Builds Ikarus' HDJ81 Aussie-Style Build (4 Viewers)

[ikarus]

How did you clear the IC piping of the indicator lights?
I just cut the back out of mine since my JTX quad lights have an indicator, and intend to replace them once I find a shallow mount led indicator of some sort.

I was just looking at that last night. They don't fit perfectly - on the passenger side the IC piping is a little too high and it pushed the turn signal down. driver's side is fine. If you find a shallow LED turn signal let me know.

I know in the PDI instructions and some videos I watched they mentioned that the lower you can drill the hole to go through the radiator support, the better your turn signals will fit. Not much help now that it's all installed though

 

[ikarus]

Big thanks to @Outsane (Solve Function) for making me a RHD version of the cabin filter. Looking forward to a dust-free cabin.

Finally chopped the lower grille trim enough to clear the IC piping and AC lines. Now I can get the front end back together

I just need to trim these two tabs off the back of the grille to fit up against the intercooler:

New fuel filter. I need to replace the 3 fuel hoses next.

 

[mudgudgeon]

Big thanks to @Outsane (Solve Function) for making me a RHD version of the cabin filter. Looking forward to a dust-free cabin.

Thanks for posting this. Will go order one now!!

 

[mudgudgeon]

At the risk of joining the needs, speedo calibration can vary from the factory by a few percentage points, plus calibration can vary with wear and tear.
Tire size calculations get you close, but check speedo with a GPS

 

[ikarus]

Thanks for posting this. Will go order one now!!

Hit up Lee solvelee@gmail.com - tell him Max sent you. I don’t know if he has RHD up on the site yet

 

[mudgudgeon]

Hit up Lee solvelee@gmail.com - tell him Max sent you. I don’t know if he has RHD up on the site yet

Dropped him a PM so we'll see how that goes. It's not on his etsy pages

 

[ikarus]

Trimmed a couple areas on the grill where it was contacting the IC, trans cooler and lines.

Cleaned up some surface rust and brushed on some touch up paint since I didn't feel like taping things off to spray. New wiper linkage, arms, wipers and hardware. Reinstalled the cowl with a new seal as well.

 

[Outsane]

Dropped him a PM so we'll see how that goes. It's not on his etsy pages

Most of my items are at
Solvefunction.com
I'll add this to the website

 

[duece71]

I need a RHD cabin filter as well.

 

[ikarus]

Started it up for the first time since June. Fired right up no problem. I threw the driver's seat in, filled up with coolant and took a trip into town to buy diesel.

As expected, I just have the preheat coil light on. Haven't decided if I'll follow the directions on that Russian forum and remove a couple wires.

Other than that, things are good. I'll be going down the tuning rabbit hole soon. I had a couple rough idles at the beginning where it allllmost shut down but didn't. And think I felt it go into fuel cut once and I also got one backfire... not sure what was up with that.

Max EGT I saw was about 1000° F going up a sustained hill at 50 mph so I think I have lots of room there. Boost maxed out at 9-10 psi. Excited to keep learning!

 

[Lo2aY]

Clean build!

 

[mudgudgeon]

Started it up for the first time since June. Fired right up no problem. I threw the driver's seat in, filled up with coolant and took a trip into town to buy diesel.

As expected, I just have the preheat coil light on. Haven't decided if I'll follow the directions on that Russian forum and remove a couple wires.

Other than that, things are good. I'll be going down the tuning rabbit hole soon. I had a couple rough idles at the beginning where it allllmost shut down but didn't. And think I felt it go into fuel cut once and I also got one backfire... not sure what was up with that.

Max EGT I saw was about 1000° F going up a sustained hill at 50 mph so I think I have lots of room there. Boost maxed out at 9-10 psi. Excited to keep learning!

That backfire must have been serious!

Your hood is gone completely!!

 

[ikarus]

Final deep cleaning before the interior goes back together.

Got this gum or something out of the back seat using a combination of Chemical Guys stain remover and steam.

Removing the coin holders since all they do is collect gunk and are hard to clean. Might just replace with switch blanks for now.

Some of you will be dismayed to learn that I didn't add sound deadening to the interior. haha. ran out of time and money, can you believe that

Working on a band-aid fix for the rear hatch rust. Grinding it down, paint inside and out with rust encapsulator, bondo, then paint. Since I have that other hatch I'll be interested to watch and see how effective a more temporary fix can be.

Next up, knuckles. They really weren't in too bad of shape inside and out but I have a broken stud. Any thoughts on getting this out?

 

[FMC80]

Final deep cleaning before the interior goes back together.

Got this gum or something out of the back seat using a combination of Chemical Guys stain remover and steam.

Removing the coin holders since all they do is collect gunk and are hard to clean. Might just replace with switch blanks for now.

Some of you will be dismayed to learn that I didn't add sound deadening to the interior. haha. ran out of time and money, can you believe that

Working on a band-aid fix for the rear hatch rust. Grinding it down, paint inside and out with rust encapsulator, bondo, then paint. Since I have that other hatch I'll be interested to watch and see how effective a more temporary fix can be.

Next up, knuckles. They really weren't in too bad of shape inside and out but I have a broken stud. Any thoughts on getting this out?

That sucker really broke off in a bad way in there. Can you center punch it and drill it out?

 

[prwillard2]

That sucker really broke off in a bad way in there. Can you center punch it and drill it out?

What side is this? Do you have ABS? I have an entire drivers knuckle for a 75, may fit your 81. I have the studs too.

 

[ikarus]

That sucker really broke off in a bad way in there. Can you center punch it and drill it out?

That got it. Spun out easily, luckily there was no corrosion.

What side is this? Do you have ABS? I have an entire drivers knuckle for a 75, may fit your 81. I have the studs too.

Thanks man but it looks like I'm good! I appreciate it though

 

[ikarus]

Success on the knuckle. Little bit of pitting to clean up on the ball.

 

[mudgudgeon]

That got it. Spun out easily, luckily there was no corrosion.

Thanks man but it looks like I'm good! I appreciate it though

This drill bits always look so wrong!

 

[mudgudgeon]

Success on the knuckle. Little bit of pitting to clean up on the ball.

Personally, I'd just degrease, use some phosphoric acid to convert the rust, clean, paint . . .




Or run it as it is

 

[duece71]

That got it. Spun out easily, luckily there was no corrosion.

Thanks man but it looks like I'm good! I appreciate it though

Whew! Could have been much worse. Great job on all of this Max, this thread will be very helpful for my interior someday.