- Thread starter
- #161
It has been a while since my last update, allot has happened. I am at the tail end of the build for the Land Cruiser and preparing for trip which I should be on the road in September. The majority of the metal fabrication and paint/body is complete. I just got the completely rebuilt injectors/injection pump. The head, block, and engine internals are being cleaned/getting their tolerances checked per the engine manual as we speak. Once this is complete I will drop the power train back in and finish the vehicle.
The following as been completed since the last update:
- Fabricated the roll and the overhead center console
- Fabricated the sleep platform in the rear
- Fabricated the dual fuel fill neck for both the main and auxiliary tank
- Finished the rust repair and painted the body. I decided to fill some of the joints with metal templates and seams that divide the body such as the windshield frame hinge. I never plan on taking the roof off the vehicle or putting the windshield. I decided to Herculine the bottom half of the vehicle for abrasion resistance and paint the top half/hood. Underneath the vehicle and in the interior floor is Line-x.
- Mounted the roof and roof rack. I reinforced the fiberglass roof with more fiber glass. Then I Herculined the bottom of the top and primed/painted/clear coated the top. The roof rack was sand blasted, welded to repair rust spots, and painted/clear coated.
- Installed the limb risers (Lines going from the roof rack to the front bumper, which break up vegetation).
- Fabricated and painted the exterior window guards for the four side windows, the two rear ambulance doors, and the two rear curve glass windows.
- Welded the Master hasp shackle locks on both driver/passenger doors and the two rear ambulance doors. This will make it extremely hard when the vehicle is left unattended to physically break the doors open or pick the locks.
- The fuel injection pump and injectors have been serviced. They were disassembled, cleaned, and inspected. Upon inspection they found rust on the fuel side of the pump and pitting on the barrel sealing surfaces. There was wear through the pump and they also found rust in the injectors and all the nozzles were bad. They rebuild the pump using new parts as needed. The pump was mounted on a calibration stand and calibrated to manufacture's specifications. All the injectors were rebuilt using new nozzles, gaskets, and heat shields. The opening pressures were set to 118-121 bar and pop tested.
- I disassembled the entire engine and the components were sent out to be cleaned, check for integrity (magna flux and it came out okay after I called them), and have the internals tolerances checked (camshaft, crankshaft).
- Ordered new engine gasket/seal rebuilt kit, new oil pump gears and pressure relieve valves for the oil pump and oil cooler.
What is left to do in the last two phases of the build
Phase 1 (July-August):
- Install seats
- Install four point seat belts
- Finish modifying the hood locks
- Mount the entire air system (air tank, air compressor, air distribution block that has the air locker solenoids on it, air reel, air pressure regulator, moister separator) and hardline it.
- Install all the gauges into the dash and the RPM on the steering column
- Install the switch box in the overhead console
- Mount the CB antenna on the back of the roof rack, drivers side at a 45 degree angle.
- Mount and install the CB radio.
- Mount and install the front and rear off-road lights
- Mount and installed the main headlights with stone guards
- Mount the front turn signals
- Install the main wiring harness
- Mount the electric cut off switch and switching fuel valve for both tanks
- Install the ARB off-road fridge
- Make and install the sleeping platform pads/locks to retain the sleeping platforms to the roll cage; reinstall the sleeping platform with the pulley hardware
- Mount the black solar shower cylinder on the side of the roof rack
- Install the white LED interior lights
- Connect the winch to the auxiliary battery and install cooling fan for the winch
- Install inverter
- Mount the two 1LB fire extinguishers in strategic spots within the vehicle
- Mount the rear view mirror
- Install the radio/speakers/amplifier
- Install the four steel fans I bought. Two should be on the driver/passenger and two should be mounted to cool two people sleeping the back of the Land Cruiser.
- Install the front windshield, four sliding glass windows on the side of the body, and the two rear curved glass windows plus tint.
- Mount and connect all three of the Optima batteries
Phase 2 / Completion / Stress testing the vehicle (End of August – Begning of September):
- Clean all the parts associated with the engine and prep for high temp primer/engine paint and then paint the engine parts gloss black/aluminum
- Assemble and install the engine (This is also including the cooling systems, turbo, electrical connections, oil catch can, the piece of stainless steel I bought as a head shield for the turbo, etc.)
- Install the transmission
- Install the already fabricated transmission/transfer case skid plate (It will need a little tweaking to work)
- Fabricate and install the sump skid plate
- Finish repairing the and mounting the driver/passanger doors and the rear ambulance doors
- Install the vacuum reservoir system to the brake booster and vacuum pump on the alternator
- Install the front grille Toyota Land Cruiser/Diesel emblems
- Weld expanded metal on the turn signal protectors (front and rear turn signals)
- Install the intake snorkel
- Install the exhaust
- Make a ladder from the 1” box tube to access the roof rack
- Make a pull out for the stove in the back from the 1” box tube
- Install drive shafts - Install transmission plate cover and bend the transmission/transfer case levers for right hand drive.
- Mount the fuel tanks and connect the fuel lines
- Mount and install coolant overflow reservoir and windshield wiper reservoir
- Check the preload on the bearings for the front axles, make sure to fill the front knuckles with grease when done; check back axles as well if needed.
The following as been completed since the last update:
- Fabricated the roll and the overhead center console
- Fabricated the sleep platform in the rear
- Fabricated the dual fuel fill neck for both the main and auxiliary tank
- Finished the rust repair and painted the body. I decided to fill some of the joints with metal templates and seams that divide the body such as the windshield frame hinge. I never plan on taking the roof off the vehicle or putting the windshield. I decided to Herculine the bottom half of the vehicle for abrasion resistance and paint the top half/hood. Underneath the vehicle and in the interior floor is Line-x.
- Mounted the roof and roof rack. I reinforced the fiberglass roof with more fiber glass. Then I Herculined the bottom of the top and primed/painted/clear coated the top. The roof rack was sand blasted, welded to repair rust spots, and painted/clear coated.
- Installed the limb risers (Lines going from the roof rack to the front bumper, which break up vegetation).
- Fabricated and painted the exterior window guards for the four side windows, the two rear ambulance doors, and the two rear curve glass windows.
- Welded the Master hasp shackle locks on both driver/passenger doors and the two rear ambulance doors. This will make it extremely hard when the vehicle is left unattended to physically break the doors open or pick the locks.
- The fuel injection pump and injectors have been serviced. They were disassembled, cleaned, and inspected. Upon inspection they found rust on the fuel side of the pump and pitting on the barrel sealing surfaces. There was wear through the pump and they also found rust in the injectors and all the nozzles were bad. They rebuild the pump using new parts as needed. The pump was mounted on a calibration stand and calibrated to manufacture's specifications. All the injectors were rebuilt using new nozzles, gaskets, and heat shields. The opening pressures were set to 118-121 bar and pop tested.
- I disassembled the entire engine and the components were sent out to be cleaned, check for integrity (magna flux and it came out okay after I called them), and have the internals tolerances checked (camshaft, crankshaft).
- Ordered new engine gasket/seal rebuilt kit, new oil pump gears and pressure relieve valves for the oil pump and oil cooler.
What is left to do in the last two phases of the build
Phase 1 (July-August):
- Install seats
- Install four point seat belts
- Finish modifying the hood locks
- Mount the entire air system (air tank, air compressor, air distribution block that has the air locker solenoids on it, air reel, air pressure regulator, moister separator) and hardline it.
- Install all the gauges into the dash and the RPM on the steering column
- Install the switch box in the overhead console
- Mount the CB antenna on the back of the roof rack, drivers side at a 45 degree angle.
- Mount and install the CB radio.
- Mount and install the front and rear off-road lights
- Mount and installed the main headlights with stone guards
- Mount the front turn signals
- Install the main wiring harness
- Mount the electric cut off switch and switching fuel valve for both tanks
- Install the ARB off-road fridge
- Make and install the sleeping platform pads/locks to retain the sleeping platforms to the roll cage; reinstall the sleeping platform with the pulley hardware
- Mount the black solar shower cylinder on the side of the roof rack
- Install the white LED interior lights
- Connect the winch to the auxiliary battery and install cooling fan for the winch
- Install inverter
- Mount the two 1LB fire extinguishers in strategic spots within the vehicle
- Mount the rear view mirror
- Install the radio/speakers/amplifier
- Install the four steel fans I bought. Two should be on the driver/passenger and two should be mounted to cool two people sleeping the back of the Land Cruiser.
- Install the front windshield, four sliding glass windows on the side of the body, and the two rear curved glass windows plus tint.
- Mount and connect all three of the Optima batteries
Phase 2 / Completion / Stress testing the vehicle (End of August – Begning of September):
- Clean all the parts associated with the engine and prep for high temp primer/engine paint and then paint the engine parts gloss black/aluminum
- Assemble and install the engine (This is also including the cooling systems, turbo, electrical connections, oil catch can, the piece of stainless steel I bought as a head shield for the turbo, etc.)
- Install the transmission
- Install the already fabricated transmission/transfer case skid plate (It will need a little tweaking to work)
- Fabricate and install the sump skid plate
- Finish repairing the and mounting the driver/passanger doors and the rear ambulance doors
- Install the vacuum reservoir system to the brake booster and vacuum pump on the alternator
- Install the front grille Toyota Land Cruiser/Diesel emblems
- Weld expanded metal on the turn signal protectors (front and rear turn signals)
- Install the intake snorkel
- Install the exhaust
- Make a ladder from the 1” box tube to access the roof rack
- Make a pull out for the stove in the back from the 1” box tube
- Install drive shafts - Install transmission plate cover and bend the transmission/transfer case levers for right hand drive.
- Mount the fuel tanks and connect the fuel lines
- Mount and install coolant overflow reservoir and windshield wiper reservoir
- Check the preload on the bearings for the front axles, make sure to fill the front knuckles with grease when done; check back axles as well if needed.
