Builds Our PanAm rig build thread (1 Viewer)

[FlyAddiction]

I Tee'd into the factory fuel line for ease of installation and so far it works flawlessly. Contrary to what is mentioned in a previous post, the barb fitting size for the factory fuel line is not 3/8" but 1/2" and the barb fitting for the Webasto fuel line is not 1/4" but 3//16".

Due to the lack of space beside the heater, I mounted the fuel pump on the fire wall, using existing threaded hole.

The exhaust is fastened via stainless zip tie thru holes in the heat shield and a S.S. bracket on the inside of the fender.

I used the 7 day timer to operate the unit and mounted it under the factory diff locker switch.

 

[FlyAddiction]

Awesome build. Did I miss the shower? I'm planning on putting a tank in my HDJ80 where your gas cans are.

No shower yet...
But I am planing to run one using the Webasto and a heat exchanger when my truck looks more like this;

Tom's Fahrzeugtechnik

Without that ugly box on the roof...

 

[thelal]

so thats a 'heater' unit (and not for shower) when camping standing still and draws from fuel line itself with its own 'burner'?

 

[FlyAddiction]

so thats a 'heater' unit (and not for shower) when camping standing still and draws from fuel line itself with its own 'burner'?

Currently the heater draws fuel from the main line with its own pump and burns it internally. The diesel combustion heats up coolant that is pulled from the engine block and returned to the heater core line via its own coolant pump. In its current configuration it only heats up the engine for cold starts. By adding a series of valves and a "coolant to water" heat exchanger to the hot side would allow me to have hot water on demand. But that is not going to happen in the near future!

 

[TuffMudder]

Last week update:
-ordered and installed new dome and reverse lights from www.superbrightleds.com. Fast shipping and great product.

You wouldn't still happen to have a link or part number you used for the reverse lights? My are completely useless, so want to go with a brighter, preferably led light to see if it helps

 

[IanB]

You wouldn't still happen to have a link or part number you used for the reverse lights? My are completely useless, so want to go with a brighter, preferably led light to see if it helps

Check out PFRAN (vendor) for high powered LED reverse lights.

 

[TuffMudder]

Check out PFRAN (vendor) for high powered LED reverse lights.

Just bought a pair. Thanks @IanB

 

[FlyAddiction]

I havent had much time to update this build thread lately. Lots has changed since pur panamerican trip. We now have 2 year old and a 2 week old baby. I have still.found the time to work on the teuck a bit.
Heres an update;
Last summer we drove from our home in the canadian rockies to the east coast. We took 3 months to complete the round trip. Prior to leaving i changed the water pump, belts, all fluids and timing belt with all OEM parts as always.
I also built a roof top tent fron scratch. Our trip down south for 6 months with a soft shell tent exposed a lot of design flaws common with most if not all tents on the market. I wanted to address looss fabric, floppy door awnings, s***ty to average tent fabrics, door and screen design and height above roof. I also wanted to find an alternative to gas struts.
Photos and details to come.

 

[FlyAddiction]

Our road teip went awesome. We drove above the great lakes all the way around Gaspesie, took a ferry to the north coast of the Saint Laurent river and wet as far east as you can go. The scenery was breathtaking and i would reccomend it to anyone.
When we got back home after our 3 month drive, i ordered and installed a brand new OEM radiator and changed my main batery to a group 31.

The day we left on the trip our first son turned 1!

 

[FlyAddiction]

When I originally built the bumpers, sliders and other accessories, we used chassis saver as a primer and spray paint. It turned out to be a terrible way to save money. 4 yeards later all the parts have significant rust and pitting.

 

[FlyAddiction]

I decided to remove everything attached to the frame, sand blast and paint with endura industrial polyurethane. I also cleaned up all the mild surface rust from the frame and painted it with Endura Metaltech primer and endure ex2c topcoat. The metalteck is similar to chassis saver as it is designed to be a rust encapsulating 1 part paint, but it is a polyurethane designed for harsh industrial environments.

 

[FlyAddiction]

I ended up being a way bigger job than anticipated. In hindsight, i would have taken the frame off completly. It required a lot of bending and twisting under there to get all the grime and rust off and to get paint on everything. The result is great. The finishes i used should be more durable that original.

While i was taking everything off, I changed the wheel bearings all arround, replaced the TRE and drag link ends with 555's, changed a leaky front diff seal and rebuilt the front knuckles. I also got an alignment done.

And then I got this in the mail. !!!

The tuck had a 3" aluminized steel exhaust on it when I bought it. Before we left on our first pan am trip, I had taken it off the truck, wire wheeled the rust off of it and painted it with high heat paint.
Turned out to be the biggest waste of time ever. 3 years later it was swiss cheese.

 

[FlyAddiction]

Local quotes for a local shop to make a ss exhaust fron scratch was north of 2500$ and 1100$ for crushed aluminized steel pipe.
The PPD performance exhaust was 600$ plus an additional 550$ for shipping.
Build quality and fit is great and installation was a breeze. Ill post pictures later

 

[thelal]

The PPD performance exhaust was 600$ plus an additional 550$ for shipping.
Build quality and fit is great and installation was a breeze. Ill post pictures later

Is that from Aussie?
Headers ok? didn't need replacing

Rerusting and painting looks great. Did mine recently but not to that level (hoping to do in a few years)

 

[IanB]

Wow, the frame treatment turned out great, I'm sure that was a pile of work!

The PPD exhaust includes a downpipe, or uses the stock one still?

 

[FlyAddiction]

Is that from Aussie?
Headers ok? didn't need replacing

Rerusting and painting looks great. Did mine recently but not to that level (hoping to do in a few years)

Yes from Australia.

 

[FlyAddiction]

Wow, the frame treatment turned out great, I'm sure that was a pile of work!

The PPD exhaust includes a downpipe, or uses the stock one still?

From turbo all the way back

It sure was a lot of work!

 

[thelal]

bolt up ok? you happy to recommend them (considering the same system but including headers)

 

[FlyAddiction]

Its been a while since I did anything but regular maintenance on the old girl. I finally got the ok from the finance mister to chop the truck and turn it into my dream overland camper.
The tear out has started, my sliders rear bumper and drawer setup are now sold and there is no turning back! It is a bit overwelming as the to do list is extremely long but I am very exited to get going. I need to turn the cruiser into a UTE by the end of this winter and will then take my time to build the camper cell over the next year and a half.
Here are the project main goal:

-Sit and sleeps 2kids and 4 adults
-ability to use the truck as "pickup" first while I build the camper cell
-stay at or under gmvw
-camper must be pass thru.
-The roof and back of the cab will be removable when the camper is on
-no doors on the camper for now, access will be done thru the rear doors
-24" frame extension
-maintain same departure angles

More details will be provided as I execute the various steps.
Here is a few super rough renderings of the project:

 

[FlyAddiction]

Pics of the progress. everything that was behind the rear seats is for sale.