Builds Oman -> SoCal 1995 FZJ75 Troopy (3 Viewers)

[prwillard2]

Started trying to install my Kaymar rear. It would seem one of two things is happening:

1. My frame is not square
2. My Kaymar isn't "bent" enough to fit the OEM holes it says to use (that I enlarged per instructions).

Unsure if I should just drill slightly larger holes to allow some play in the mounting of the bar, or if I should find some way to put pressure on the bar to bend it into the correct position.

Thoughts?

 

[janyyc]

Just to rewind to your rear barn door, obviously those rivets are not OEM either and it looks like there was some haphazard Omani repair to that door… I would definitely inspect that closely and perhaps replace the door.

 

[prwillard2]

Just to rewind to your rear barn door, obviously those rivets are not OEM either and it looks like there was some haphazard Omani repair to that door… I would definitely inspect that closely and perhaps replace the door.

This was a police vehicle/ambulance before in Oman. Believe they had riveted checker plate to the back doors.

 

[Owyhee Jackass]

Have you tried putting a heavy duty tapered punch in one of those three bumper holes and forcing it to align enough to get bolts started in the other two? That trick usually works for me with items like bumpers and hitches etc.

 

[prwillard2]

Have you tried putting a heavy duty tapered punch in one of those three bumper holes and forcing it to align enough to get bolts started in the other two? That trick usually works for me with items like bumpers and hitches etc.

Have not. Don't think I'll be able to get enough force that way. Going to try and make the wholes a tiny bit later to give me some wiggle room.

 

[prwillard2]

Was able to get the bar on by expanding the holes I drilled in the OEM bumper holder bar. Then using some man to press as hard as I could while trying to hammer in the bolts with my other hand.

Eventually got it on, but disappointed in the lack of instructions with the bar, the overall fit, and the powder coat which is already flaking off in places.

Additionally the wings do not go up very far, I figured they would go up farther.

Now to figure out who to install the swing outs, zero instructions provided or online from what I've found.

I'll also need to figure out where to tap into for the brake/blinker lights on the bar. My 1995 didn't have any lights on the OEM bumper.

 

[RHINO]

for the swingouts all you do is drop them on the spindles, tighten the nut and fasten the sta-clamps to the predrilled holes.

 

[prwillard2]

Additionally, you're supposed to drill another hole in the frame and put a bolt through the square opening in the frame to attach to the underside mount of the bumper.

My truck has some sort of metal piece inside the frame that prevents me from putting a bolt through the square and into the hole I drilled.

 

[RHINO]

well that looks like a right PITA,,, however there are captive nuts and blind nuts that could be used,,, maybe even drill and tap a piece of flat stock to drop in there and then fiddle it around with a piece wire till you can thread a bolt in? i been down that road many a time.

 

[prwillard2]

Got the swingouts on. Was only able to wire up one of the bumper lights so far.

Anyone with a Kaymar care to clue me I on where you tapped everything? And also where you tapped into the license plate light?

You also have to gently massage the exhaust with a deadblow hammer to bend it out of the way to have the Kaymar fit.

 

[svsisu]

I haven't looked at this thread in a long time, but I know there was a lot of detail in it. Installation is for a 77 series, but should be close enough to answer some of your questions.

Kaymar 76 Series Workmate fitment for 77 Series

Since my initial purchase of the truck, I knew I would need a bumper for the truck. The truck had the factory bumper and trim panels removed. My original goal was to replace the missing components. After sourcing all the needed parts from a LJ78, I did just that, and was very happy with fit and...

forum.ih8mud.com

 

[troopyoverlander]

The rear bar looks great! Quick question-Did you put any diff breather extenders?

I was looking at buying this one, but it doesn't look like they ship to the US: PDP Diff Breather Kit | 70 Series - https://perthdiesel.store/products/diff-breather?variant=30829017932

 

[prwillard2]

The rear bar looks great! Quick question-Did you put any diff breather extenders?

I was looking at buying this one, but it doesn't look like they ship to the US: PDP Diff Breather Kit | 70 Series - https://perthdiesel.store/products/diff-breather?variant=30829017932

Not yet, on the list of things to do. Replaced my front breather already with an OEM one as my original was covered in oil/dirt.

 

[RHINO]

Radiator ordered through PWR is super nice! Sides of the radiator are reused from the OEM radiator. Luckily mine are in decent enough shape that they will work.

i dont see Land Cruiser listed on the website,,, did you have to call them?

 

[prwillard2]

i dont see Land Cruiser listed on the website,,, did you have to call them?

Yes, I had to get them to special order me one. The schematic they have even said diesel on it, but obviouly I am not running a diesel. Let me dig through my emails and I'll try and find one.

You will need the steel sides of your OEM radiator.

 

[prwillard2]

@RHINO you will need to contact Jason Smith at PWR North America. Jason.Smith@pwrna.com

This is the radiator they built. Will need your OEM sides of your radiator.

 

[RHINO]

thank you !!! great info for all of us

 

[AirheadNut]

Let there be washed windshields! Second picture is before, third is after.

View attachment 3413961

View attachment 3413962

View attachment 3413963

Did the Honda windshield sprayer nozzles require modification of the holes in the hood?

 

[prwillard2]

Did the Honda windshield sprayer nozzles require modification of the holes in the hood?

Nope! Fit perfectly in the current opening

 

[prwillard2]

Flooring finally going back in the troopy!

Spectrum Second Skin jute heat insulator added where old OEM jute used to be.

The double sided foil of the jute is a big hindrance honestly. I've had to score the underside numerous times to get the vinyl to bend correctly. Then use a dead blow mallett to attempt to get into the right place.

I need a carpet stretcher or something of the like. Hoping over time the ripples flatten out.