Princess Rig: Diesel Manual Troopy-Style Pop-top Conversion and Off to Adventure (1 Viewer)

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I ended up here after following along the 'Clunk..' thread, and promptly killed a couple hours at work (there aren't any benefits to working in a cubicle, but I'll take what I can get...) reading through this entire thread.

Incredible build, and I thoroughly enjoy the writing. All inspirational.

Good luck on the odd noise (sorry I cannot offer advice there), and I'll be watching for the continuation of the truck-house life.

Regards,
Travis.-
 
I ended up here after following along the 'Clunk..' thread, and promptly killed a couple hours at work (there aren't any benefits to working in a cubicle, but I'll take what I can get...) reading through this entire thread.

Incredible build, and I thoroughly enjoy the writing. All inspirational.

Good luck on the odd noise (sorry I cannot offer advice there), and I'll be watching for the continuation of the truck-house life.

Regards,
Travis.-
Thanks man. Glad I could help pass a cubicle day a bit better.

Truck house life will continue. Just possible not until the motor is completely rebuilt. 6 hammered BEBs with 4000mi and no obvious cause is not comforting with the trips I have planned.
 
I've been meaning to circle back around to this thread and document some of my adventures in the big girl since the build. But with data limits, crappy cell reception, and constantly having to plan my next move, it never happened.

I am going to add a few photos of the last 18mo of traveling around the western US. I may get around to adding a few mini trip reports if people are interested.

I also want to add some reviews of equipment that I'm running and a bit of a "what worked, what didn't" compilation. That might come together slowly and piece-meal, but maybe it will help someone out down the road.

Some Stats:
-18mo Travelling and living in my 80.
-Almost exactly 25,000mi driven
-Average around 20mpg. Best 24mpg, worst probably about 17mpg aired way down and rough terrain. Average 600mi range with factory sub-tank.
-Longest dirt stretch: ~10 days & 400mi out of a 500mi stretch from outside of Escalante, looping through Capitol Reef/Henry Mountains/Glen Canyon/Maze District
- 750mi hiked. ~80,000ft elevation gain. About 15mi/gal water. Two pairs of shoes destroyed. One knee blown out. Three times I *probably* should have gotten stitches. Only one near death experience.
-Zero flat tires somehow.
-Aired down probably at least 100x.
-Zero major breakdowns. Racking my brain for minor breakdowns... Just some necessary re-torquing of suspension parts coming loose and oil changes/tire rotations. But quite a few "What's that thump? That's new. Sh*t." moments. A few of which still haven't been solved. Lol.
-At least 130 Native American sites visited (passion of mine).
-3 Nat'l Park Junior Ranger badges earned.
-Dozens of showers stolen by sneaking into State Parks/RV Parks. Hundreds of showers outside in the elements.
-Most time this trip spent in WY, UT, NV, and Death Valley.
-Favorite places this round: Bighorn Nat'l Forest, Shoshone Nat'l Forest, Headwaters of the Green River, San Raphael Swell, Death Valley (4 months deep diving my favorite place on earth), northern Capitol Reef, Maze District.

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Man that sounds like an incredible adventure. Way to put that 80 to work living up to it's expectations!!!!
 
Been wondering how your travels have been going. Thanks for circling back and posting some of your adventures. Looks like an awesome time with some challenges thrown in to make it more memorable when looking back at it down the road.
 
Wow great Picture, thanks for posting !!

Wondered how you adventures were going.

How did that tail gate storage work out ?
 
Wow great Picture, thanks for posting !!

Wondered how you adventures were going.

How did that tail gate storage work out ?

Hopefully updating soon on most/all mods & updates.

The Rugged Bound/Big Country tailgate storage has been great. Countersinking the mounting bolts was key. I spend a lot of time sitting/cooking/working on the tailgate. I have struggled with the latches sticking but I think I’ve finally completely sealed the tailgate from dust so maybe now they’ll stay lubed.
 
Thanks for the inspirational read. The truck's even the right color! Yeah, punching the holes in the dash can be intimidating, but those bars are just so damn handy.
 
Just wanted to post up here that now I have a blog of sorts if anyone wants to follow my travels in my 80. Up to now it's been boring hiking based but I'm hoping this winter to start adding some more 4WD content and drives.

www.pocketsfullofdust.com
@kungfumechanic on Insta


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Well I'm back again. And determined to actually update this thread finally a bit.

I added another ~14,000mi to the rig this year in the American West. I had a mostly worry-free trip as far as the rig was concerned, but there were a few dramas.
-A leak developed at the turbo outlet
-A very weird mysterious condition where the truck started running poorly over many months and then miraculously fixed itself.
-And one tire destroyed with a 3" sidewall gash in Death Valley. It was a road that was recently bulldozed after flooding last year. I know of 4 people that got flats on that road soon after opening. Rocks crushed/split by the bulldozers tracks seem to be to blame.
-I was slowly developing a steering issue that was intermittent and hard to pin down. After a while I checked the PS fluid and it was horribly burnt. A Walmart turkey baster & several reservoirs of fresh fluid later and all was well again. I didn't think I need to upgrade the PS cooler only on 33s and not rock crawling. But I guess I do.
-The 2yr old reverse light indicator switch on the H151 transmission failed and started pissing fluid out of the transmission. Enough so that I only noticed when I found oil on the back bumper. Yikes. I guess I'll have to just upgrade the transmission then. :rofl:

Lots of time spent this year searching for Waterglyphs and petroglyph caves around St. George UT, Arizona strip fun, a gnarly drive to a long hike to a pictograph cave, spent Thanksgiving at Alstrom Point, a trip to Whitmore Overlook, lots of time in Gold Butte, and of course about 3 months in Death Valley. Plus a LOT more you can check out on my blog.

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I'm hoping to add some equipment/upgrade reviews that I failed to do last year. With just under 40k miles on the rig since it's build, I think I've had enough time to get a feel for everything. Lol.

Planned upgrades/maintenance in the next month or so include:
-Pulling & cleaning the intercooler just to be safe due to the turbo oil leak.
-Adding a cabin air filter.
-Adding a pre-filter to the airbox because I am getting copious amounts of dust in the filter too frequently.
-Adding a power steering cooler.
-Possibly upgrading to 35" tires.
-Flush ALL fluids.
-I'm replacing my BEBs again. They only have about 35k miles on them, but after I destroyed the first set of new ones in about 4k miles, I decided that I wanted to pull the ones I have in there now and see how they were doing. But seeing as new Toyota bearings are only around $10ea from Partsouq and it's such a PITA to get the oil pan off, I may as well just replace them. I'll post condition when I get there.
-Oh and apparently I'm upgrading to a NEW H152F transmission??


As I was researching upgrading to 35s and what re-gearing I might want to do if did, I read a lot of threads on how the lower 1st gear & higher 5th on the H152 was pretty much a perfect match on an HDJ80 with 35s. As re-gearing either the diffs or the transfer case (I was leaning towards doing the x-fer) is already quite spendy, maybe an H152 upgrade was a better idea. I also read that a few people had purchased one in the US which I found hard to believe. Rabbit-hole entered...

I saw several dealers online advertising that they had 33030-60C51 in stock. But after calling a baker's dozen dealers in the US I was getting odd results. Several said that the part number was invalid and not in their system. Several said it was in their system but they couldn't get it. Several said that there was ONE left in the US, but since it was on the West Coast and I was on the East Coast that the West Coast warehouse would "never send it to us". Which I thought was very odd. Out of curiosity I ordered it through one dealer only to have the order cancelled an hour later.

A very knowledgable parts center guy (there's only 2 kinds of Toyota parts guy in the US: either they've been there 30yrs or just a month...) said that the H152F was listed as a Type E part. Apparently Toyota has a scale for parts from A to F and F is "discontinued and actively destroying" parts? Yikes. First time I've heard that but I thought it was interesting. So 33030-60C51 is apparently now discontinued and on the way out? I have no idea if it will be superseded and if it is, if the ratios will change again. This old parts guy also couldn't figure out why there were ANY H152's in the US and guessed that they were being held in the US for dealers in South America where VDJ7# truck got these transmissions? Either way, with only one apparently left in the US, I called the only local dealer that had the part number in his system to see if he would try to get the West Coast warehouse to send the transmission over. I love small town dealers because half the time they're just bored and up for a challenge. He said he'd try and to call back in 5 days to see if they canceled the order or if it showed up.

He called me back the NEXT morning, 24hrs later, to tell me the transmission was on his loading dock when he got in that morning. WHAT??? Somehow Toyota moved that transmission from the Portland warehouse to Erie PA in less than 24hrs. The parts guy said that he can't get parts from the local hub that fast and the only way it was possible is if they shipped it out several days before he ordered it. He was flabbergasted. Even so, I managed to talk him down off of retail pricing a bit and took it home for $2900. Which seems WAY too cheap for a brand new Toyota transmission to me, but I'm not complaining.

Anyone need an input shaft & bell housing for a 70 series V8? Hahaha.

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Well the last, damn... going on 2 months has been a LOT of hurry up and wait. I haven't been able to get my proverbial s*** together on parts orders and have been wasting LOADS in shipping fees. But that's how it goes sometimes.

First my order for OEM BEBs was one bearing short. Fat fingered that one i guess. Ordered it from the local dealer instead of Partsouq to "get it fast". That was a day before the nation-wide dealer computer failure. After 3 weeks of my local telling it'll be here the day after tomorrow I gave up & ordered it from Dubai.

In the meantime I tore down the new H152 (so weird to pull apart a new box) to get the correct input shaft in there. I had that buttoned up in a day and ready to go.
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Next I wrestled the old H151 out. Bloody hell is that fun. It took me about 4-5hrs i think AFTER everything was disconnected. The trans tunnel is just too small to accommodate a couple tabs on the passenger side. But eventually I got there.

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I also finally figured out why I had been fighting a massive transmission oil leak and needing to refill frequently at the end of my last trip:

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The breather T had come completely out.
 
Next I went in to replace the BEBs. Checking my records they're only about 35-40k miles old. But after the earlier saga of damaging a set of Taiho bearings in about 4-5k miles, I wanted to check on these OEM bearings that I put in. It very quickly dawned on me that at a total cost of like $70 it was stupid not to just replace them again no matter what they looked like as long as I was in there. Getting there is 95% of the work.

The saga mentioned above of the one elusive bearing set me back quite a ways time-wise but I eventually got in there. The bonus being that there's lots of room to work with the transmission out. Haha.

So here they are:


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Top row is Rod and bottom row is cap.

I had hoped that some over-fueling in the initial turbo/pump set up was to blame for a lot of the damage to the Taiho's. (Which I did rectify.) And it probably helped. But These are a bit more hammered than I would like for 35-40k miles.

It's interesting to note that I have no cavitation or other damage. Just a bit hammered on the compression end of things.

Having bashed up both Taiho's and OEM bearings, I am definitely in the camp that lays the blame for this flaw on the piston design. Some day, when something else forces me to take the head off, I'll do the pistons. But until then it's cheap and relatively easy to do the BEBs every ... maybe 75-80k miles?
 
Next up was a bit of a clutch saga. I was running a Terrain Tamer HD clutch kit and I spent a lot of time (way too much time) trying to get specs on a new clutch plate. At 40k miles I had no idea where I was in the life-span of a TT HD plate. And the internet was no help. I eventually got a rep somewhere to say that they typically get 40-80k miles out of the HD clutches depending on a lot of factors.

So, thinking about how much of a PITA it was to get the transmission out, I decided to just order another clutch and see for myself.

My used clutch plate:

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When I finally received the new one I got down to some measuring.:
Total thickness: New ~8.55mm average. 40k miles ~8.20mm average.
But that's kind of a useless measurements because replacement spec is depth to the rivets. Which annoyingly varies wildly from rivet to rivet on these clutches.
Minimum depth to rivet was 1.8mm New and 1.5mm used (going up to 2.2 & 2.0 for the deeper rivets). Replacement spec is minimum 0.3mm to rivet.

So vague math on the would say the my clutch plate was only 20-25% used? Huh. Which should give me something conservatively around 150k miles minimum on a new clutch?

All quick and dirty math but good to know. Which unfortunately means that I dropped a lot of money on a clutch I didn't necessarily need. Lol. I guess I have a back up now.

The only part of the TT kit that I felt was in rough shape after 40k miles was the throwout bearing. It has a distinct crunchiness to it already. The new kit came with a fresh off-brand (I think it was MRK Japan?) but with the new math of clutch life-span, I didn't want to be dropping this all again in 50k miles just to do the throwout bearing. So I ordered an OEM one from Toyota since those seem to last like 250-300k miles in stock trucks.

So the bearing I ordered was 31230-60181.

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Crap. Further research and the help of some of the seriously unsung heroes on here (looking at you @mudgudgeon ) I have determined that the MOST likely reality is that Toyota used one set of clutch cover/bearing on early 80s and a different set on later models. As long as you get all the components for ONE of those as a set (clutch plate/cover/bearing/fork) it will work on any year truck. Which is why the TT kit doesn't need to specify which years it's for.

The 31230-60181 appears to be for late 1HDT and all petrol models. As far as I can tell.

So the bearing I needed was 31230-60130. Apparently there's a 3rd option which is for the 275mm flywheel (which was what mine came with stock from the factory as a British market truck) 31230-60120. Which I'm guessing is the stock bearing that would go with the 1HZ non-turbo models which general came with the 275mm instead of the 300mm that came on the turbo trucks.

Unfortunately I missed on the 50/50 shot of which bearing I ordered and now I have an expensive useless bearing and had to order the correct one. ARGH! But hopefully when that arrives this will be all sorted and we get the damn transmission in & drive it.
 
A questions for the collective here: I've been getting copious amounts of dust in my air filter even under moderate conditions. Granted my turbo creates more suck than an NA engine and my custom airbox just sucks open in the passenger fender (without that weird plastic thing Toyota has in there). But still.

Pulling the transmission I noticed this huge opening at the trailing edge of the fender. Being right behind the wheel, I imagine ALL the dust gets flung up in there. It appears that something was once covering this opening. Possibly part of the stock running board mounts/cap?

Anyone have a stock-ish truck with running boards that can clue me in?

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I can't confirm what one with running boards looks like, but mine is also open. (this is the driver's side, but it's open on the pass side as well)

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