This thing is cool! I love seeing stuff like this. It takes balls to just start hacking a vehicle apart and determination to see it through. Love it! 
Build Lexus lx450 chinook expedition vehicle
- Thread starter SWCruiser
- Start date
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Crazy! I dig it and will be watching the build.
I think this is going end up being a nice build. My dad had one of those Chinooks, a 1977. I spent way to much time working on it.
To the people who are commenting about it being top heavy, it shouldn't be an issue. Remember this is a lightweight empty box, so there is little weight up high, and much less than having a roof rack with a spare tire or jerry cans. Think of a land rover discovery. With the way the poster is setting it up, all the weight is going to be very low down, near frame level. I wouldn't be surprised if once this is built, the center of gravity is lower for this than a stock bodied truck with the same lift.
To the people who are commenting about it being top heavy, it shouldn't be an issue. Remember this is a lightweight empty box, so there is little weight up high, and much less than having a roof rack with a spare tire or jerry cans. Think of a land rover discovery. With the way the poster is setting it up, all the weight is going to be very low down, near frame level. I wouldn't be surprised if once this is built, the center of gravity is lower for this than a stock bodied truck with the same lift.
- Thread starter
- #64
Cary's comments are spot on. Even after replacing the floor with 1 1/4 plywood two stong guys can lift the entire chinook. I doubt that would be possible to do with rows of seat, two doors, rear hatches, roof, glass etc. I am pretty sure as it sits now there is a considerable net loss of weight. For a similar outfitted armored 80 I think Ill come come in lower. Additionally, all the heavier items, extra battery,water tank, propane cylinder and cargo boxes will be below the floor of the chinook. As for the interior all of the weight will be 6" or more down from the lx roof. For reference, all cabinets and other items will be mounted below the bottom of the large window on the chinook. So Cary is right that the COG should be lower than a full body and roof rack. To make it even less likely to tip Im pushing out the wheels 2" all the way around.
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- Thread starter
- #65
After completing, or so I thought, all the welding and cutting I seam sealed the entire box and then proceeded to paint with Al's liner.... Why don't they tell you to mix only a quart the first time around
I ended up wasting over a quart because the pot life was so short!!!!
I was excited for the big day when the Chinook would find its permanent home. I pulled up to the Fiberglass shop and only about half the work was done... The body work wasn't complete. The floor was suppose to be entirely fiberglassed... and the top was still a mess.... Over the next 5 days I was down at their shop getting it prepped for Al's liner. I was fustrated because i thought this would be a 1-2 day process and I would have time to Bear Hunt and start work on the interior... oh well these projects never follow the timeline or budget you expected...:whoops:
I decided to speed up the process and Lined the bottom with Al's liner. Here's a pic of me prepping to roll it on.
I also had time to work on some of the small things like rebuilding the rear door. I had to replace and beef up the frame.
I ended up wasting over a quart because the pot life was so short!!!! I was excited for the big day when the Chinook would find its permanent home. I pulled up to the Fiberglass shop and only about half the work was done... The body work wasn't complete. The floor was suppose to be entirely fiberglassed... and the top was still a mess.... Over the next 5 days I was down at their shop getting it prepped for Al's liner. I was fustrated because i thought this would be a 1-2 day process and I would have time to Bear Hunt and start work on the interior... oh well these projects never follow the timeline or budget you expected...:whoops:I decided to speed up the process and Lined the bottom with Al's liner. Here's a pic of me prepping to roll it on.
I also had time to work on some of the small things like rebuilding the rear door. I had to replace and beef up the frame.
- Thread starter
- #66
The day to mount the Chinook finally came!!!!
We muscled it on there and I was anxiously waiting to step back and see it in all its glory..... 
The overhang was sitting 4" high over the cab, WTF!!!!!!!! I tried to convince myself for 15 minutes I could get it to work... but that was futile. I know it would bother me every time I looked at it... How did this happen?????? I don't usually make mistakes like that especially on something so critical....
It was a combination of things... When they glassed the new floor in they actually glass it in a couple inches lower than the original.
Also the original makeshift platform had a forward slope. Both of these things resulted in a 4" error...
After some swearing I said lets get this off. They tried to convince to work with what I had but that wasn't going to fly.
I drove home in complete irritation and the grinder provided some good therapy. I cut the entire rack down in an hour and half and by the next morning had it rewelded with improvements. Heres a pic showing the new level of the floor. You can see the new glass below the original compartment. It should have been resting directly on the floor.
We muscled it on there and I was anxiously waiting to step back and see it in all its glory..... The overhang was sitting 4" high over the cab, WTF!!!!!!!! I tried to convince myself for 15 minutes I could get it to work... but that was futile. I know it would bother me every time I looked at it... How did this happen?????? I don't usually make mistakes like that especially on something so critical.... It was a combination of things... When they glassed the new floor in they actually glass it in a couple inches lower than the original.
Also the original makeshift platform had a forward slope. Both of these things resulted in a 4" error...
After some swearing I said lets get this off. They tried to convince to work with what I had but that wasn't going to fly.
I drove home in complete irritation and the grinder provided some good therapy. I cut the entire rack down in an hour and half and by the next morning had it rewelded with improvements. Heres a pic showing the new level of the floor. You can see the new glass below the original compartment. It should have been resting directly on the floor.
- Thread starter
- #67
The next night I was able to get the chinook mounted and it rested perfectly atop the cab!!!!
The floor is secured by 12 3/8 x 3" bolts. The metal roll bar is also welded into the Chinook metal frame. I figured there would be not flex between the cab and body and doing a fixed joint would be the cleanest and easiest. We shall see how that works out. I also cut the cargo door compartments for the floor.
I the below pic you can see the metal roll bar and the chinook metal frame. At the bottom of the pic is a round tube welded between the two. I also took and old jack handle and made a bar to keep things from flying off the cab storage area.
The floor is secured by 12 3/8 x 3" bolts. The metal roll bar is also welded into the Chinook metal frame. I figured there would be not flex between the cab and body and doing a fixed joint would be the cleanest and easiest. We shall see how that works out. I also cut the cargo door compartments for the floor.I the below pic you can see the metal roll bar and the chinook metal frame. At the bottom of the pic is a round tube welded between the two. I also took and old jack handle and made a bar to keep things from flying off the cab storage area.
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- #68
One of the issues bothering me the most was how to solve the side gaps between the cab and chinook. Below is a pic is what i had to work with. In the original setup the fiberglass was bolted to the cab. I guess this would have been ok but then you have to make the cab to the exact dimensions. Seemed like a lot more work for someone like me... After going back and forth between using sheet metal and fiberglass i finally decided glassing the entire joint would look the cleanest and also be fairly straightforward. I cut foam spacers to cover the joint and then added two layers of mat. This was my first time glassing and I was pretty excited about how it turned out. Al's liner makes everything look professional....
Nice. Projects like these are the province of people who can handle several setbacks a week and you are clearly the right personality for it. Which means you're also the type of personality that will quickly move onto something else and sell it. Dibs on buying!!
DougM
DougM
- Thread starter
- #70
Doug,
That crossed my mind when I was completely exhausted and staring at the 4" gap. But Im also the type that won't let things get the best of me and will always finish a project. As I get older though Im becoming less inclined to start new projects, budgets and timelines are always underestimated. Experience counts for something. This is probably the last big one ill undertake until I really have extra time on my hands. I have to work on this while traveling between the East coast so I basically get a 4-5 days every few months. When I finally finish this one I'm going to enjoy it That being said I am building a second one. 
on the east coast. This one is a learning process and I obviously already learned from my mistakes.... To be honest I think a vehicle like this is perfect for my needs. It will park in a normal parking spot, is self contained and can get me almost anywhere I've been so far in my lx450. It will also setup in a flash. I will also keep all my gear in it so when I am back all i have to do is fillup and go.... I think I would only consider selling if I found another to build that had a diesel.
That crossed my mind when I was completely exhausted and staring at the 4" gap. But Im also the type that won't let things get the best of me and will always finish a project. As I get older though Im becoming less inclined to start new projects, budgets and timelines are always underestimated. Experience counts for something. This is probably the last big one ill undertake until I really have extra time on my hands. I have to work on this while traveling between the East coast so I basically get a 4-5 days every few months. When I finally finish this one I'm going to enjoy it
That being said I am building a second one. on the east coast. This one is a learning process and I obviously already learned from my mistakes.... To be honest I think a vehicle like this is perfect for my needs. It will park in a normal parking spot, is self contained and can get me almost anywhere I've been so far in my lx450. It will also setup in a flash. I will also keep all my gear in it so when I am back all i have to do is fillup and go.... I think I would only consider selling if I found another to build that had a diesel. - Thread starter
- #71
skills
I should mention that something like this may seem daunting but to be honest its fairly straightforward. Looking through some of the builds I've seen on Mud there are things with a lot more complexity and are more time consuming. I learned to weld only recently and basically learned to fiberglass last week. I also work out of a small carport and my tools are crammed into a small storage area. Im sure people with nice workshops and access to a variety of tools could do some amazing work on a similar platform. Ive seen unbelievable expedition builds on the exportal. In any event it does feel good to build things to my own specs. Im very paticular with my stuff and judging by all the OCD i see on Mud Im one of many
For referencee- I have about 11 days into the build.
I should mention that something like this may seem daunting but to be honest its fairly straightforward. Looking through some of the builds I've seen on Mud there are things with a lot more complexity and are more time consuming. I learned to weld only recently and basically learned to fiberglass last week. I also work out of a small carport and my tools are crammed into a small storage area. Im sure people with nice workshops and access to a variety of tools could do some amazing work on a similar platform. Ive seen unbelievable expedition builds on the exportal. In any event it does feel good to build things to my own specs. Im very paticular with my stuff and judging by all the OCD i see on Mud Im one of many
For referencee- I have about 11 days into the build.
- Thread starter
- #73
Gas fill tube diameter
One of the issues with the Chinook at this height is that the filler is to high. I had to bend it slightly down and its still not low enough. I also want to mount the propane tank in the space and it won't fit with the filler there. Can someone take a measurement on the fuel line? Im thinking about using flexible fuel line and running it in front of the tire or above the tank if that can be managed. Im not with the vehicle now so trying to organize the parts before i head back.
thanks
PS are rear lights available for 70's era toyota pickups??
One of the issues with the Chinook at this height is that the filler is to high. I had to bend it slightly down and its still not low enough. I also want to mount the propane tank in the space and it won't fit with the filler there. Can someone take a measurement on the fuel line? Im thinking about using flexible fuel line and running it in front of the tire or above the tank if that can be managed. Im not with the vehicle now so trying to organize the parts before i head back.
thanks
PS are rear lights available for 70's era toyota pickups??
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- #75
Dan......no...... Any recommendations on a similar shape replacement. i should have figured this out before fiberglass and liner.... Mine arent terrible but the gaskets are toast. And i drilled the lens thinking i could buy replacements
If the tail lamps are contemporary to the cab in the first photos (I believe that's what Chuinook used) there is nothing else like them. 1978 was the last year.
Maybe you could fit FJ40 lamps, say 1978 or so? Those are rectangle without a taper.
Maybe you could fit FJ40 lamps, say 1978 or so? Those are rectangle without a taper.
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- #77
FJ40 Tail lights
.. thats what I originally thought they were. I was too overwhelmend and wasn't really paying attention until after completing the fiberglas work. I had the oh sh*& moment when I stood behind wondering how my old 40 lights fit into an irregular shaped hole.
I kind of like the taper but I guess I'll have to see if the body can be cut to fit 40 lights.
Yes, the original incorporated the lights belonging to the chassis. I think this was probably the most straightforward in terms of building these. They were spliced kind of sloppy but Im not sure if that was original.
.. thats what I originally thought they were. I was too overwhelmend and wasn't really paying attention until after completing the fiberglas work. I had the oh sh*& moment when I stood behind wondering how my old 40 lights fit into an irregular shaped hole.I kind of like the taper but I guess I'll have to see if the body can be cut to fit 40 lights.
Yes, the original incorporated the lights belonging to the chassis. I think this was probably the most straightforward in terms of building these. They were spliced kind of sloppy but Im not sure if that was original.
How about trying to source them from salvage?