Builds A Re-Build of 2004 78 Series Troopy 1HD FTE

Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
In collaboration with tmarx I managed to buy a well kept and maintained 2004 78 Series Troopy that has the OEM 1 HD FTE turbo diesel motor fitted.

This is the Troopy as it was bought.
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But in all honesty i wasnt completely happy with the "looks" of the Alu-Cab pop top conversion, to me it was just fugly, so i got it into my head to change it to the Alu-Innovations pop top RTT and at the same time have a host of other alterations and modifications done.

Prior to taking up my booking at Alu-Innovations i did some small bits n pieces my self.

I just had to remove the fugly side plumbing - done

1st off I fitted some arm rests
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Then I decided to fit LED rear lights and front indicators.
720p.mp4


next to do was to fit an EGT and EMS system,
This turned into a bit of a mammoth task as the position I chose to drill for the thermocouple just happened to have a reinforcing rib which eventually broke the drill bit and the broken piece fell into the turbo. So off came the turbo and exhaust manifold.
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The offending hole then had to be welded closed.
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The EGT gauge working
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Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
Then it was time to fit the PDI front mount intercooler from the Antipodeans
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Then it was fitting the catch can.
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Also had a friend make up some OEM stickers for the rear
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Then it was off to Alu-Innovations where the Troopy got a real good hair cut.
BTW the trucks original owner was a Photographer, and he had a flip down windscreen fitted, which I was determined to return to stock.
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In the meantime work has been progressing albeit slowly.
Most of the modifications requested, the manufacturing process has commenced and partly completed with lots awaiting powder coating and finishing prior to fitment. The OEM windscreen and weatherstrip is on order.
Now Troopy has a new hair style
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I managed to find a set of good condition grey leather BMW 3 series seats which have now been fitted, and the seat + seat and half has been redstributed.
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I will update as the work progresses.
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
Apologies about the pics - dunno what the hell flickr was doing
 
Joined
Jun 16, 2020
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Location
Calgary, AB
Nice work, and thanks for posting! Beautiful rare truck.
What went into removing the old roof conversion? Did they need to cut again? Heat gun?
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
Yes, the original AluCab Hercules Pop top roof conversion had to be cut off, using a "Nibbler". The biggest task was to remove all the Sikaflex adhesive.
But the fugly roof is gone and the better looking Alu-Innovation pop top is on.
Now just to get all the other fit out done.
 
Joined
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Location
Cape Town - South Africa
Cut a huge chunk out of the side of the troopy to fit a pull out fridge slide

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prwillard2

SILVER Star
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Oceanside, CA
Cut a huge chunk out of the side of the troopy to fit a pull out fridge slide

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Definitely looking forward to seeing that finished product!
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
UPDATE PICS

The inside sides of the Troopy have been carpeted, The bathroom Gull Wing has been fitted, The Kitchen unit Gull Wing has been fitted, The rhs rear door drop down coffee station is in, the lhs rear door drop down wash-up basin is in.
And the final touches to the side pull out fridge slide are being done before it goes to panelklapper for repainting.

Pull out fridge slide
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LHS Kitchen unit Gull Wing
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RHS Shower cubicle Gull Wing
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Sides of interior have been carpeted
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LHS Rear door drop down wash-up station
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RHS Rear door drop down coffee station
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Joined
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What an awesome truck! looking forward to seeing the progress
Cutting a big hole in the side i think i would have opted for a 3rd door conversion, over just a pull out fridge. beggars cant be choosers though
what else is on the "TO DO" list?
 
Joined
Aug 16, 2006
Messages
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Location
Cape Town - South Africa
On the TO DO list,.,.,.,.,.
2 x 30Ltr stainless steel water tanks, with pumps and level guages. 1 mounted in each side panel of the vehicle. Youll notice that the reinforcing steel ribs on the inside of the side panels have been removed to facilitate fitment.
I have removed the old ARB air pump and replacing it with a 340Ltr/min Military Spec Nardi air pump that will feed into a 30Ltr under chassis mounted air tank.
Victron 12/12 - 30A DC DC charger, Victron MPPT 100/30. 13V 220AH Lithium Ion battery. Victron Smart 702 Battery monitor. Victron 12V 230V 800W pure sine wave inverter. 3 x 135W semi flexible solar PV panels.
Interior cupboards and drawers down left and right hand side
2nd drop down 45Ltr fridge slide on left rear. 8Ltr centre console fridge.
QuickPitch 270 Degree awning. QuickPitch en suite shower cubicle with 6ltr propane water heater. Propane gas bottle mounted on rear door
Set of injection moulded wheel flares. Window tinting, Mosquito net for rear opening.


In the longer term = change 2nd and 5th gear to longer ratio, change tyres to MT 285/75 x 16 (33 inch). UNICHIP 5 stage tuning chip with electronic boost controller
Recover the grey leather BMW seats
 
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
Some Update Pics

2nd Fridge slide (Drop down) and Kitchen Box installed. Frame for the other drawers still to be made.
Inbetween the 2 fridge slides there will be a cabinet of drawers extending up to just below the roof line.
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Frame for drawers and side cavity boxes
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The Freezer pull out slider with drop down door
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Shower cubicle box
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Joined
Aug 16, 2006
Messages
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Location
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Both the Gull Wings and Drop Down tables are custom made, But the company that makes them, now keeps them in stock for the two standard rear doors and windows. The two front windows are the same, but the the two rear are different, there is a LHS and RHS.
The gull wings also have optional interior mounted boxes that makes the space more useable. or they can just be used for side access to the rear.
 
Joined
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Messages
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Location
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Small Update

Frames for cupboards and drawers are being finalised.

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Joined
Aug 16, 2006
Messages
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Location
Cape Town - South Africa
UPDATE:

The 2 x 30Ltr water tanks are going in, one already fitted. The side of truck has been drilled for the water tank fillers
The left hand side drawer unit frame and drawers are done, the drawers internally are being carpeted.
Shelf over rear fridge needs to be attached and covered.

Progress is being made albeit at a snails pace.

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Left hand side water tank
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Joined
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New Zealand
Nice Job mate and good luck on your modification, Good choice Aluminum cabinet wondering how much Weight you have added by your cabinet ? What will be panels? ply wood or Aluminum? Im fabrication my cabinet fully aluminum too,
Just wondering why you chopped off your Alucab roof? any issue with it? such expensive change
 
Joined
Aug 16, 2006
Messages
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Location
Cape Town - South Africa
The aluminium frames are surprisingly light (1.6mm wall thickness) so far the heaviest components are the HD ball bearing drawer sliders, they are much heavier than expected.
The paneling on the aluminium frames are PVC Clic-Loc flooring planks, available in multiple colours and wood like patterns, they are thin (+/- 3.5-4.0mm), light weight and not susceptible to water and moisture (cos PVC) also, they clic together nicely so you dont see any seem joints, added bonus is theyre very easy to cut with a DIY circular saw.

I chopped off the AluCab Hercules (Gen1) pop top (it was one of the very 1st ones they made) cos it was just FUGLY (the front was too vertical and looked too big for the profile of the truck) and also it had started separating from the vehicle roof at the front RHS.

PS I also removed the fugly plumbing pipes down the sides of the truck
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Last edited:
Joined
Aug 16, 2006
Messages
437
Location
Cape Town - South Africa
UPDATE PICS:

Ive been in Middle East and Europe for the past 2 ½ weeks so I was quite anxious to see how much progress has been made on Troopy while Ive been away

What cant be seen in the pics is - all the side and rear windows have been tinted, and I decide to add an additional 40Ltr water tank under the chassis (to supplement the 2 x 30Ltr side mount tanks)

90% of the wiring has been installed for all the power points (12v and 220V) as well as water pumps and air compressor.
1 x MPPT100/30; 1 x DC-DC charger Orion 12-12/30; 800W pure sine wave inverter; 1 x 220V-12V battery charger compatible with Li Ion: Shunt for Victron Smart Battery Monitor.
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The drawer for underneath fridge has been done, just needs its laminate front
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Most of the drawers have been covered in laminate
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These 2 Drawers are surprisingly cavernous (1.35mtr long) Im surprised how much they will hold
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Power point installed into the Kitchen box
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The additional drawers
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Cover and shelf for the rear fridge
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Joined
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Messages
437
Location
Cape Town - South Africa
A Few Update Pics

Its starting to come together now.

Main storage unit with 6 drawers
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Carpeted cover for drop down fridge slide
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The two grocery / food drawers. The side cavity is for the 2 x Front Runner fold up chairs.
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The drawer under fridge for gas cooker and Mandela Microwave.
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2 x 220V socket outlets, 1 fed direct from shore power, and the other fed from Inverter
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Fridge in slide
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Electric windows installed.
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