Builds Stormtroopy, a 2002 HZJ78 turned surf wagon

[ROUSER]

So I took this opportunity to install a Harrop/Eaton E-locker with a new set of Nitro Gears.

 

[gkanai]

Do you know why the pinion teeth broke? That sounds like a rare event to me, no?

Nice that you could upgrade to lockers. How hard was it to install the Harrop bits to the diff? Did the diff have the plumbing already?

 

[ROUSER]

Do you know why the pinion teeth broke? That sounds like a rare event to me, no?

Nice that you could upgrade to lockers. How hard was it to install the Harrop bits to the diff? Did the diff have the plumbing already?

Have no idea why it broke? It just did, and I’m glad it happened stateside vs on the road in Central America. All the parts went in with no issues and a hole was drilled in the housing for the two wires to pass through.

 

[SNLC]

You might think about doing a bunch of rust proofing. Beach use and coastal towns will kill it sooner or later.

POR15 or Rust Bullet the whole chassis, even flood the inside. Do in side all hollow body panels and the floor inside the truck too. It will help a lot to keep the rust at bay.

I have a bunch of friends in Santa Catalina. Been there a number of times for up to three months. All their vehicles are wasted in that village though due to rust.

Cheers

 

[ROUSER]

I finally got around to rolling on some Monstaliner in the cab/bed of the Troopy. First the floor pans and bed were scraped and lightly sanded.

 

[ROUSER]

Once the edges were taped, wires suspended, and bolt holes plugged, I brushed on Chassis Saver. I used almost a whole quart to cover the area to be lined. The fumes were strong, so I used a 3M mask to keep me straight.

 

[ROUSER]

After the Cassis Saver was dry, I re-scuffed the area and rolled on the Monstaliner. I went with the Medium Quartz Grey color as opposed to the black, I like the contrast between the white, grey, and black used in the interior. Every ounce of the 1 gallon kit was used. As I neared the end I was worried I wouldn’t have enough, but fortunately it was the perfect amount. I went through 4 foam rollers, glad I bought the extra cause they do and will come apart during the application process. The fumes were not an issue for me with the liner, but it was a bit messier than the Chassis Saver.

 

[ROUSER]

Since I had the aluminum skins out for the Monstaliner application, I had them powder coated. I also put on some Dynamat type stuff underneath the skins. Between the liner and the Dynamat type stuff the road noise has been significantly reduced. As well as the metallic rattle being eliminated.

Didn’t get a pic of the side wall skins installed, but it looks just like the rear door skins.

Yes, the Troopy barely fit into the garage. I had to completely air out the tires, drive it in, and partially air back up. The neighbor thought I had lost my mind!

 

[ROUSER]

I found a pretty well constructed rear drop down table from Front Runner. It is well made, doesn’t rattle, stays shut, and has a hide/slide wooden cutting board built into it.

I used rivnuts instead of the provided hardware to attach it to aluminum door skin as well.

Here is a link
Drop Down Table - by Front Runner

 

[JohnnyUtah2]

Im enjoying your build. Thanks for taking the time to document your progress. I always think about doing that and then end up in a hurry to finish the project. Any plans to turbo charge the 1HZ?
Cheers.

 

[ROUSER]

Im enjoying your build. Thanks for taking the time to document your progress. I always think about doing that and then end up in a hurry to finish the project. Any plans to turbo charge the 1HZ?
Cheers.

Thanks!

No plans for a turbo, I don’t mind being slow especially when living in the jungle where you rarely reach speeds over 30mph.

 

[TonyP]

I found a pretty well constructed rear drop down table from Front Runner. It is well made, doesn’t rattle, stays shut, and has a hide/slide wooden cutting board built into it.

I used rivnuts instead of the provided hardware to attach it to aluminum door skin as well.

Here is a link
Drop Down Table - by Front Runner

View attachment 1710733

View attachment 1710735

View attachment 1710734

I dig that table. Where did you purchase yours from? Looks like FrontRunner themselves is out of stock.

 

[ROUSER]

I dig that table. Where did you purchase yours from? Looks like FrontRunner themselves is out of stock.

I got it direct from them...

 

[ROUSER]

Before I rolled on the Chassis Saver and Monstaliner, I fabbed up a sleeping platform, with a storage box towards the front. Here are some pics of it before the 3 top wood surfaces were carpeted and installed.

The platform utilizes the same mounting points as the original rear bench seats.

 

[ROUSER]

Here are pics of the finished seeping/storage platform. The rear most part of the platform is a press fit with a support bolted to the wood. It can be popped up and pushed over the fixed part of the platform to expose a place to sit with the rear doors open when we are at the beach. I used 1” steel, with .5” marine ply, the ply was sealed and covered with indoor/outdoor carpet.

 

[ROUSER]

I used the forward most wall of the storage box to hang 2 emergency kits, fire extinguisher, axe, and the handle to my Moore Power Puller.

 

[ROUSER]

Also installed an ARB Twin Air compressor on the storage box wall. I used a Witt’s End coupler guard mounted to the drivers side seat mount. And the little box next to the coupler is a Wheelen PA/horn.

 

[ROUSER]

New door skins(door cards) were delivered from Australia. Manufactured by Australiaian Door Cards, they are a plastic type material with a nice texture to them. They came with all the snap in inserts that connect to the original mounting holes. I must say the packaging was top notch, they came in a wooden frame that fully protected them during transport. I added two extra holes to each for the Nissan Patrol arm rests I had mounted when I first got the Troopy.

Toyota Land Cruiser 75, 78, 79 Series ABS Door Trim Panels. Rugged & Waterproof. | eBay

 

[ROUSER]

I have been getting ready to drive back to Panama and am taking advantage of the ease of attaining parts and accessories here in the States. On the interior I have added a Whelen PA system with emergency type horn, a set of Black Duck seat covers from OZ, fabbed up some cup holders, installed a shift lock, and added a shovel mount to the rear storage area.

 

[ROUSER]

As for the engine and drivetrain, installed a radiator bashplate from OZ, new rear main seal, pilot bearing, Excedy clutch kit, and blanch ground the flywheel. Also put in a completely new transfer case, it was a $500 difference between new and rebuilt, so I went with a new unit. Also extended the breather to the engine bay. Air filter and fuel filter were also serviced.