Builds OL'BETSY ZX: 1991 HZJ77 (4 Viewers)

[JDM Journeys]

Back to the BACK!
Pulled everything out of the cargo compartment, and got working on the deck I had put in previously. Started by cutting out a circle for the propane bottle to sit in. Also finally cut an access hatch for the storage bin that’s been covered by base plate since the fall. While there was easy access, I screwed down the battery hold downs too. This will make more sense when it goes back in. (water tank is sitting at the back for reference.)

If you look closely under my switch pod thingy, you can see the finger hole which will allow me to pull the hatch. As you 77 folks know, the under-storage goes all the way across at the back, so it would be a shame to completely seal it up. I’m picturing an air hose in there, or maybe tow straps? We’ll see once everything else is in place.

And here is the hatch pulled - I let the OE carpet go into the cavity so the space will be quieter in case there are rattly bits in there.

Still have finishing bits to do obviously, like carpeting over the wood at the back, painting the edge of the hatch, etc. But getting there!

 

[JDM Journeys]

The next challenge is decking over the space in between the drawers. This is more of a challenge because the drawer tops both slide, and the rollers are a few inches from the top. So I made a bridge at the back out of angle, which will serve as the hinge point for the wood panel on top. At the front there are support pieces under the edge of my pod, and I'll put a pocket on top to level up the panel. Here's a mockup. Still need to put carpet on it as well...

 

[Jordan345]

Cold weather brings out the crazies, doesn't it?

If you've been following this thread (and really, why would you? ) then you might remember a few weeks back I was driving her home from work, and appeared to experience a freeze-up. My theory was that the early Oct fuel I was still running was likely summer diesel, and temps had dropped, so I was getting gelling at the filter.

Fast forward to yesterday (after I got fuel AND added some diesel 911) I decided to swap the (pretty new) filter, just to ensure I wasn't going to have more issues. Meanwhile, our temps have plunged into the -30 degree celsius and below mark, and although I put the heat on in my garage, I only managed to get it to 10C, near the heater.

Anyways, finished the filter change. Started it up. Ran like crap. Pumped the primer, took it for a drive, white smoke, still ran like crap. Came home, pumped the primer some more, and lo and behold: MOHR LEAKAGE. But not just at the filter to housing o-ring. Nope, at the bottom sensor seal too. GREAT.

Today I removed, reinstalled and tightened everything. Pumped it back up. Seemed to be leak free? Whew. Started it up. So far so good. Went to go for a drive, got halfway around my loop and it started losing power again almost like it was freezing up. See a pattern here? Limped it home where it barely idled in the garage, with lots of white smoke. Pumped the primer which seemed to bring the idle up, and watched for leaks as I did so.


Wait a minute. Bubbbles? At the edge of fuel heater element housing.
View attachment 2875526

CURSES! I just found my air/fuel leak. Arggg. Looked at new orings for the heating element, but it seems like it might even be leaking where the plastic meets the metal housing?
View attachment 2875528
As much as I'd like to retain the heater, I'd prefer to keep fuel PRESSURE, and the heater housing is NOLA, so I ordered the one without the heater (23301-17050) as well as a new o-ring for the water drain (23344-54010) and a new fuel filter to IP fuel hose (95332-10040) just in case.


Cold weather quickly points out the weak points of your fuel system, even as it frustrates you to the point of madness.

View attachment 2875527

View attachment 2875529

Great thread. Been following and reading. I ironically just had this happen to my hzj77 this week in the cold here at home in kamloops. The parts to replace the preheat /filter housing will be tough to source, let me know how you come out there. My solution was to simply replace all 4 o rings from an o ring kit from napa. I have both the sae and the metric, thinking the metric would work. The metric was actually to thick even at 2.5 secrion diameter but the sae worked well if you stretched a smaller one on than the diameter would suggest. The originals get flattened out over time and with the cold it just allows air in stalling the engine. I had my wife and two kids in the cruiser driving home from town in - 30 and it stalled 9 times over 20 km. Each time priming the hell out of it, beating the starter into submission and getting a couple km out of it. Frustrating to say the least. Been about a week now and no issues. Would have sucked if this happened ice fishing a couple weeks ago in the back country. Eish a long drive of priming and starter strain.

 

[Jordan345]

Back to the BACK!
Pulled everything out of the cargo compartment, and got working on the deck I had put in previously. Started by cutting out a circle for the propane bottle to sit in. Also finally cut an access hatch for the storage bin that’s been covered by base plate since the fall. While there was easy access, I screwed down the battery hold downs too. This will make more sense when it goes back in. (water tank is sitting at the back for reference.)
View attachment 2880491
View attachment 2880492

If you look closely under my switch pod thingy, you can see the finger hole which will allow me to pull the hatch. As you 77 folks know, the under-storage goes all the way across at the back, so it would be a shame to completely seal it up. I’m picturing an air hose in there, or maybe tow straps? We’ll see once everything else is in place.

View attachment 2880498
And here is the hatch pulled - I let the OE carpet go into the cavity so the space will be quieter in case there are rattly bits in there.
View attachment 2880510

Still have finishing bits to do obviously, like carpeting over the wood at the back, painting the edge of the hatch, etc. But getting there!

Looks great. Agree on wasted space. I used mine for water pump and plumbing for hot water shower system, with intake ports coming out of bumper (intake and outtake). My air compressor is mounted to the side of my drawers on driver side wheel well.

 

[JDM Journeys]

Quite a bit warmer today, owing to the Chinook. So I had to take advantage.

Made some progress with the rear drawer deck. I had some 8020 extrusion laying around, and decided to try to use it for the rear compartments. Started off with a frame…

The idea on this side is to make easy access to front and top, to allow for using the propane hose, and also to be able to lift the tank out for filling. And of course its not a simple matter of attaching the top deck to the tops of the drawers, since as I mentioned, they slide. So the deck needed to be completely independent of the drawer.

Okay, propane tank fits in! So far so good.

Cut/bent a piece of metal and used my fancy edge tool up and down each side to give it a little more rigidity, although 18 ga sheet is pretty solid as it is, for this application. Then filed and massaged until it would slide into the grooves, with a little tension to reduce rattles.

Obviously still needs finishing, i.e. carpet, paint, etc. But lets get the structure done first.

Okay, on to the top. 3/4" plywood gets the call.

Thought I’d start the other side, and after a much quicker mess about with 8020, the framework was done. My jigsaw crapped out (20 years old) so I figured I’d simply flip the right side wood over, and try it, along with my already bent metal. LOL. It fit EXACTLY on the left side too! Hehehe. Not planned, but I guess that’s a good thing in case I have it all apart and put them back wrong?

That’ll do it for today. Can’t wait to put the carpet on top and make it look a little more polished, but not there yet…

 

[JDM Journeys]

Great thread. Been following and reading. I ironically just had this happen to my hzj77 this week in the cold here at home in kamloops. The parts to replace the preheat /filter housing will be tough to source, let me know how you come out there. My solution was to simply replace all 4 o rings from an o ring kit from napa. I have both the sae and the metric, thinking the metric would work. The metric was actually to thick even at 2.5 secrion diameter but the sae worked well if you stretched a smaller one on than the diameter would suggest.

Thanks! I decided to simplify and order the housing that doesn't have the heater in it. Also... The heated housing is NOLA but the standard one is, OEM from all the major suppliers. I'm hoping to see it late this week or early next, as soon as they get back from their new years parties in the UAE.

I looked at the o-rings but figured the primer pump itself is probably reaching the end of its life too so why not kill two birds with one stone?

I've been fighting white smoke on and off since the summer, so I'm hoping this is the last price of the puzzle? Also have filter to IP hose coming too, just to be thorough...

 

[Rigster]

Thanks! I decided to simplify and order the housing that doesn't have the heater in it. Also... The heated housing is NOLA but the standard one is, OEM from all the major suppliers. I'm hoping to see it late this week or early next, as soon as they get back from their new years parties in the UAE.

I looked at the o-rings but figured the primer pump itself is probably reaching the end of its life too so why not kill two birds with one stone?

I've been fighting white smoke on and off since the summer, so I'm hoping this is the last price of the puzzle? Also have filter to IP hose coming too, just to be thorough...

I have made a mental note of this Phil, as I was always confused with you having all the issues with air in the fuel system. I assumed there would be pressure/leaks. But before the pump, it makes sense there would be suction/air induction, thus giving you the nightmarish inconsistencies!

I feel like this should resolve that part of the puzzle for you indeed. Liking the innovations in your build buddy! I am waiting for it to warm up a bit to continue the trailer build... but I just sold my house and so far have nowhere to move to so that is going to take up my time for a while, especially if I end up buying another reno project!

 

[coldtaco]

Thanks! I decided to simplify and order the housing that doesn't have the heater in it. Also... The heated housing is NOLA but the standard one is, OEM from all the major suppliers. I'm hoping to see it late this week or early next, as soon as they get back from their new years parties in the UAE.

I looked at the o-rings but figured the primer pump itself is probably reaching the end of its life too so why not kill two birds with one stone?

I've been fighting white smoke on and off since the summer, so I'm hoping this is the last price of the puzzle? Also have filter to IP hose coming too, just to be thorough...

I have a new one of these if you are interested in it. I bought it for a project that never got done. It’s the heated kind but new so maybe you can get a few good years of service out of the seals.

 

[JDM Journeys]

I have a new one of these if you are interested in it. I bought it for a project that never got done. It’s the heated kind but new so maybe you can get a few good years of service out of the seals.

View attachment 2885179

View attachment 2885180

Well darn it - mine's already ordered and paid for. Thanks for the offer though. I hope to see it pretty soon. Although with the way the temps have been the last three weeks, I'm probably not going to put it in quite yet.

 

[JDM Journeys]

Things are beginning to take shape.

I've been looking for years for suitable replacements for my action packers. They work, they're cheap, and they're light, but they're also tapered at the bottom, and don't stack or nest side by side, or top to bottom. I'd planned to eventually get FR wolf packs, but have put it off because of the cost (in Canada, the shipping and exchange puts a wolf pack at a decent chunk of change). I also thought that there could be a way to avoid the constant strapping, tying down and general pain in the ass-ery that comes with most bins.

But let me back up at little. So my base at the back is two OVS drawers. One holds my pots, pans, stove, dishes, cutlery. The other is destined for tools, and heavier stuff. Each drawer top has a slider, and built in cutting board/tray thingy. On one sliding top my fridge is tied down. On the other slide I pictured storage for food. But I wanted it to be easy to remove to go into the house, the grocery store, or even the picnic table, depending on the setup. Action packers have done the job, but not great.

And if we are going to spend on wolf packs, let's see what else is available locally first? And then... I saw RED.

More specifically, Milwaukee RED.

PACKOUTS!

Totally modular, avail in half and full size, and almost the perfect dimensions for the top of my drawer. And even better, you can get a bolt on base which all the other boxes click into. NO STRAPS required! I measured the height I wanted (still want a thin view out the back window), put together about 50 different combinations, and wound up with this setup:

Its the mounting plate, with 22" toolbox, and two 10" half width ammo style boxes, each with bail handles. All can be opened in situ (even the bottom one) or slid out for even greater access. One thumb pull on the mechanism allows you to slide the box forward and off the stack, with no messing about with straps.

Even though the footprint on these is a little smaller than my trusty double action packers, my usable storage volume has increased. And the handle on top just begs to be carted around the grocery store, gathering sustenance for the next adventure.

I'm so excited about this (not very well kept) "secret" solution that I might actually write it into a story - its been a while...

 

[AirheadNut]

That’s a fantastic solution! Way to think outside (maybe inside? ) the box.

 

[Jordan345]

Thanks! I decided to simplify and order the housing that doesn't have the heater in it. Also... The heated housing is NOLA but the standard one is, OEM from all the major suppliers. I'm hoping to see it late this week or early next, as soon as they get back from their new years parties in the UAE.

I looked at the o-rings but figured the primer pump itself is probably reaching the end of its life too so why not kill two birds with one stone?

I've been fighting white smoke on and off since the summer, so I'm hoping this is the last price of the puzzle? Also have filter to IP hose coming too, just to be thorough...

If the grey smoke is occuring during cold mornings and has stumbling and rough initial idle than i would inspect your glow system. I also struggled w not smoking out the nieghborhood, needing to depress throttle or idle up on the manual screw a bit to keep it running. My glow plugs were fine and primary glow workjng but secondary glow was not operating. The secondary system resister was shot and it is no longer made. However, a 2h has a compatible resistor and i was able to swap it in and voila. Cold start and grey smoke no longer a problem. I was plagued with that for two years of canadian winters. Radd cruisers here in kamloops helped me with that and as always been able to provide parts very quickly and at a very good cost. Chances are many common items may already be present and available. There is a well set up webstore to browse.

 

[Jordan345]

Things are beginning to take shape.

I've been looking for years for suitable replacements for my action packers. They work, they're cheap, and they're light, but they're also tapered at the bottom, and don't stack or nest side by side, or top to bottom. I'd planned to eventually get FR wolf packs, but have put it off because of the cost (in Canada, the shipping and exchange puts a wolf pack at a decent chunk of change). I also thought that there could be a way to avoid the constant strapping, tying down and general pain in the ass-ery that comes with most bins.

But let me back up at little. So my base at the back is two OVS drawers. One holds my pots, pans, stove, dishes, cutlery. The other is destined for tools, and heavier stuff. Each drawer top has a slider, and built in cutting board/tray thingy. On one sliding top my fridge is tied down. On the other slide I pictured storage for food. But I wanted it to be easy to remove to go into the house, the grocery store, or even the picnic table, depending on the setup. Action packers have done the job, but not great.

And if we are going to spend on wolf packs, let's see what else is available locally first? And then... I saw RED.

More specifically, Milwaukee RED.

PACKOUTS!

Totally modular, avail in half and full size, and almost the perfect dimensions for the top of my drawer. And even better, you can get a bolt on base which all the other boxes click into. NO STRAPS required! I measured the height I wanted (still want a thin view out the back window), put together about 50 different combinations, and wound up with this setup:
View attachment 2887052

Its the mounting plate, with 22" toolbox, and two 10" half width ammo style boxes, each with bail handles. All can be opened in situ (even the bottom one) or slid out for even greater access. One thumb pull on the mechanism allows you to slide the box forward and off the stack, with no messing about with straps.
View attachment 2887069


Even though the footprint on these is a little smaller than my trusty double action packers, my usable storage volume has increased. And the handle on top just begs to be carted around the grocery store, gathering sustenance for the next adventure.

I'm so excited about this (not very well kept) "secret" solution that I might actually write it into a story - its been a while...

I like those Milwaukee bins alot. I had built a half dozen versions of drawers on my various cruisers and ended up installing the Front Runner drawers w wolf packs and sliding top while we were living in Botswana. I have to say they are convenient and well suited to keeping kit separated and tidy. We use them often here as well as they all have their purpose. Kitchen gear, recovery gear, food gear, cooking gear, straps and such and then an empty for misc gear. 6 in total. If i were to do it again i would only do one side and have my national luna on the floor as its so damn bulky at 82 liters or whatever it is. I have used the action packers as well and love them but really dont need to used them much when everything is all tucked away. The other odd storage helper is the mesh roof loft. All the kids clothes and pillows get thrown up there for easy access.

 

[JDM Journeys]

If the grey smoke is occuring during cold mornings and has stumbling and rough initial idle than i would inspect your glow system. I also struggled w not smoking out the nieghborhood, needing to depress throttle or idle up on the manual screw a bit to keep it running. My glow plugs were fine and primary glow workjng but secondary glow was not operating. The secondary system resister was shot and it is no longer made. However, a 2h has a compatible resistor and i was able to swap it in and voila. Cold start and grey smoke no longer a problem. I was plagued with that for two years of canadian winters. Radd cruisers here in kamloops helped me with that and as always been able to provide parts very quickly and at a very good cost. Chances are many common items may already be present and available. There is a well set up webstore to browse.

If you wade back a page or two in my ramblings (you probably don't want to do that ) you'll see that I had the same issue. I also found the 2h resistor but it wasn't a close enough match for my liking (on paper) but I managed to find the OEM one (an NOS unit on eBay) still in the box.

That cured my secondary glow perfectly. Glow system is fully tested and functional, incl new OEM glowplugs too. But you're right. When that resistor goes, it causes havoc. Good to know the 2h unit is a good option if i ever need another.

No, my smoke was white and def air/fuel related. It was happening after warm up, and was accompanied by some fun stalling as well. Lol. Canada Post just received my package today in Calgary, so I should have my new filter head by... End of the month?

 

[JDM Journeys]

I like those Milwaukee bins alot. I had built a half dozen versions of drawers on my various cruisers and ended up installing the Front Runner drawers w wolf packs and sliding top while we were living in Botswana. I have to say they are convenient and well suited to keeping kit separated and tidy. We use them often here as well as they all have their purpose. Kitchen gear, recovery gear, food gear, cooking gear, straps and such and then an empty for misc gear. 6 in total. If i were to do it again i would only do one side and have my national luna on the floor as its so damn bulky at 82 liters or whatever it is. I have used the action packers as well and love them but really dont need to used them much when everything is all tucked away. The other odd storage helper is the mesh roof loft. All the kids clothes and pillows get thrown up there for easy access.

Thanks! I think they are going to do the job nicely.

I've been putzing around with drawers for over a decade myself, from ones I made myself, to adapted office units etc. Lol. These are my first "proper" ones, even if the "budget" variety.

Yeah it's nice to have the fridge a bit lower if possible. Mine is tiny in comparison at 40L, so easier to put on top.

I have a net up at the headliner as well. Great use of space. Mines an Amazon special. I'd love to see yours for comparison!

 

[Jordan345]

If you wade back a page or two in my ramblings (you probably don't want to do that ) you'll see that I had the same issue. I also found the 2h resistor but it wasn't a close enough match for my liking (on paper) but I managed to find the OEM one (an NOS unit on eBay) still in the box.

That cured my secondary glow perfectly. Glow system is fully tested and functional, incl new OEM glowplugs too. But you're right. When that resistor goes, it causes havoc. Good to know the 2h unit is a good option if i ever need another.

No, my smoke was white and def air/fuel related. It was happening after warm up, and was accompanied by some fun stalling as well. Lol. Canada Post just received my package today in Calgary, so I should have my new filter head by... End of the month?

I must have missed that as i did read from start to finish. Thats good to know you found some on ebay - i was sourcing from retailers vs. The world. Seemingly somebody always has parts somewhere. What would we do without the interweb!

 

[Jordan345]

Thanks! I think they are going to do the job nicely.

I've been putzing around with drawers for over a decade myself, from ones I made myself, to adapted office units etc. Lol. These are my first "proper" ones, even if the "budget" variety.

Yeah it's nice to have the fridge a bit lower if possible. Mine is tiny in comparison at 40L, so easier to put on top.

I have a net up at the headliner as well. Great use of space. Mines an Amazon special. I'd love to see yours for comparison!

I had the an arb 50 (not sure of exact size) and it was a good fit but top didnt open all the way being so high and on top of a slider. The NL one takes up so much more space but it still gets trapped by the roof unless i slide the whole slide deck out. I still have to climb up on the bumper to see and access. Anyways, the net is custom from a gear sewing shop when we lived in toronto last year. Nothing really
special but can post when i snap a photo today. I sure like the Milwaukee boxes. Where are they sourced,? Order or local like home depot,?

 

[JDM Journeys]

That'd be great. I'd also love to see how you attached the net. That was the trickiest part for me.

Milwaukee packout is available at Home Depot - you got it. Specific configurations will possibly need to be ordered but plenty of sizes are available. They are quite pricey, but having them in hand, I think they're worth it? That's subjective I guess?

 

[Guyute]

That'd be great. I'd also love to see how you attached the net. That was the trickiest part for me.

Milwaukee packout is available at Home Depot - you got it. Specific configurations will possibly need to be ordered but plenty of sizes are available. They are quite pricey, but having them in hand, I think they're worth it? That's subjective I guess?

Run a loft net and strap style fishing rod holder as well. Found that rock climbing bolt hangers worked well to secure it all. Have four up there now I think. Two in the far back above the gull wings (captive nuts under liner), then two behind the grab handle using the same bolts. Works a champ. Couldn't find a picture... but here are the bolt hangers I used >>

Metolius - Spring Force Bolt Hanger

-B

 

[JDM Journeys]

Oooh I wondered if there were captive nuts back there somewhere! I'll have to do some investigating! Excellent info! Thanks! Ill check out those hangers too...