Builds DUKE - 1993 HDJ80 / 1HD-T / 5-Speed / 3x Locked / LHD *A slow DIY build / resto*

[bryce0225]

I'm excited. Bring it back to life. It was a pile of junk. By the time I'm done with it, I'm not sure I would like to take the 80 out. But then again, I've lots of friends over seas that want to come for a visit, so what's better then two vehicles. Paint it exactly the same color as the 80. It's a foot longer and 4" taller in the cabin, and then there is the popup. Design would be similar to the 80, all metal, but probably a bigger dual zone fridge, and diesel hydronic heater and a diesel stove. It's going to be fun.

Diesel stove!? That a
l sounds amazing. I’ll be dreaming and living vicar through you haha!

 

[ofer bruhis]

Diesel stove!? That a
l sounds amazing. I’ll be dreaming and living vicar through you haha!

Webasto makes a double burner.

 

[bryce0225]

Finally! I went to a custom hose fitting shop (hose man inc) and they helped me get the correct fittings for the secondary fuel filter / water separator. I ran from tank, to Racor, to OEM filter. Works great! No more air getting in! I also painted the housing with black chassis paint so it looked just a little more OEM and refreshed.

 

[bryce0225]

I finally got around to fully deleting the ABS and LSPV on Duke.

The axles and control arms are now clean from any wiring looms Thanks to @NLXTACY (wits end) and the awesome plugs that takes the sensors place. The ABS pump is out of the engine bay, freeing up space And weight. The brakes perform better than they ever have!

I also installed SLEE extended braided SS brake lines (chassis to axle only).

Overall, it was a painless easy job. A couple flare fittings on the brake lines proved tricky. I broke 2 bolts on the bracket of the LSPV, so i ended up cutting the whole thing off with a Dremel.

 

[bryce0225]

Willwood proportioning valve for the rear brakes installed. Easy install and works very well.

 

[bryce0225]

I have completed the new rear storage platform… extremely proud and excited. I am working through a more detained write-up here: 1993 HDJ80 Platform DIY build - Camping & Daily Hybrid use - https://forum.ih8mud.com/threads/1993-hdj80-platform-diy-build-camping-daily-hybrid-use.1282795/#post-14416268

Here are some photos of the final product:

 

[ofer bruhis]

Bryce,

Looks great. Next should be the tail gate storage. I bought 304 food grade stainless precut to size, so it could be used as direct cooking countertop. The rest of the hardware is from Amazon. It's a few hours of install and a few 100 $, but you can have all this space for your 'kitchen stuff'. I can send you all the details if interested.

Cheers mate.

By the way, May 14-21 we will be exploring all the overlooks of the north rim of the GC. Join?

--o

 

[bryce0225]

Bryce,

Looks great. Next should be the tail gate storage. I bought 304 food grade stainless precut to size, so it could be used as direct cooking countertop. The rest of the hardware is from Amazon. It's a few hours of install and a few 100 $, but you can have all this space for your 'kitchen stuff'. I can send you all the details if interested.

Cheers mate.

By the way, May 14-21 we will be exploring all the overlooks of the north rim of the GC. Join?

--o

Thanks! I am interested. It is definitely next on the list, though I am still torn between keeping it crafted or not. We still use it as a seat often.

 

[ofer bruhis]

Thanks! I am interested. It is definitely next on the list, though I am still torn between keeping it crafted or not. We still use it as a seat often.

Bryce,

The stainless metal was from here. I used 304 so it's food grade and we can use it as a counter top. Dimensions are for 80 series tailgate on the photo, but you can measure your own. I had to round one corner on each to match the tailgate and drill holes for the latches.

The hinges were stainless. This is the link, but currently unavailable, just buy something similar. The latches are marine grade and I needed to 3D print round spacers in the back, because it's meant for plywood and the sheet metal is too thin. I can send you 4 spacer if you do the project. The shocks are 8" long when compressed. Tack welded the hinges to the back of the stainless plates and rivets to the tail gate. We sit on them but use a yoga mat (in cold weather ).

Good luck mate. It never ends.. But its fun!

Cheers

--o

 

[bryce0225]

We did some work strengthening the hard-stop in the tire swingout. All of the weight would rent on the gas strut, which felt like it was bound to break. Now the strut pushes the swingout into the hard-stop before it reaches its full length. We also welded the gas strut in its place and the top lug bolt in place for easier mounting of the spare.

 

[bryce0225]

Swingout repainted and working better than ever! Holds a 33in tire, bike and rack, trasharoo, and 5lbs propane with ease!

 

[bryce0225]

Huge huge spoiled upgrade… Scheel-Mann seats installed. Vario XXL in grey

The instal was as bolt-in as you could get. I’ve heard of people having figment issues with the Planted Bracket, but this is easily avoidable if you call Toby and Scheel-Mann and the folks at planted. You need to specify that you need a Scheel-Mann seat bolt pattern on the bracket. Scheel -Mann also supplied me with a custom bracket that allows the seat belt receiver to slide with the chair and Planted was kind enough to delete the seat belt bracket from their adapter since they are all made to order.

The grey cloth and leather match the interior of the 80 PERFECTLY… and the comfort is unreal. Completely transformed the truck. Yes, they are expensive, but wow… they are worth it.

 

[ofer bruhis]

Huge huge spoiled upgrade… Scheel-Mann seats installed. Vario XXL in grey

The instal was as bolt-in as you could get. I’ve heard of people having figment issues with the Planted Bracket, but this is easily avoidable if you call Toby and Scheel-Mann and the folks at planted. You need to specify that you need a Scheel-Mann seat bolt pattern on the bracket. Scheel -Mann also supplied me with a custom bracket that allows the seat belt receiver to slide with the chair and Planted was kind enough to delete the seat belt bracket from their adapter since they are all made to order.

The grey cloth and leather match the interior of the 80 PERFECTLY… and the comfort is unreal. Completely transformed the truck. Yes, they are expensive, but wow… they are worth it. View attachment 3016380View attachment 3016382View attachment 3016384View attachment 3016381View attachment 3016383

Bryce, hope to see it in person next month

 

[bryce0225]

Added a small fold down table with what I ad in the garage… consider it a prototype for the eventual steel one. I just wanted to get some use-time on one to figure out what I want. The main purpose is to have a good place for the water Jerry can.

 

[bryce0225]

Instead of hauling around a giant bulky saggy trasharoo, I teamed up with my buddy Dustin at Temporarily On Leave to customize the escape gear tire cover into something that would fit our needs. Mesh pockets for wet river shoes, key loop, addition pocket for recover gear, all while keeping the trash pocket.

 

[bryce0225]

Did some regular maintenance and went on a casual 4000 mile journey.

 

[MooseMichaels]

I've been following you on IG for a while and just came across this thread. Please, please keep up the good work. I love the taste, aesthetic, photography, and period-correctness here. Very inspiring! Every time I see more photos, I feel the need to have an 80 instead of a 100.

 

[OffRoadScott]

Willwood proportioning valve for the rear brakes installed. Easy install and works very well.
View attachment 2992065

What Wilwood valve did you use, is it the same one from @jcardona1 build thread, did you have to change the brake line fittings?

 

[bryce0225]

I've been following you on IG for a while and just came across this thread. Please, please keep up the good work. I love the taste, aesthetic, photography, and period-correctness here. Very inspiring! Every time I see more photos, I feel the need to have an 80 instead of a 100.

Haha thanks I appreciate it! If I wasn’t all in on the 80 series (Being my first and only model of cruiser I’ve owned), I would be all about the 100 series. More comfortable but still super timeless and good looking.

 

[bryce0225]

What Wilwood valve did you use, is it the same one from @jcardona1 build thread, did you have to change the brake line fittings?

I used this one “ Wilwood Engineering 260-12627 Adjacent Proportioning Valve Knob Style (M10 x 1.0 BF inlet) “… found it on amazon. Any one should work without having to modify the fittings as long as its M10 x 1.0 BF fittings.