Builds Troopy Trial No. 2

[Willis]

It sat outside looking sad for awhile. Busy trying to finish customer projects meanwhile plugging a few hours each night into the troopy.

Got the 1HDT installed along with the new H55!

Sidebar: somewhere in all this the shop picked up a 1991 HZJ75, sold the truck and had to stop everything else to completely build it out for the customer that bought the truck.

For some reason I really struggled with the alternator wiring. I've never had to wire in an alternator from scratch. 5 hours of research led me to the conclusion that the wiring from the external regulated old 3F alternator wasn't going to translate to the modern 1HDT alternator. Simpler than I thought, the solution was just running new wires.
Posting this for posterity because I couldn't find any good info on 2F, F, 3F to 1HZ/1HDT swaps.

A new 8 Gauge wire from the Alternator Post to Battery, Fuseable link at the battery side.

Out of the 3 prong pigtail:
Battery Sense wire to the battery, fused at 5amp at the battery side.
IGN wire to one of the previous IGN wires in the engine bay to fire the alternator up.
Light...well I didn't wire that one in - I can watch my voltmeter. I might circle back to that later.

Seems to work, charging at 14.5v and now my wiper motors, headlights, etc REALLY work. They were pretty slow/dim before.

Made a harness for the alternator, winch, glow plug signal. Routed around the grill because I'm anal about a clean engine bay

This is the final product. There will be an ARB dual compressor mounted with a bracket over the ugly spot left by the dual battery system(I'm just going to run one)
I wanted my battery to just have two cables running to it, so I routed a busbar on the battery tray to keep the wires organized.
The glow plugs are wired to a starter solenoid with a momentary switch under the key.

The 1HDT swap has almost as few wires as a 12HT swap, which I love.

1 to the starter
1 to the fuel solenoid,
A glow relay/switch system
3 wires to the alternator
1 to the temp sensor
2 for the EGT
3 for the boost gauge

That's about it besides engine grounds.
Although I do have to figure out how to make the Tach work.

 

[Willis]

We had it running great from a fuel bottle in the engine. Actually started and bled itself out within 2 or 3 cranks, was very impressive. However when I switched to the real fuel routing to the tank it struggled, and if it had sat for a few hours it would refuse to fire back up without heavy priming. After wasting a Saturday in frustration, checking fuel lines, fuel line sizes, fuel solenoids, second guessing my fuel pump working(ha) I finally realized the 3 gallons or so I had in the (freshly drained of gasoline) tank was simply not enough to reach the tank pick up. Another couple gallons of gas and it fired back up, bled itself out and purred for minutes. I drove it to the gas station to fill the tank completely and it's been great since.

I've driven it around the block a few times but currently can't drive it for awhile until I get some actual exhaust beyond the small flange out of the turbo. It's blackening the firewall. Soonest opening is August 12....

I tried to upload a video but couldn't get anything through, so this picture will have to suffice

 

[Honger]

Beautiful! This turned out really nice.

Don't suppose you want to get rid of some 3F parts cruft do you? (charcoal canisters, AC compressor and mount)
I'll shoot you a PM. =)

 

[SKULLYOTA]

So you converted this one to 12v too?

 

[Willis]

So you converted this one to 12v too?

1HTD engines are generally 12v, the only part that is 24v is the starter. HDJ81s are 12v, but they double power for the starter. Not sure why. 12v 1HZ starter cranks this one over fine.

Most troopies are 12v as well.

 

[SKULLYOTA]

1HTD engines are generally 12v, the only part that is 24v is the starter. HDJ81s are 12v, but they double power for the starter. Not sure why. 12v 1HZ starter cranks this one over fine.

Most troopies are 12v as well.

Interesting....

 

[flx]

1HTD engines are generally 12v, the only part that is 24v is the starter. HDJ81s are 12v, but they double power for the starter. Not sure why. 12v 1HZ starter cranks this one over fine.

Most troopies are 12v as well.

That really depends of market, all the European ones will be 24V.

 

[Willis]

That really depends of market, all the European ones will be 24V.

"Most" troopys are not European market.

 

[goexplore]

It sat outside looking sad for awhile. Busy trying to finish customer projects meanwhile plugging a few hours each night into the troopy.

Got the 1HDT installed along with the new H55!

Sidebar: somewhere in all this the shop picked up a 1991 HZJ75, sold the truck and had to stop everything else to completely build it out for the customer that bought the truck.

For some reason I really struggled with the alternator wiring. I've never had to wire in an alternator from scratch. 5 hours of research led me to the conclusion that the wiring from the external regulated old 3F alternator wasn't going to translate to the modern 1HDT alternator. Simpler than I thought, the solution was just running new wires.
Posting this for posterity because I couldn't find any good info on 2F, F, 3F to 1HZ/1HDT swaps.

A new 8 Gauge wire from the Alternator Post to Battery, Fuseable link at the battery side.

Out of the 3 prong pigtail:
Battery Sense wire to the battery, fused at 5amp at the battery side.
IGN wire to one of the previous IGN wires in the engine bay to fire the alternator up.
Light...well I didn't wire that one in - I can watch my voltmeter. I might circle back to that later.

Seems to work, charging at 14.5v and now my wiper motors, headlights, etc REALLY work. They were pretty slow/dim before.

Made a harness for the alternator, winch, glow plug signal. Routed around the grill because I'm anal about a clean engine bay

This is the final product. There will be an ARB dual compressor mounted with a bracket over the ugly spot left by the dual battery system(I'm just going to run one)
I wanted my battery to just have two cables running to it, so I routed a busbar on the battery tray to keep the wires organized.
The glow plugs are wired to a starter solenoid with a momentary switch under the key.

The 1HDT swap has almost as few wires as a 12HT swap, which I love.

1 to the starter
1 to the fuel solenoid,
A glow relay/switch system
3 wires to the alternator
1 to the temp sensor
2 for the EGT
3 for the boost gauge

That's about it besides engine grounds.
Although I do have to figure out how to make the Tach work.

Love that busbar off the battery. I’ve been getting increasingly frustrated by local garages adding more and more wires from the positive terminal. Do you have a link for this, or recommend something similar?

 

[Willis]

Love that busbar off the battery. I’ve been getting increasingly frustrated by local garages adding more and more wires from the positive terminal. Do you have a link for this, or recommend something similar?

Thanks! Makes it easy installing accessories for sure, not having to try and cram loads of wires onto the battery. I love getting a truck into the shop for a build and immediately removing 90% of the battery terminal connections!

This is the one I used. Blue Sea has a bunch of larger options as well if you'd like more than one post. Really just google "battery busbar" and you should have endless results.

2019, Power Bar Dual BusBar

www.electricalhub.com

 

[goexplore]

Thanks! Makes it easy installing accessories for sure, not having to try and cram loads of wires onto the battery. I love getting a truck into the shop for a build and immediately removing 90% of the battery terminal connections!

This is the one I used. Blue Sea has a bunch of larger options as well if you'd like more than one post. Really just google "battery busbar" and you should have endless results.

2019, Power Bar Dual BusBar

www.electricalhub.com

Thanks Alex. I'm lost when it comes to electrical, so what seems simple to others, confuses the hell out of me. I also start twitching when I see lots of cables coming of single terminals and a rats nest. I should really take the opportunity to learn the electrical work myself so I'd only have myself to blame.

 

[Willis]

Driving over the past month I've had to work out some kinks -
-Up hills the water temp would climb, turns out the OEM radiator couldn't handle the 1HDT or was just old. Swapped for a new 3 core aluminum and it's been great ever since.

-Starter Solenoid would not engage whenever it was wet weather (No joke) -dismantled it and found all the contacts dry and were sticking together. Cleaned and lubed seem to work along with cleaning and running new grounds around the starter.

-Annnnd despite having been told the H55 transmission was rebuilt at Valley Hybrids, it makes a terrible noise in neutral. Goes away when the clutch is engaged. Idle bearing is shot.
Might swap out for an actual new H55.

Now the fun stuff -
Went to the desert to test my truck and a white one we built for a customer -
This is where I found my radiator wasn't up to par. White truck did spectacular

 

[Willis]

I sourced an OEM hood pad. I think it's rad that Toyota had heat protection right above the exhaust and turbo -

My wife and I spent the weekend prepping our floor and walls for sound deadening. I was very pleased to see an original rust free floor under the mats -

Another nice surprise was finding the last remnant of the Propane system I had already removed. This explained why my rear tank gauge was peaked at max. Removing this fixed that.

Floor coated, right before we installed a second layer of foam sound deadening over this coating.
It's Lizard Skin Sound Insulation - took 2 gallons and 3 coats. Seems to help, maybe a placebo...

All of this was to prep for the buildout. I wanted 80/20 with aluminum siding for lightness (I've played the wood game)
I traded some labor to a friend of mine. It started out well but when I saw him using screws to hold the sides on, I decided to just pick it up and finish on my own. Took quite awhile to swap them all out, but I'm happy with the result now.

I also commissioned another friend of mine to build canvas covers for the panels. Very happy with those.

Just waiting on the seat cushion and draw pulls now. A few kinks to work out, but it's all 80/20 modular and easy to move around.

 

[SNLC]

Ahhhh, the Shiba! I sure miss mine. I been thinking about getting another but don’t have time to raise a puppy.

Troopy looks great too.

Cheers

 

[Willis]

Ahhhh, the Shiba! I sure miss mine. I been thinking about getting another but don’t have time to raise a puppy.

Troopy looks great too.

Cheers

I'll just have to come visit and you can borrow mine for awhile.


Side note, does anyone know what I need to buy to get my Tach to work?
1985 FJ75 tach - ran off alternator/coil?
1994 1HDT motor - two wires off injection pump sensor

Swap to a 1HZ tach from an early 90s HZJ75?

 

[Bogan]

Hell yeah dude. Great seeing this being documented (including Ethan's flight of the Prado). Always inspiring to watch y'all build rigs.

 

[coldtaco]

what snorkle is on the white troopie?

 

[Willis]

what snorkle is on the white troopie?

Safari HZJ75
pn - SS70HP

I think it's the new one for 70s. It was quite time intensive to install, had to modify the airbox... a lot

 

[Willis]

I finally received my Long Range Tank from LRA. Install was fairly easy, besides taking all my interior out but I wanted to do that anyway to fix some things. I ran my fill to the tank into the hood with a quick connect hose fitting - I was not about to drill a giant hole in the side of the truck for water.

I'm trying to plum in to a heat exchanger to get a hot shower, in addition to a pump for hot and cold.
Getting this to work just right is quite the challenge.


I installed an Espar D2 - best mod on the truck for sure. Having a warm cabin in the morning feels like cheating at life.
I don't have many images of this, but here is the exhaust.

Also, my friend made window insulation for all 9 windows

 

[Willis]

I see this forum continues the trend of worst on the internet: no one replies unless to argue about part numbers.
So here-
Photo porn from my wife and I's 10 year anniversary trip around Idaho and East Oregon

Oh I got truck-lite LED headlights. I have fought LED lights for 10 years but they saved me on the literal first day of the trip. Spotted a deer in the middle of the road where the candles the FJ75 came with would not have seen. Was able to slam the brakes and swerve to miss it by a foot.
But they don't work when it's snowing.