Builds My 1981 HJ45 Troopy build

[Chamba]

I'm not sure if I missed it, but why did you cut the front seat mount off?

That thing is really coming together. I'm happy to see that your garage looks just like mine

Josh

 

[RufusTheDufus]

I cut the seat mounts off because I'm going with heated buckets from a Cadillac STS.

 

[RufusTheDufus]

A little more progress (finally)

A consulting job has kept me away from the Troopy for far too long. I've finished a bunch of little things. Today's accomplishment was a set of gusseted mounting points for the IPOR skid plate. This is my solution for the removed torque tube. It's essentially a 1/4" thick cross member that should be stronger than the stock torque tube and protect the H55/Toybox/splitcase setup. Now that this is done I can get some Rust Bullet on the frame.

 

[RufusTheDufus]

Rear locker

I've never setup a differential so I was a little apprehensive tackling installing an ARB air locker. It really wasn't that bad. The front end is getting one too.

Here's a couple photos of me testing it to be sure it works properly.

 

[RufusTheDufus]

And here's how I used the IPOR 40 series skid plate as a cross member to support the Toybox:

 

[2fpower]

They should have that picture in the dictionary under "bullet-proof"

WOW. Nice work studly!

 

[RufusTheDufus]

Finally got the rear axle finished and back under the Troopy this weekend. Disc brakes are installed too.

I took measurements for new drive shafts today. I was a bit surprised that the front and the back should both be the same length, 38.25 inches measured from the differential flange to the tcase. Time to make use of my Tom Wood's coupon from the Yankee Toys Fall Gathering.

 

[Chamba]

Finally got the rear axle finished and back under the Troopy this weekend. Disc brakes are installed too.

I took measurements for new drive shafts today. I was a bit surprised that the front and the back should both be the same length, 38.25 inches measured from the differential flange to the tcase. Time to make use of my Tom Wood's coupon from the Yankee Toys Fall Gathering.

Wow, that's great - interchangable drive shafts! That's a great length too.

I love the way your rig is coming together.

Josh

 

[RufusTheDufus]

Alternating

I'm getting anxious to hear the engine run since installing the rebuilt injection pump.

I spent some time fabricating a bracket for the Isuzu NPR/GMC style diesel alternator. (Unfortunately I neglected to snap a photo of it.) I've got the vacuum pump hooked up and will tackle the wiring tomorrow. I'll also need to come up with a top bracket to keep tension on the v-belt.

The alternator is an 80 amp internally regulated type so I'll need to do a little wiring work. The 45 is currently setup for an externally regulated alternator. There are a few threads here on Mud that deal with Isuzu diesel swaps that have the info on wiring one of these up properly.

I'm switching to this type of alternator because they are easy to find just about anywhere in North America and are about 25% of the price of the stock Toyota diesel alternator (if you can find one).

 

[DanS HJ-45]

Seriously?

An HJ-45, with a turbo, and a toybox, and ARBs?

Too sexy! Too sexy!

I like the alternator, a lot. I wonder if I could fit one to the faux-lux? 80 Amps would make me feel a lot more comfortable if I ever add a winch or bigger lights.

Dan

 

[RufusTheDufus]

The goal with this truck is to have a go-anywhere camping vehicle. (I bolted the 8274 winch in place yesterday.) I will be building a receiver type hitch soon to tug the CDN M101 trailer with us too.

 

[Combat Chuck]

Seriously?

An HJ-45, with a turbo, and a toybox, and ARBs?

Too sexy! Too sexy!

I like the alternator, a lot. I wonder if I could fit one to the faux-lux? 80 Amps would make me feel a lot more comfortable if I ever add a winch or bigger lights.

Dan

X2!

 

[Henry James the 47th]

Interesting build Rufus!

Couple of questions:

Where'd you source the 40 series H55? From Oz?

Do you have a model number or application for that Isuzu alternator or a link to a store which sells it?

 

[RufusTheDufus]

Got the H55 from SOR.

Here's a link to some of the Hitachi alternators that cross to the Hino/Izusu NPR. You can find them rebuilt at NAPA and other parts sources cheaper than the new ones on that site. The alternatorparts.com site also has the adapter plugs needed to wire the alternator into your truck. I had to swap the pulley on mine too.

This thread shows the vacuum pump and ports compared to the stock HJ45 alternator.

 

[Henry James the 47th]

Thanks for the links.

Now I have a couple more questions:

Did the 40 series H55 you obtain come out of a BJ42 and did you need to swap out the input shaft, or did you do swap the top loader plate over onto an H/F-engine compatible H55?

Also, with the alternator, what's the main difference in the mounting - are the 'ears' on the alternator wider apart or narrower? Or is the mounting bolt a different size or??

sorry for all the questions - and thanks for taking the time to answer!

 

[RufusTheDufus]

I'll snap a few photos later today. That will make it all clearer than I can explain it.

 

[RufusTheDufus]

NPR alternator conversion bracket and photos

Here's the photos as promised. After snapping these pictures I realize that I need to add a couple gussets to the new bracket to mimic the stock cast iron part a little better.

Edited to add photos of the bracket with gussets. Not pretty but hopefully functional.

 

[Henry James the 47th]

That's great - explains it perfectly!

 

[RufusTheDufus]

Did the 40 series H55 you obtain come out of a BJ42 and did you need to swap out the input shaft, or did you do swap the top loader plate over onto an H/F-engine compatible H55?

Sorry, I missed this one.

The H55 arrived from SOR setup for the H/F. I believe it was originally behind an F in an Aussie HJ47. It's been completely rebuilt along with the tcase. I added a drum brake to the tcase.

 

[Henry James the 47th]

Ah. Interesting. So, it was an HJ47 which had been re-fitted with a 2F and H55?

I tend to associate the 5-speed mostly with BJ-42's though I guess there must have been a certain number with 2F installations, in 1983~4. Does that sound about right?