Build OL'BETSY ZX: 1991 HZJ77

[Rigster]

The next iteration has begun. I was pretty close to pulling the trigger on a poptop for the ol 77. But then... I got quotes from the two suppliers in North America, and with my crappy currency exchange, it just seemed too large an expenditure for what I'd get... And it'd still be small inside...so...now?

I'm in the midst of a new plan. I've just put down a deposit on an off-road trailer which will be built for me in Canada and ready for spring. Sub 1000 lbs, small footprint, rear fold Aussie style. More details to come.

And that of course affects how the rear buildup gets redone. So I have new bits coming and some here already. My rear kitchen is getting an upgrade. As is my modest electrical setup.

Sounds exciting my friend. I can appreciate the weight of such a decision. Agony might be a little strong, but I am sure there was a lot of back and forth, weighing pro's and con's... and eventually deciding what you like to do most, and building something that fits.

Looking forward to seeing this progress!

 

[JDM Journeys]

Sounds exciting my friend. I can appreciate the weight of such a decision. Agony might be a little strong, but I am sure there was a lot of back and forth, weighing pro's and con's... and eventually deciding what you like to do most, and building something that fits.

Looking forward to seeing this progress!

You nailed it brother. Back and forth, disappointment, followed by excitement over new possibilities.

This allows me to preserve the essence of the wonderfully compact 76/77 chassis but still have a more comfortable setup. Towing a compact off-road trailer gives me both.

 

[JDM Journeys]

Finally managed to do some updating on my rear build out. Added a molle door pocket to hold my kitchen utensils...

Also got a chance to bolt down my slide out kitchen and drawer stack. Fridge can now fit lengthwise on top of kitchen.

Fridge can also slide out if needed...

I'll use the drop down table for quick stops or when I need a table but the kitchen will be full on meal prep, complete with kitchen sink.

The drawers on the left are shorter than the kitchen so that I'll have room to put my electrical system behind them.

I've started on this but didn't get far today... My plan is to attach my peripherals to the back plate and then install into the box, followed by the AGM. I also got a Bluetti AC70. That should help with the capacity.

 

[Rigster]

Finally managed to do some updating on my rear build out. Added a molle door pocket to hold my kitchen utensils...
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Also got a chance to bolt down my slide out kitchen and drawer stack. Fridge can now fit lengthwise on top of kitchen.

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Fridge can also slide out if needed...

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I'll use the drop down table for quick stops or when I need a table but the kitchen will be full on meal prep, complete with kitchen sink.

The drawers on the left are shorter than the kitchen so that I'll have room to put my electrical system behind them.

I've started on this but didn't get far today... My plan is to attach my peripherals to the back plate and then install into the box, followed by the AGM. I also got a Bluetti AC70. That should help with the capacity.
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Loving it Phil! I also couldn't help but notice how much snow you guys have already!!

Our local ski hill (SilverStar) has opened already and the boys have been up several times already. One of their friends dislocated his shoulder on one trip, and another friend broke his collar bone. Sheesh!! Thankfully all my boys have first aid training to help while they waited for ski patrol.

Meanwhile back down in the valley the two peas in a pod anxiously awaiting their turn for some sno-fun:

We've had a couple of little dustings, but that is about it!

 

[JDM Journeys]

Loving it Phil! I also couldn't help but notice how much snow you guys have already!!

Our local ski hill (SilverStar) has opened already and the boys have been up several times already. One of their friends dislocated his shoulder on one trip, and another friend broke his collar bone. Sheesh!! Thankfully all my boys have first aid training to help while they waited for ski patrol.

Meanwhile back down in the valley the two peas in a pod anxiously awaiting their turn for some sno-fun:
View attachment 3785026
We've had a couple of little dustings, but that is about it!

Looking great buddy! The plow sits like it's waiting patiently...

We got a pile in November and into the low minus teens. But December is starting with a Chinook. Lol.

My electrical box is kind of a crappy cheapy but I'm starting to assemble the components that will live inside. Looks like the back panel will hold the fuse box, mppt controller (warranteed from Renogy), Victron 24/12 DC>DC charger, and batt circuit breaker. The AGM battery will live in there too...

 

[Musafir]

I think my side exit exhaust is done? Just finished adding another hanger and a 90 degree tip on the end. It feels very firm (given the three rubberized mounting points) and although it is close at certain points, I'm hoping it'll prove rattle free in the long term. One good washboard pounding may have something to say about that, but we'll see.

Here are a few final pics, before I get it out on the road and really put it to the test.

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I angled the camera for maximum exposure but in day to day, walking up to it, the exhaust isn't very notieceable. The cobbled together previous version had a bend after the wheel well (and before it snaked over the frame) that was quite hideous looking, so in my opinion this nice straight run of stainless looks much better.

It's going to be hard to get used to switching my "smoke gauge" to the right hand mirror...

I am sure you already thought about this but its going to be very difficult to add sliders wit that exhaust. If you wanna go back to Moab i think you are going to need them.

 

[Guyute]

Looking great buddy! The plow sits like it's waiting patiently...

We got a pile in November and into the low minus teens. But December is starting with a Chinook. Lol.

My electrical box is kind of a crappy cheapy but I'm starting to assemble the components that will live inside. Looks like the back panel will hold the fuse box, mppt controller (warranteed from Renogy), Victron 24/12 DC>DC charger, and batt circuit breaker. The AGM battery will live in there too...
View attachment 3785428

Good timing. Keep the pics and info rolling. Following along. Just started going through my set-up and rethinking some things too. Bought a Redarc battery equalizer on a black Friday deal. Money pit is deepening.

 

[JDM Journeys]

I am sure you already thought about this but its going to be very difficult to add sliders wit that exhaust. If you wanna go back to Moab i think you are going to need them.

Never say never, but I have no plans for sliders at this point. Moab didn't tickle my rockers last spring, or any of my trips previously. Hmmm... That sounded dirty...?

Although... if I did another side exit on the other side, you could almost argue that I DO have sliders?

 

[JDM Journeys]

So after running it for exactly 2000 kms post turbo with stock fuelling (and it was lean even before turbo) this morning I finally turned up the fuel ¼ turn. First drive hasn't really shown any difference in heat produced ( EGT or water temp) but boost definitely builds faster and there is a little more thrust evident... Not surprising

I'll run it like this for a few more thousand k's now and see how it goes...

EGTs that sit at 500-550°F most of the time is starting to feel pretty normal...

 

[Gun Runner 5]

So after running it for exactly 2000 kms post turbo with stock fuelling (and it was lean even before turbo) this morning I finally turned up the fuel ¼ turn. First drive hasn't really shown any difference in heat produced ( EGT or water temp) but boost definitely builds faster and there is a little more thrust evident... Not surprising

I'll run it like this for a few more thousand k's now and see how it goes...

EGTs that sit at 500-550°F most of the time is starting to feel pretty normal...

Possibly the first time I’ve seen “thrust” used in a 70 Series thread.
I’m also glad to see that you have converted to Fahrenheit.

 

[JDM Journeys]

Today I installed a new cover on my speedo, along with a few bulbs that had burned out inside the cluster.

Brand new part. Still available!

The old "glass" was so opaque it was difficult to see through. (Laid on top for demo).

So nice to still be able to access certain parts.

 

[Blue1]

Bolted the turbo back in.

Made a new (slightly longer) drain line with barbed AN10 fittings. My boost gauge didn't arrive yet but I have all the piping finally figured out for the intake. Using the manifold adapter means that none of the factory 1hdt rubber hoses work so I had to get creative with silicone hoses. But I did use the 1hdt airbox cover with the elbow built in. It's 3 inches instead of the 1hz's 2¾ inch diameter output.

Pics coming...

Did you tap the block for your turbo oil drain or did you put a fitting into the oil pan. I've got everything to install a turbo on the HZJ73 but this is the last detail I need to sort out. Well that and cond connecting rod bearings. Did you inspect yours or replace them before putting the turbo on ?

 

[JDM Journeys]

Oil pan is where I put the drain. I pulled it to weld the bung in and do the big end bearings at the same time. I wouldn't turbo without replacing them and it wasn't that hard to do. Then AN fitting/hose from turbo to pan.

This is all detailed with part numbers a few pages back if you want specifics. Two of my bearings were on their last legs so I'm glad I changed them. 300k kms so it was time to check in any event.

 

[JDM Journeys]

Maintenance today...

Fuel and air filters got changed today, and the new filter was refilled with LiquiMoly Diesel Purge. Then I did glow plugs. It was starting fine, but with a tiny bit of smoke and 10 seconds of rumble when it was cold cold. We can do better. So six brand spanker OEMs got the nod.

Subsequent start was smokeless and rumble free. I'll keep the old ones for spares since they really aren't bad once they're cleaned up.

Also... I ordered a cluster. My speedo has been a little iffy sometimes in the cold and the needle has a wOw in it. The rest of the gauges are faded too and Zubair my parts hero found a cluster that only had 56k kms on it. So I bit the bullet and ordered it...

 

[Blue1]

Oil pan is where I put the drain. I pulled it to weld the bung in and do the big end bearings at the same time. I wouldn't turbo without replacing them and it wasn't that hard to do. Then AN fitting/hose from turbo to pan.

This is all detailed with part numbers a few pages back if you want specifics. Two of my bearings were on their last legs so I'm glad I changed them. 300k kms so it was time to check in any event.

Thank you, and also sorry for asking about something you had already posted. I had read through your whole build a while ago and was doing a quick look again so must have missed it. I'll go back again and read through your turbo install again.

 

[JDM Journeys]

Thank you, and also sorry for asking about something you had already posted. I had read through your whole build a while ago and was doing a quick look again so must have missed it. I'll go back again and read through your turbo install again.

No no no. It's a long convoluted thread LOL so no worries! I was just pointing it out in case you hadn't seen it. No worries!

If you have more questions by all means fire away!

 

[Blue1]

I went back ( far enough this time ) and reread everything. Thank you for the detail. It appears that most people doing BEB's are managing to use standard size bearings. I an effort to get everything together for a turbo install I think I'll risk it and order a set of standard bearings and rod bolts and hope that I am in that same camp. I also have a boost compensator as well to install so your info on the HAC has been helpful too. I need to complete rust repair first then I'll be on to the turbo part of my project. I'm sure I'll have questions then so thank you in advance !

 

[JDM Journeys]

I went back ( far enough this time ) and reread everything. Thank you for the detail. It appears that most people doing BEB's are managing to use standard size bearings. I an effort to get everything together for a turbo install I think I'll risk it and order a set of standard bearings and rod bolts and hope that I am in that same camp. I also have a boost compensator as well to install so your info on the HAC has been helpful too. I need to complete rust repair first then I'll be on to the turbo part of my project. I'm sure I'll have questions then so thank you in advance !

Happy it is of help to someone. My hope was standard bearings would be good but I did measure with plastigage just in case. Turned out to be the right choice, but I was ready in case I needed a different size.

It is definitely peace of mind once they are swapped.

Best of luck!

 

[JDM Journeys]

I went back ( far enough this time ) and reread everything. Thank you for the detail. It appears that most people doing BEB's are managing to use standard size bearings. I an effort to get everything together for a turbo install I think I'll risk it and order a set of standard bearings and rod bolts and hope that I am in that same camp. I also have a boost compensator as well to install so your info on the HAC has been helpful too. I need to complete rust repair first then I'll be on to the turbo part of my project. I'm sure I'll have questions then so thank you in advance !

I'm still amazed at how much I was able to reduce my EGTs after doing the turbo. Where I could previously flirt with 1200F (if I didn't ease up)… now the highest I've gotten (intentionally ascending a hill in 5th, which I don't normally do) is 680F. When I drive it normally I'm usually sitting in the 450-550 fahrenheit range. Way easier to manage here in mountainous terrain than before. 14 psi is my absolute max boost and I added very little fuel (half a turn) and then turned it back a bit.

At one point I actually checked my Auberin EGT gauge to make sure I hadn't inadvertently switched it to Celsius, it was such a dramatic difference.

Even if I add on 150° for being post turbo they are still very reasonable temps.

 

[JDM Journeys]

A few things have arrived for olBetsy. If you've been following along for any length of time you may have caught my mention of having an overland trailer being built. Because of where I'll be taking it, brakes will be a big plus, so I'll be putting this in soon:

It is happy with 24 volts which makes things a lot easier.

I also bought some new comms... I've been wanting a mobile for a long time. Also been wanting APRS. This will be able to do it while using simplex uninterrupted.

No antenna picked out yet but soon...