How much weight can it support?

[MikePL]

I am about to build an expedition camper from scratch, but based on the 80-series. Lots of grinding and cutting, a custom made cabin etc... How much 'weight abuse' do you think the frame can withstand? And what about the alloy wheels?

My initial assumption is that a rather stock FZJ80 weighs around 5000lbs and with this weight it can go over really rough terrain, harsh bumps and even have a few minor jumps from time to time and some serious flexing. Also the stock alloy wheels are known for its strength as they are forged and produced to really high standards.

But what if I increase the weight to 7500lbs and at the same time drive over smoother terrain like gravel roads, sand, careful driving over ditches instead of jumping over them etc... You know, more like camper stuff and not hardcore wheeling. Will the truck make it?

 

[hoser]

I don't have any answers for you but I've stumbled on this guidebook from Toyota regarding body/camper building and alterations. It is written for the 70 series but the information is still useful for you.

http://www.toyota-tech.eu/BBG/Land Cruiser BBG BBGJ1004/cont/pdf/BBGJ1004.pdf

 

[NLXTACY]

Holy crap there is a lot of great info in the PDF even if you aren't making a camper!

 

[BamaPaul]

Very good information in there It has now been saved into my cruiser files

 

[FaulkenCruiser]

In my experience with weight handling/bearing equipment the safety factor is a 5:1 ratio. I think you'd be ok and any area of concern could probably be shored up with more support/gussets or beefed up suspension. Hey you can build anything, it's just a matter of $$$ and imagination.

Just curious.....are you thinking of building a cabover type rig?

 

[TheBigBoy]

In my experience with weight handling/bearing equipment the safety factor is a 5:1 ratio. I think you'd be ok and any area of concern could probably be shored up with more support/gussets or beefed up suspension. Hey you can build anything, it's just a matter of $$$ and imagination.

Just curious.....are you thinking of building a cabover type rig?

X2. I'd be fish plating the chassi and making sure the weight distribution is correct as to reduce leverage.

 

[MikePL]

I have already pulled the body off the frame. In front of the front axle will go a Mitsubishi Canter/Fuso cabin. The 'living space' will be custom made of fiberglass just to keep things light. After the rear axle will go a big container for LPG fuel (around 150 liters). A new gasoline tank will be made and will be placed in the original location but it will hold over 150 liters instead of the stock 90-100 liters. On the opposite side of the frame, just to distribute the weight will go the water tanks (approx 150 liters).

So there is a lot of added weight but obviously not all at the same time. I will fill the LPG tank mainly in Europe because there are many LPG stations. In this case I can keep just a few liters of gasoline (like 20-30). In Africa/Asia fuel is cheap so I will fill gas an keep the LPG tank empty.

I have some experience when it comes to making campers so this project is a challenge but a pleasant one, and a happy end is the only end. Currently the project is on hold because I have big personal and financial problems so I am looking for some sponsors but I hope all will end up well. I am simply sitting at the drawing board and gathering information because it is the only thing I can do, but I will move on some day.

The camper will be similar to the typical Canter/Fuso setups as seen below:

I have decided not to go with the Canter/Fuso frame and engine because in Europe only 2WD vehicles are available, because I prefer Toyota engines (over here the Canters have small engines) and because there are many more aftermarket off-road accessories and parts for Land Cruiser.

 

[Photoman]

Fwiw, here is a weight distribution from my notes of my 1997 at 8135 lbs.

DS Front 1918 lbs
PS Front 1720 lbs.
DS Rear 2293 lbs.
PS Rear 2359 Lbs.

I know other times mine was at 8400-8500 lbs. This was really too much and was probably with 123 gallons of gas.

Bill

 

[canman]

I haven't been able to download and open the file, but working with MB on the G-wagon for the Canadian Army they had to make numerous changes to the vehicle to meet the weight requirements we had regarding a 1500 kg payload requirement excluding any weight required for the armoured protection system. The vehicle ended up with a GVWR of 4800 kg which I believe was 1000 kg greater than anything they had done previously. Changes included upgraded front axle (2.2 tonne vs 1.8 tonne). Beefier front pitman arm and brkt. Heavy duty springs and shocks. Frame (boxed) was strengthened with center member located the entire length of frame. In the end the vehicle still developed numerous body cracks in the floor where the body mounts were located (Note: The vehicle was already fitted with a "double" floor pan). These were all subseqeuntly reinforced. Aside from the additional weight and mechanical issues, there are the legal issues associated with exceeding any of the manufacturer stipulated axle weight ratings, vehicle gross weight rating, and vehicle gross combination weight ratings - big no-no if your caught.

 

[MikePL]

Thanks for the replies. After a few days I still couldn't find any more information. The link which Hoser gave us is very helpful, but there are quite a lot of differences between the 7-series and 8-series frames so I am still trying to find the same guide for the 8-series.

I am not planning to excess the usual weight of a fully off-road-aromured FZJ80 by much, at least this is what I hope. So far the assumptions are the following:

- frame and engine 4000lbs (can anyone confirm this?)
- Mitsu cabin 600lbs
- thin fiberglass 'living space' 600lbs
- equipment/furnishing 700lbs
- water 250lbs
- LPG fuel 300lbs
- fuel 250lbs

That makes 6700lbs for the filled vehicle. I assume luggage and passengers will be no more than 1000lbs

These are all assumptions and will probably vary but I assume that the final weight will be in the 7500-7900 mark.

Will the alloy wheels make it? And the frame?

 

[e9999]

am impressed with your determination and skills. Good for you.

Wondering about the big picture though. Aren't you taking the long and difficult way to do this? First thing that came to mind was why you aren't using a Mitsu or Isuzy type vehicle in the first place. You addressed that. But am still wondering if there aren't easier/better alternatives that would not require reinventing the wheel. A Mog came to mind... Or maybe even some of the Eastern Euro vehicles?

 

[scottryana]

Yeah this seems like quite a project, but to convert a non cab over to a cab over you are going to be faced with all kinds of issues like steering, shifting, throttle and brake linkages, etc. Why not just start with a medium duty offroad chassis?

 

[MikePL]

Unfortunately after months of looking at the European market, I couldn't find anything equally reliable and in a similar price range.

1. Mitsubishi and Isuzu trucks all come only in 2WD options and manual tranny. The engines are also too small. If a 4.2 diesel is rather OK for a 2.5ton HDJ80, then will a 2.8 or 3.0 diesel be ok for a 3.5ton camper. I don't think so. Apart from that there are not so many aftermarket modification options for Mitsu/Isuzu. This is a commercial vehicle so no aftermarket/bling market like for a Land Cruiser. The big bummer is the lack of auto tranny.

2. Unimog is just too heavy, too expensive and I have also seen only with manual tranny. The newest models have maybe an auto tranny but the oldest ones cost a lot (like 20K$) and are still horrbile brute trucks. I can't imagine my petite wife driving one of these: the cabin is just primitive, zero comfort.

3. Other European trucks and vans are just pure crap. Small engines, no tilt cabins (hard access to engine), engines mounted across the vehicle axis, manual trannies and no 4WD. I have one of these and it causes problems all the time. The newer ones have common-rail diesel engines which are a nightmare.

I really wish I had a suitable vehicle for me but I'm afraid there isn't one: 4WD, boxed frame, cab-over, tilt cabin, auto tranny, either a diesel non-turbo engine (like the 4.2 from HZJ80) or a simple gasoline engine and creature comforts for my wife who will drive with me (easy steering, elec windows, comfy adjustable seat).

The last, but very important factor is price. A beaten FZJ80 cost me $6000 and the Mitsu cabin will be $1000. This is not much over here...

 

[Surfy]

much 'weight abuse' do you think the frame can withstand? And what about the alloy wheels?

I dont think that the 80`er is weaker than the Land Cruiser 200.

With the 200`er it wasnt a problem to do a transafrica with near 4to and alloy wheels - maybe this information helps.

I also decide that comfort is one of the important things, when you want to do some extended overlanding stuff.

Surfy

 

[1morebike]

I'm surprised no one has talked about the brakes. I would think you would have to beef them up a decent amount to stop that much weight and if you were traveling mountain passes I would be looking for the run out signs.

 

[MikePL]

Brakes are no problem. It is just a matter of making sure all the calipers work. The 100-series pads on the front also work well. Remember that this is going to be a camper with extended capabilities and not a monster truck with 37" swampers.

31 or 33" wheels will brake OK.

 

[devildogcruiser25]

I can't link it from my phone, but search lx450 camper/chinook and take a look at what he is doing. I think it's similar to what you are describing

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