Build Prado on a diet, bob / double cab

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I run two winches..
The mid mount PTO is for forward winching only...
The rear electric is mainly for forward winching but I have set it up to allow a loop to be pulled off the drum and take it out the rear... And run it thru a snatch block..Really for a last resort self recovery...
As for issues with rope hanging underneath... When stowed i put it under a slight tension.... The hook is clipped into a loop on the front bar and the winch is wound in...
So the rope is taught in its pulley run.

When winching it may sag a bit from time to time but I have never had it snag on anything...
My mate has what is called a "winch challenge" style truck and we do competitions with a similar setup and again it has never caused any issues.
The only thing I have done is when it does droop it doesn't fall onto anything hot like the exhaust and melt the rope and its away from drive shafts etc etc
 
Door jambs, roof, A pillars and front fire wall / cowling painted... Doors, bonnet and front clip next week.
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Merry Christmas everyone. Bit more completed and my build. So close to being finished....
Here are some of the latest photo's. Some things done a little differently. Snorkel is now inside the L/H guard and exits out the top to follow the A pillar. Allowed for better guard protector bar design. Just have the front bar to finish off, bit of grinding, mount recovery hooks and paint.
Any questions on how I did what just ask away, have heaps of photos, too many to flood the server with in one hit.
Enjoy.
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Probably my last update before I get her dirty.
Well it went thru our Cert process here in NZ. And passed after a few tweaks to some little things.
And now is fully legal to operate on NZ roads.
One of the tests is a Brake test, having to stop 3 times from 100kph to 0 in 2 mins with min deceleration pulling 0.65g's. Try doing this on factory pads and 35 inch tyres !. But she passed with room to spare hahahah.
One mod which I particularly like is grafting in a tiptronic shifter from a Subaru, which works in turn with a replacement trans ECU.
It allows me to take full control of the auto and also either set auto trigger points for the Torque converter to lock and unlock or manually control when it locks.
So she is basically completed. just in the process of fine tuning the rear radiator fan trigger points, have purchased an Auberins PID controller with the plan of having it trigger a low speed fan and then a high speed fan at the desired temp trigger points.
Also have scored some LED lights off Ebay to replace the the sealed beams. With Toyota's negatively triggered headlight system I am having to add some relays to make it all work, but others have been there and done that before.
Onto some pics.
The photo of the shifter has scince been modified to have the original T bar top for the push button.
I will throw up some more pics later when I have them downloaded into one place.
For those interested here is my Facebook folder with most if not all of my build photos. Note you dont need facebook to see them.

Prado Bum cut | Facebook

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Excellent work! Nice to see the project to completion. Congratulations. Show us pictures of it getting dirty too!! :steer:
 
kbushnz said:
The Bob is on hold while I save up for bar work....
So started playing with the rear brakes.
Totally sick of the drums filling up and losing the handbrake....
So I am retro fitting some Subaru Leone calipers which have the integral hand brake mechanism.
Matched with Nissan GU rear disc's to get the most pad contact and also fit inside 15 inch rims.
Have cut off the old backing plates and caliper mount.
Made a up a new plate using Solidworks and cut a prototype. Need a bit of adjustment here and there but its looking good.
The Subaru pad comes past the disc a few mm but this will be trimmed off to pass our local cert rules (we are allowed to trim the pad)
The trimmed pad will still have a larger surface area on the disc than the original factory pad...
Note: Photo's are of my first cut at the mount plate.. New one to be made to get the caliper in closer and also rotate it down a bit so the original handbrake cables are inline....
So all good.
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Hi Calvin,
Good to see your truck is all sorted!! Well done ! I’ve been in contact with you regarding brackets for the Leone setup a couple of years ago. How did they fair with cert and did you grind out any of the leone bracket?? I’m sitting with the same issue and would be keen to go down this path..... are you making or selling these? Hope to hear more from you regarding this thanks.
 
bravo31 said:
Hi Calvin,
Good to see your truck is all sorted!! Well done ! I’ve been in contact with you regarding brackets for the Leone setup a couple of years ago. How did they fair with cert and did you grind out any of the leone bracket?? I’m sitting with the same issue and would be keen to go down this path..... are you making or selling these? Hope to hear more from you regarding this thanks.
Click to expand...

Sorry for the late reply, been away down South Island. I had to grind a wee bit out of the new brackets. And a bit out of the throat of the caliper for it to fit. Naturally didn't let on to the cert man.... I have a extra set of brackets which I will sell off soon.... As they are no good to me.
 
kbushnz said:
Sorry for the late reply, been away down South Island. I had to grind a wee bit out of the new brackets. And a bit out of the throat of the caliper for it to fit. Naturally didn't let on to the cert man.... I have a extra set of brackets which I will sell off soon.... As they are no good to me.
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I have acces to a plasma cutter so either if you want you can sell the brackets if they are the made to suit ones or send the file and I’ll get it cut locally. What ya thinking in $...? Cheers
 
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