ booster
- drive by wire conversion
- 200 series twin turbo 1VD 4.5 V8 diesel. Probably going to upgrade a bunch of things on ti along the way, like G turbos, improved oiling, and intake upgrades. Definitely delete the stupid EGR.
- old-skuul ram assist steering on the front axle

So that's the hardware part.

current progress to date:

body shell chopped down, body work done, painted custom matte silver/ orange, mounted to frame, suspension chopped, custom axle brackets made.

Recently, we've brought in a bunch of 1VD-FTV engines, and i've been ripping around in a genuine VDJ76, so now i'm ruined. No inline 6 will ever suffice again.

So the plan has changed. I'm going to sell off this 1HD-T and put in a 200 series twin turbo 1VD. Much scouring of the internet has not shown anyone putting a 200 series VD into a 79, so maybe this will be the first.

So some of the future challenges will be to mate a RHD 200 series engine and harness into a LHD early style dash truck. So lots of switchabouts needed on the electrical front. I'll likely be using a PDI 200 Series FMIC with twin inlets and outlets, and shoehorn that in the mix too.

Follow along and I'll try and answer questions as best i can.

If you're looking for a VD swap into your rig, email me at clinton(at)vertoutfit.ca and i'll help out.

Here we go...

 

[BiffS]

Body chop and fit-up trials.

keeping the power everthing off the Prado body, and i don't think that factory double cab trucks ever had a sunroof. but this one will..

 

[BiffS]

3/16" frame braces and boxing. fully seam sealed prior to epoxy painting.
weld-thru copper rich primer both sides under the steel.
TMR upper frame side link brackets, Johnny Joints and 1/4 wall DOM chromo link tubing.
All suspension brackets on frame and elsewere designed and made in house.

 

[BiffS]

dura-seal seam sealing at all factory joints, 3 layer sound insulation in all the fenders, arches, and body. Raptor liner inside and out for rust proofing and sound deadening.
the previously considered 1HD-T roughed in for fit up.

 

[BiffS]

back from paint and body panels fitted up and fitting up the interior sound proofing.

 

[BiffS]

200 series engine. Look at all that complex emissions crap on top that has to be deleted!

the 200 series has a different oil pan from the 79 series engines, which puts the oil filter up front, rather than by the scavenging pump at the rear on the single turbo models. This may have to be changed in the future to better fit around the front axle, which will be pushed forward 35mm and caster corrected to suite about 8" lift. Overall vehicle height will hopefully be under 84" (so it can fit in my underground parking)

this engine will be fully broken down and rebuilt/ refreshed. The 1VD is prone to oil starvation issues in the top end, which leads to valve train failures. This can easily be addressed with preventative maintenance and some mods to the block/ oil spray system. The 1VD has two oil spray bars above the cams to provide some topical lubrication of the cams.

These have some of the most complex oiling systems ever.

 

[dmjay]

Epic

 

[Dougal]

I read the title and was expecting a hack job that was never going to work. But this looks aweseome.

 

[BiffS]

Sorry Guys, I'm crap with the updates, but here goes--->
- Rear links are all made, brackets on axle, Dobinson coilovers fitted. I had to fly to Aus to actually get these direct from the St.Kilda Dobinson dealer direct. got a free hoodie (jumpa) out of the deal.
- Decided on Micket Thompson Baja PRO XS 40" on Nomad 503 rims. The color is a bit too green for my liking, but we will see how it goes.
- Got the insulation and sunroof back in, (have you seen a sunroof double cab before? probably NOT!), and floors, etc done.
- Wiring o-rama now. Adapting a 200 series engine harness (automatic) to manual, 200 series keeping the electronic turbos, 79 harness for the 79 oil pan (more on that below), to older style 79 LHD dash harness from a HZ. Lots of conversions here. Good thing i have loads of wiring diagrams.
- Pulled apart one of the 200 series engines that we brought in, looks good, but off to the machine shop for a full cleanout and a hone. Second engine block back already for a light hone, wash down and reassembly with OE parts. While dry fitting the 200 engine to the build, one thing became apparent is that the 200 series oil pan puts the sump directly in the path of the front drive shaft. That, and the oil filter assembly is directly under the steering box brace. no bueno.

So to solve this, i've chosen to fit up a 79 style pan, but this has it's own challenges.
- No return for second turbo scavenging pump
- no supply for second turbo oiling
- different locations of oil supply tube for left turbo
- oil level sensor in different spot
- oil supply for left turbo on the 200 comes form the side of the pan. Needs modification now for the front pickup.
- different pickup tube for sump
- different mounting block on scavenging pump. the 79 series pump is tapped for a third line, but the 200 is not.

The 200 has different engine mount brackets as well both on the engine and the frame, to make room for the labarynth of hoses and ducts. This will be a challenge for later with a likely custom dual input FMIC into this setup. The top mount isn't going to work, as i have already got a HZ hood painted to match. So for now, i'm going to use the luxury 200 series hydraulic engine mounts since the frame brackets for HZ are in the wrong spot and they're so big that they'll hit the turbos. Better to start with a clean slate.

Since I'm coilover front too, the choice was made to link it later, in order to just get it rolling hopefully in time for upcoming may long weekend. That necessitated new, longer, and even more caster corrected arms to clear the 40's brakes and long stroke. My goal was to keep it under 7' total height, and have lots of travel. So custom is needed. So we drew up some arms that were 65mm longer and lots more caster. Cut them, welded in house and they're going to get test fitted before finishing.

oh, and a tray / canopy that we are also getting made for us too. This one is a placeholder for now, as the kitchen sink is nearly 6' in the air. A bit hard to wash or cook with.


-

 

[BiffS]

rear end shots.

full up and ride height