Build Saudi 75 1 - Tilda Bogue Service Station

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Been busy here wrapping up CAD work, getting things laser cut and installing the new wheels, among other things.

New wheels went on today, look and drive really well. For those interested, I’ve listed the specs below:
Braid Dakar T Rally 16” x 7” -20mm offset yielding a 3.170” backspace. With the Yokohama Geolandar G003’s, the treads just stay within the arches. No rubbing anywhere as one would expect but I also haven’t had a chance to really give the truck some articulation due to the weather.

New wheels!

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Next was test fitting the stainless steel tail gate cover I sent out for laser cutting. This fits really well and will install the rivnuts tomorrow to complete the installation:

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Lastly, got around to a few minor updates; new shift knob and mounted the rear shock reservoirs piggy back style on the shock bodies.

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So, making progress on the bed storage... After several calls with Decked, it became apparent they had no interest in supporting or selling me one of their units. Two different sales folks told me "we don't have interest or will support custom builds so good luck"... So, on to the next vendor, Truck Vault. I was able to get in contact with one of their reps and she was more than happy to help. They sent over some pictures of other configurations they have done for some ideas so here we go!
Mocked up the bed, along with the spare tire for clearance, translucent feature on top is the preliminary concept for the overall dimensions of the top cover:

FZJ75 Bed view with top cover translucent.webp


Next, started some preliminary space analysis for the drawer, both in height and width:

Current Height from bed to bottom of vault cover.webp


FZJ75 Bed View width between wheel wells.webp


If any of you need a model of the bed, or some dimensions for other projects for a 75 bed, just let me know. I can also provide 79 series dimensions as well. I can provide the 3D in a neutral file format or 2d, whatever works best.
 
DrRock said:
So, making progress on the bed storage... After several calls with Decked, it became apparent they had no interest in supporting or selling me one of their units. Two different sales folks told me "we don't have interest or will support custom builds so good luck"... So, on to the next vendor, Truck Vault. I was able to get in contact with one of their reps and she was more than happy to help. They sent over some pictures of other configurations they have done for some ideas so here we go!
Mocked up the bed, along with the spare tire for clearance, translucent feature on top is the preliminary concept for the overall dimensions of the top cover:

View attachment 4064625

Next, started some preliminary space analysis for the drawer, both in height and width:

View attachment 4064627

View attachment 4064628

If any of you need a model of the bed, or some dimensions for other projects for a 75 bed, just let me know. I can also provide 79 series dimensions as well. I can provide the 3D in a neutral file format or 2d, whatever works best.
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I'd love the 79 data. I have one inbound. We'll need to get these rigs together up here in New England.
 
navydivedoc said:
I'd love the 79 data. I have one inbound. We'll need to get these rigs together up here in New England.
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Sounds good, let me do a final confirmation on the dimensions and then I can send you over the info. I know someone who has a 79 series but if you can let me know what year yours is then I can triple check. I’d hate to give you a 3D model that isn’t correct.

Looking forward to seeing yours in person here in New England.

Cheers, James
 
After a bit of a delay on my part, I got my Manta headers and extractor back from Swain Coatings and they are now ready for installation. These headers are stainless steel but the coating helps in two ways; 1. Keeps heat in the header thereby increasing the velocity of the exhaust gasses thus improving performance and 2. Helps reduce temperatures in the engine compartment. Swain Coatings offer a premier product that is thicker and better for performance than many other commercially available ceramic coatings that mostly only provide a nice finish. Below is a link for anyone who wants to nerd out on exhaust coatings :)


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DrRock said:
Sounds good, let me do a final confirmation on the dimensions and then I can send you over the info. I know someone who has a 79 series but if you can let me know what year yours is then I can triple check. I’d hate to give you a 3D model that isn’t correct.

Looking forward to seeing yours in person here in New England.

Cheers, James
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I would appreciate a model as well. My 79 is coming in March as well. THX!
 
Hello @navydivedoc and @wardharris I'm still in flight with this and am waiting confirmation from another member here with dimensions. As soon as I have updates I will post and get your information so I can send the file over.

On this topic, I've got my concept finalized for my final draft with Truck Vault. Spent some time figuring out how to access the areas on the sides and front of the bed and came up with this layout. There will be lids as well but wanted to show the access. I'll also be switching to a Chassis Unlimited Tire holder. The factory holder poses a challenge with my alloy wheels as I'd need additional egress to get the tire out and it would need a new back plate since I'd have to flip the wheel around. I've also added two 48" sections of L-track for holding down additional gear. Once this initial concept is approved with Truck Vault, I'll incorporate some custom hold downs for 1Up bike mounts too. idea here being that these will be removable to make the whole setup as flexible as possible.

Front iso view;

Bed Front.webp



Top View:

Bed Top.webp
 
DrRock said:
Hello @navydivedoc and @wardharris I'm still in flight with this and am waiting confirmation from another member here with dimensions. As soon as I have updates I will post and get your information so I can send the file over.

On this topic, I've got my concept finalized for my final draft with Truck Vault. Spent some time figuring out how to access the areas on the sides and front of the bed and came up with this layout. There will be lids as well but wanted to show the access. I'll also be switching to a Chassis Unlimited Tire holder. The factory holder poses a challenge with my alloy wheels as I'd need additional egress to get the tire out and it would need a new back plate since I'd have to flip the wheel around. I've also added two 48" sections of L-track for holding down additional gear. Once this initial concept is approved with Truck Vault, I'll incorporate some custom hold downs for 1Up bike mounts too. idea here being that these will be removable to make the whole setup as flexible as possible.

Front iso view;

View attachment 4078959


Top View:

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Click to expand...
WOW
 
Tonight I braved the elements (garage was 18F inside) and completed the installation of the stainless tail gate inner panel I had made from the CAD I completed. The installation went really well well and I’m really happy with the results.

Parts List:
1. Stainless steel laser cut panel to my specification
2. 30 M6 304 stainless steel riv nuts
3. 30 M6 x 15mm 304 stainless steel button head torx screws
4. Anti seize as required

Pro tips:
1. Always use anti seize on stainless fasteners to reduce galling, especially when threading into a female stainless thread.
2. For button head screws, I prefer torx drive as it reduces the chances of stripping the drive when removing as 304 stainless is softer than carbon steel.
3. When installing panels with many fasteners like this, position the panel and drill one hole in the gate and install the riv nut. Confirm the position and then drill and riv nut a hole on the opposite side. Install the fasteners in these two holes and then drill 3 more holes using the panel as a guide. I also use a transfer punch to get the hole correct. Repeat the process of installing the riv nuts in these three holes. Once done, then one can transfer punch, drill and riv nut the remaining holes. This ensures a nice fitment. Lastly, once I had the panel completely installed, I was able to put the tail gate up to access the 4 holes and drill those for mounting the tail gate clamps.

Sano.

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Got the Manta exhaust installed, wohoo! Overall the process was pretty straightforward if that’s even possible when dealing with these exhausts. The Manta exhaust is very well made and I was very happy with the overall fitment. Things got a little tight around the point where the downpipe exits the engine bay and goes into the wheel well which necessitated some minor trimming of the fender. The fit in that spot of the wheel well is really snug which of all the outcomes I prefer as it gives maximum clearance from the tire. The other huge positive is that the Manta setup splits the exhaust into two additional places vs the factory setup. First split is the crossover pipe that traverses from just behind the RH door across to the muffler and the second is the tail pipe is separate from the muffler section. This makes the installation much easier!

Out with the old:

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..and in with the new.

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The exhaust note is really pleasing yet retains the factory noise levels which is nice as I like a quiet truck. There is no droning throughout the rpm range and it definitely feels like there is a bit more torque but that is hard to properly assess. Thanks to Evergreen Offroad for getting me this setup.

One more picture of all the factory hardware part numbers for reference.

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sark said:
crossing my fingers that we cross paths so I can see this in person!
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Where are you located in New England? I'm hoping to do the Vermont Overland this year and I'll be at SAS 10 this summer in Colorado.
 
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