Toyota Landcruiser HJ47 Ute with Isuzu 4BD1 conversion Build

Joined
May 2, 2011
Messages
2,996
Location
Paradise
Good to see your getting stuck into the 45 for the trip around OZ. I'm looking forward to checking the truck out in person when you come through my part of the world.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Well I fitted a Warn high mount winch last week, And took the vehicle out for its first run since doing a lot of work to it. It still runs the original 2H engine. It performed well, But despite new seals all around it still leaks rain in to the cabin somehow. I'll have to unload a tube of silicone around the body I think. Drives quite nice, I think the 3.7 diff gears are quite a good ratio even just with the stock 2H.

Ive got to go back out bush to work tomorrow, but I have the Isuzu head at a head shop getting the valves reseated and the head skimmed. Hopefully that will be enough to get the big old diesel running nicely. I'm debating whether to take the injector pump to a specialist for a calibration and get the injectors done while I'm at it. It should be all sorted out when I fly back into town next week.

My camper assembly has copped a redesign (again) while Ive been working on other things, I was originally going to have quite a tall slide on camper to try and fit a motorbike inside it, but I've long since given up on that, and will be just taking some bicycles instead. this means I can have a much lower camper frame. The camper with the roof top tent on top of it will be no higher than the existing tray headboard. The 12 foot aluminium dingy will rest on top of the tray headboard and on another steel 'hoop' the same profile as the headboard, at the back of the tray. The dingy will have to be removed to set up the tent.

In other news, the cool looking clear coated bare steel body is not surviving very well! Rust is appearing all over the place. I think I may have to strip it and put proper paint on the body. Thats a bugger mainly cos I would have to fix all the dents for normal paint to look any good!

Oh well, Back to work!
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Well I got the engine running finally, it had rusty exhaust valves, and fuel 'varnish' in the injector pump. So I had the head, injector pump and injectors rebuilt and now she runs beautifully! I have a rebuilt h55f gearbox being built which should be ready sometime in the next week. I still haven't made any progress to speak of with the bellhousing adapter though, that's going to take some work! I'll see if I can load some pics of progress.
 
Joined
Jul 31, 2014
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191
Location
Burnie tasmania
Sounds like a nice build I'm hoping to take my 55 around the big island in the next year or two. I know what you mean about service in shops everything just seems too hard makes you wonder how some of them stay in business. Subscribed.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Well its been nearly 2 years since beginning this thread, I got locked out and somehow couldn't log back in with my devices at the time.

Ive got a bit to catch up on. The short of it is that The engine is fitted, goes hard, and we're currently 8 months in to our big around Australia trip with no major problems yet.

The bare metal thing did not last as predicted by Cleg, So I painted it up in the factory 416 Dune Beige. The vehicles original and my favorite 40 series colour.

As it turns out, the clutch (Clutch Industries 4Terrain from a HJ61 Turbo) is no where near strong enough to handle the torque that the engine is putting out. this is currently the weak point of the driveline, but while we are travelling fully loaded at about a 3.5T GVM it serves as gearbox/diff overload protection. It still transmits plenty of torque regardless. We can overtake 52m long road trains on the outback highways with ease.

I ended up designing a 3D model of the bellhousing I needed to fit the H55 Box and engine together. I got this made in China and delivered. (5 day turnaround! crazy hey!) It was machined out of a billet of 6061 Aluminium. Shouldn't break! I also designed the clutch throwout fork and got that machined out of 4340 chrome-moly. the quality, speed and price was unbeatable. I'll be using this process for future projects for sure!

I used 2X Donaldson filters each rated to 250CFM at 6"water of vacuum. they have cyclonic dust seperators in the intake which gives them a reasonable dust capacity. I worked out I needed 500CFM airflow at full tilt, but in hindsight the clutch cant handle the torque at that airflow anyway, so realistically I could have used a smaller turbo, less ducting, one air filter and achieved the current power that I have (which I'm very happy with!). All good lessons!

my camper ended up weighing much more than I expected (as usual) and for weight reduction/simplicity I haven't made it removeable (yet).
I'll get some photos up as soon as my technology permits.

I welded up a monster of a fuel tank out of two old tanks that needed repairs, managed to get 275L out of it. This combined with the factory tank gives me 360L useable in total. Also a massive overkill! It has been useful in the far remote north, but realistically for the complication/risk/weight I'd be better off just buying the fuel at the exorbitant prices up there. you just don't need the 2480km range!

Fuel economy has been worse than expected, but I guess the vehicle weighs 600kg more than expected, so thats not helping! It's worked out to about 14.5L/100km (thats about 16.2 US MPG for you crazy non metric types!) I was hoping for more like 12ishL/100km. (20ish
 
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Well its been nearly 2 years since beginning this thread, I got locked out and somehow couldn't log back in with my devices at the time.

Ive got a bit to catch up on. The short of it is that The engine is fitted, goes hard, and we're currently 8 months in to our big around Australia trip with no major problems yet.

The bare metal thing did not last as predicted by Cleg, So I painted it up in the factory 416 Dune Beige. The vehicles original and my favorite 40 series colour.

As it turns out, the clutch (Clutch Industries 4Terrain from a HJ61 Turbo) is no where near strong enough to handle the torque that the engine is putting out. this is currently the weak point of the driveline, but while we are travelling fully loaded at about a 3.5T GVM it serves as gearbox/diff overload protection. It still transmits plenty of torque regardless. We can overtake 52m long road trains on the outback highways with ease.

I ended up designing a 3D model of the bellhousing I needed to fit the H55 Box and engine together. I got this made in China and delivered. (5 day turnaround! crazy hey!) It was machined out of a billet of 6061 Aluminium. Shouldn't break! I also designed the clutch throwout fork and got that machined out of 4340 chrome-moly. the quality, speed and price was unbeatable. I'll be using this process for future projects for sure!

I used 2X Donaldson filters each rated to 250CFM at 6"water of vacuum. they have cyclonic dust seperators in the intake which gives them a reasonable dust capacity. I worked out I needed 500CFM airflow at full tilt, but in hindsight the clutch cant handle the torque at that airflow anyway, so realistically I could have used a smaller turbo, less ducting, one air filter and achieved the current power that I have (which I'm very happy with!). All good lessons!

my camper ended up weighing much more than I expected (as usual) and for weight reduction/simplicity I haven't made it removeable (yet).
I'll get some photos up as soon as my technology permits.

I welded up a monster of a fuel tank out of two old tanks that needed repairs, managed to get 275L out of it. This combined with the factory tank gives me 360L useable in total. Also a massive overkill! It has been useful in the far remote north, but realistically for the complication/risk/weight I'd be better off just buying the fuel at the exorbitant prices up there. you just don't need the 2480km range!

Fuel economy has been worse than expected, but I guess the vehicle weighs 600kg more than expected, so thats not helping! It's worked out to about 14.5L/100km (thats about 16.2 US MPG for you crazy non metric types!) I was hoping for more like 12ishL/100km. (20ish
PIIIIIIIIIICS!
 
Joined
Sep 3, 2007
Messages
8,871
Location
New Zealand
Pics ............. p-r-e-t-t-y p-l-e-a-s-e........
 
Joined
Aug 11, 2013
Messages
559
Location
Scottsdale, AZ
Ditto on the pics... Excited to see the progress of your build!!
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
McbridesBeachview.jpg
Overloadedpretrip.jpg
SandyCreekCamp.jpg
ShaneandI.jpg
Tinny on top with tent.jpg
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
If you look carefully you'll notice The camping set up has changed a couple of times. the 2nd, 5th and 6th photos show the original camping set up with a tinny lifter that lifted the tinny off the roof top tent with one handed ease. This was a great set up untill I realised how heavy the whole thing was, evident in pic #2.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Pic#s 3 and 4 show the tinny on the roof without the lifter or roof top tent. this is how we originally left home, and covered about 16,000km in this format. We just used a normal ground dwellers tent for this jaunt up in the far north of the country. a couple of months ago, we had the opportunity to have the roof tent brought over to us by my father who was crossing the country towing an empty trailer. We then removed the heavily abused tinny and refitted the roof tent for the southern leg of our trip, expecting more rain and generally foul weather. Its a compromise which I really didn't want to make, but the roof topper is vastly more comfortable than the ground tent; particularly when its howling a cold gale and raining.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Pics 7 and 9 show the workings. #9 is obviously the bellhousing which I had machined in China out of a billet of aluminium. I also used a clutch slave cylinder out of a VDJ79 Landcruiser which is internal. You can see the brown coloured body of it sticking out of the gearbox side of the bellhousing.

Pic#7 shows the engine bay minus the intercooler and overflow bottle. Note the hydraulic brake booster unit between the firewall and master cylinder. I cant say I'm convinced of its value yet, in fairness I haven't resolved some air leaks on the intake of the power steering pump which means any load on the circuit results in whining and carrying on. I'll fix this one of these days! The main differences between when this pic was taken and now is that the flexible intake hose from the air filters are higher quality silicone, the high pressure compressor outlet aluminium tube has been shortened and a silicone hose added. It kept cracking due to the leverage/length of the solid tube from the turbo, and the engine vibration.
 
Joined
Sep 3, 2007
Messages
8,871
Location
New Zealand
Thanks Haydo.

That bellhousing is a work of art too.. But how to you get at the slave-pushrod and fork-return-spring?

I bet the twin 45 degree Donaldsons make people ask what size donk you've got under the bonnet.

Love it!

Thanks again for posting the pics..

:beer:
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Ok fine I'll add more

3 men in a boat.jpg

This is part of the crew Travelling with us. Out for a fish.

Battery box.jpg
A battery box I built under the tray. There is one of these on either side of the car.

Bent airbag.jpg

I fitted airbags to help carry my fat arse around. the brackets supplied were pretty flimsy. I ended up welding a bit extra steel in the bracket to stiffen it up
Tinny lifter gas strut.jpg


This is just showing more detail on the tinny lifter I made. The hinges are made from the front spring hangars of a wrecked HJ47. I used the factory bushes and an M18 bolt (I think) as the pin. Just made the clevis up out of scrap steel. The gas strut is something like 1400mm long at full extension, and gassed up to about 250kg from memory. It unclips to allow the whole frame to lower to the ground via a 12v electric ATV winch I got off eBay.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Thanks Haydo.

That bellhousing is a work of art too.. But how to you get at the slave-pushrod and fork-return-spring?

I bet the twin 45 degree Donaldsons make people ask what size donk you've got under the bonnet.

Love it!

Thanks again for posting the pics..

:beer:

Haha yeah! the disbelief when I tell them its only 4 cylinder diesel smaller in capacity than the original is pretty funny to watch!

The slave has a built in spring which keeps the cylinder pushing (lightly) on the throwout bearing. Toyota calls this "self adjusting" there is no adjustment necesary on any of those parts so access isn't a problem. I'll track down an internal photo.
 
Joined
Feb 5, 2014
Messages
46
Location
Perth, Western Australia
Bare steel cruiser.jpg

This is how the ute looked before the water got up under the clear coat. I reckon it looks awesome. Unfortunately the paint just didn't stick very well.


Internal bellhousing.jpg


This is the inside of the Bellhousing I moved the pivot point to the L/H side of the vehicle, and basically copied the geometry of the VDJ79 clutch throwout. I have since modified the offsets on the throwout fork cause I didn't quite get it right the first time. Works well now.
Oolloo crossing carwash.jpg


Giving the car a rare wash in a nice fresh water river called Oolloo river in the Northern Territory. Great spot.
 

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