HZJ105 Expedition Build

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Joined
Feb 18, 2006
Threads
17
Messages
1,038
Location
Maryborough, QLD, Aust.
G'day

As you can see from my sig line I am upgrading my 80 to a 105.

The threads on my 80 are

https://forum.ih8mud.com/80-series-tech/146800-pre-expedition-build.html

https://forum.ih8mud.com/expedition-builds/167274-post-expedition-report-pics.html

The 80 has been great but I have been thinking about upgrading to a 105 just for the fact it will have less miles on the odo. The 80 has 375000km on it now and it is starting to show its age.

On the way to work the other day I noticed the EGT gauge temp getting higher than normal. The engine temp gauge hadn't moved from its normal position. Next thing I knew there was steam coming out from under the bonnet. I had done a head gasket and because the gauge didn't register it was hot and I did damage to the motor.

I am a mechanic by trade but I haven't spun spanners for a few years now, don't have the time or the space to fix it so I got a shop to look at it. They quoted $8500 - 9000AUD to fix it. After I picked myself up off the ground I told them I'd fix it myself when I got time.

At this point in time my wife was expecting our first born any day and I wanted a decent car to take her to Brisbane in for the birth. As we had been talking about upgrading to a 105 we decided to bite the bullet and get one and then fix the 80 after Xmas. The next problem was finding one. I know you all think diesel cruisers grow on trees here but finding the exact model was proving difficult. I wanted a solid front end so factory turbos were out and I wanted constant 4wd so the base models were out. This left only 1HZ powered GXL wagons. At the time I was looking all I could find was six of that model on the net in QLD. One day reading the local paper at work I found an ad for a diesel GXL so I rang up and found this one just down the road. I rang up straight away and organised to look at it. We ended up getting it the day we left to go to Brisbane to have our baby girl.

The plan now is to build this 105 up into an expedition rig similar to the 80 using as many of the bits off the 80 as we can. Some of the bits won't fit but a lot will. I also plan on fixing some of the mistakes I made on the 80 with the 105.

The 80 is a bit tall for touring (sacrilege, I know) so the 105 won't get as big a lift. The 80 was also overweight. I am a believer in being prepared so I always carry all my recovery gear, tools, etc. I am going to try and cull down as much as I can to reduce weight without leaving any essentials out. I am also going to try and use as many aluminium components as possible.

The 80 has a steel ARB winch bar and a steel ARB twin pivot rear bar. I am going to try and modify the Genuine Toyota bullbar to accept my winch or I might even sell the bar and buy a TJM type 15 alloy winch bar. For the rear I have a couple of ideas for designing an alloy rear bar. I want the rear bar to be twin pivot still but have better departure angle than the ARB bar, not to mention I want to reduce the rear weight by a couple of tons.

I want to keep the suspension height down on this one. I have a 4" lift in the 80 but having a newborn baby girl now access to the baby seat is important as is access to underground carparks and standard height garage roller doors. I am thinking a 2" lift will be ample to allow for the weight. I am even thinking of going to airbag rear suspension, although that requires a bit more research before I make a decision.
 
Thats terrible,only 6 diesel 105 cruisers to choose from in your area:rolleyes: Im sure that will make the Americans feel better:D

Anyway good choice,I want to get a 105 next but probably a base model.
I hope mum and bub are doing ok if the happy day has arrived;)

Looking forward to the build up. A two inch lift is fine for expedition type offroading and its also safer for high speed swerves if they have to be made.
Most of your miles are done on roads to get to the tracks you want to travel on ,so the highway cruising should always be taken into account.

Turbo, N/A or the other?:D
 
I haven't done much to the new 105 yet. I have been busy with our new baby girl and Xmas, etc.

The 105 did come with a snorkel when I bought it so that is one thing I won't have to do.

One of the guys at work has a petrol 100 with alloy rims so he sold me his old steel GXL rims so now I have a spare set (to paint black;)) for extra spares and for my boat trailer. I haven't decided on tyres yet but they will definitely be 285/75R16 in a M/T patern. I am not happy with the MT/Rs so will be looking at something like MTZs.

I am also looking for a new stereo. The CD player in the 80 is ancient and we were looking at replacing it before our trip in May. It is a toss up between a single DIN head unit and keep it set up how it is in the 80 with the UHF or to go to a double DIN unit with a screen for DVD/ GPS/ reversing camera and to relocate the UHF somewhere else.

The turbo off the 80 will definitely be being swapped over to this one. I don't know if I'll forget to put the muffler on or not. I love TD without mufflers but this is a touring rig not a weekend warrior so I am thinking I will keep the muffler just to keep a low profile in remote areas.

Hopefully my sliding drawers will fit without too many modifications. Although now having a pram to fit above the drawers might require a redesign.

I'll post up a few pics of the 105 when this "cyclone" clears off and I can get outside and take some pics of it without getting wet or blown away.
 
Thats terrible,only 6 diesel 105 cruisers to choose from in your area:rolleyes: Im sure that will make the Americans feel better:D

Anyway good choice,I want to get a 105 next but probably a base model.
I hope mum and bub are doing ok if the happy day has arrived;)

Looking forward to the build up. A two inch lift is fine for expedition type offroading and its also safer for high speed swerves if they have to be made.
Most of your miles are done on roads to get to the tracks you want to travel on ,so the highway cruising should always be taken into account.

Turbo, N/A or the other?:D

Hey Rosco

The wife and bub are just fine now but it was touch and go during the birth.

It is strange going into a corner and not having the cruiser almost tip on its side from the bodyroll.:D

It will be getting the turbo from my 80. It has served me well so far and all I'll have to do is get an exhaust to suit.
 
Mick, congratulations on the new baby! I look forward to your expedition built 105. Btw, isn't the offset of those IFS GXL wheels incorrect for your 105? Cheers!
 
Mick, congratulations on the new baby! I look forward to your expedition built 105. Btw, isn't the offset of those IFS GXL wheels incorrect for your 105? Cheers!

Thanks hoser.

I'll post up pics of the rims but they are the correct rims. Mine is a HZJ105 GXL and has the OEM rims. The rims I bought for spares are from a FZJ105 GXL and are identical. They are the 16 x 8 rims with five slots, similar looking to the steel GXL 80 rims I have on my 80.
 
Oh got it. I misunderstood and thought the rims were from his IFS 100.

One of the guys at work has a petrol 100 with alloy rims so he sold me his old steel GXL rims so now I have a spare set (to paint black;)) for extra spares and for my boat trailer.
 
I am also looking for a new stereo. The CD player in the 80 is ancient and we were looking at replacing it before our trip in May. It is a toss up between a single DIN head unit and keep it set up how it is in the 80 with the UHF or to go to a double DIN unit with a screen for DVD/ GPS/ reversing camera and to relocate the UHF somewhere else.

I have been doing a bit of googling carputers and I reckon I might give making a carputer a go. My brother is a real computer guru/nerd who reckons we can knock one up real cheap.

Still not sure on whether to go for a double DIN 7" TFT screen and relocate the UHF or to go for a single DIN unit with a motorised flip up screen.

The single DIN unit would allow a simpler install as far as the UHF goes but I am not sure of the robustness of the motorised unit. Does anybody know of how they handle corrugations, potholes, etc? Keeping in mind this is an expedition rig and will be travelling over some of the worst corrugations this side of the black stump.
 
I've been using a single DIN with a folding screen (Blaupunkt, see below) in my other car for 2 1/2 years and 25 kmiles and it works good but I'd be a little bit worried about rattles it might take in a heavy duty offroader as this is a precision machine. I'd go for the double DIN.


Blaupunkt-IVDM-7002-11630814-medium.jpg
 
I've been using a single DIN with a folding screen (Blaupunkt, see below) in my other car for 2 1/2 years and 25 kmiles and it works good but I'd be a little bit worried about rattles it might take in a heavy duty offroader as this is a precision machine. I'd go for the double DIN.


Blaupunkt-IVDM-7002-11630814-medium.jpg

Thanks Grolar

I am leaning more towards the double DIN at this stage. Mainly for the reliability of the mechanism but also for the cleaner OEM look installation. I think a lot of the double DINs have motorised screens too AFAIK:confused: to adjust for sunlight viewing angles but I think there are some that are just plain screens.
 
I gave the 105 a quick service today. The 200,000km service is the next one so I'll do the big one next time. The RHF door window switch has been playing up occasionally so I had a look at it too. The plastic mount for the switch was cracked so I stripped the switch and glued the crack. Hopefully this will fix the problem and save me having to buy a replacement. The local dealer wanted $700+ for a new switch.:eek:

While I was at the dealer I got the necessary brackets to secure my dual battery. As the spot is there for the battery factory components make it a neat installation. The Trojan 115Ah battery I have is a little taller than a standard N70Z battery so I will need to put a small spacer in to let it sit square and true.

For the wiring I will use some of these Projecta terminals
BT950x150.jpg


They have distribution studs with fuses to make connecting simple. Projecta

The isolator will be a Redarc Smart Start dual battery isolators by Redarc Electronics

sbi12.jpg
 
I took the cruiser down to the local Toyota dealer to get a new key remote coded as a spare for the wife and to recode the OEM radio after I had a flat battery the other day and had to replace the battery. While I was there they told me my car had a recall outstanding on it. Something about the brake caliper bolts. They fixed that too. All up cost me $25. While I was waiting for the car to be done I went down to the local electronics shops to research touchscreens, hard drives, motherboards, etc for the carputer install. Found a couple of tasty little ideas.
 
Oh yeah,the brake caliper bolts were rattling loose on the 105 and 78/79 series.

I wish the clutch and brake pedals were that far apart on my 75 series:D Its the 1st thing you notice when you jump into a 105.

Thats a nice looking 105 ,they deserve their nick name "ship of the desert" :D

I might do something about those plastic mudflaps though. I see them all over place torn off:D

Does the Redarc thing decide which battery should be charged and which can best be used for starting?
 
Oh yeah,the brake caliper bolts were rattling loose on the 105 and 78/79 series.

I wish the clutch and brake pedals were that far apart on my 75 series:D Its the 1st thing you notice when you jump into a 105.

Thats a nice looking 105 ,they deserve their nick name "ship of the desert" :D

I might do something about those plastic mudflaps though. I see them all over place torn off:D

Does the Redarc thing decide which battery should be charged and which can best be used for starting?

I don't know what they did to the caliper bolts but I reckon I'll be keeping an eye on them in future.

The 75 pedals are close together, especially when wearing steelcaps.

Originally I wanted a white one but when there aren't many to chose from, beggars can't be choosers. I'm not a fan of grey as a colour as it is the worst colour for visibility in rainy conditions. I travel with my headlights turned on so hopefully it won't be too bad. The colour is actually growing on me a bit, it has a bit of an olive green tinge to it in some lights.

I don't know what I am going to do about the mudflaps. The ones on the 80 got ripped off. I'll have to figure something out when I build the alloy rear twin pivot bar.

The Redarc (or the cheaper copy we use at work;)) are a voltage sensitive relay. The batteries are isolated normally but when the start battery reaches 13.7V (ie, receiving a charge from the alternator and has received enough charge itself) it links the two batteries together. When the voltage drops again (ie, you've turned the car off and the batteries go to their at rest voltages) they disconnect again. They also have a manual override function that allows you to hit a switch on the dash to manually link both batteries. This is good if the crank battery is getting flat and you want to give it a hand to start the car.

There is a new VSR by BEP Marine that is a dual model. It works either way. Whichever battery receives 13.7V it will trigger the relay to link together. This is great when you have solar panels or an onboard battery charger hooked up to the auxillary battery.
 

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