Pajero 4WD Club of Victoria Public Forum Pajero 4WD Club of Victoria Public Forum

Go Back   Pajero 4WD Club of Victoria Public Forum > General Information > Do It Yourself Projects

Do It Yourself Projects Anything that you have made up yourself. Rear storage systems etc

Reply
 
Thread Tools Display Modes
  #1  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default Another long term project....GFP

Hi guys, figured I might share my current long term project (GFP glutton for punishment)
My shorty is still going well but am now concentrating on my daily driver work ute. I picked up my Ford Courier 2006 PH 2WD work ute few years back, single cab with one of them beaut XL service bodies on the back. I was pretty happy with it and had already done many mods and whilst returning home from Alice Springs one weekend, the plastic tanks on the radiator let go and dumped most of the coolant, end result one buggered motor and a day long wait in the middle of summer in the middle of nowhere. Good mate rescued me later that night and we trailered the ute home.

Ive never been a huge fan of those bloody plastic radiators and by all accounts they should be replaced around the ten year period otherwise you face risk of losing a good motor which in hindsight I found out. Long story short, it was put on the back burner for couple years during which time I started sourcing the never ending list of parts to rebuild it. First purchase (it took some finding) was a proper copper/brass radiator lol. Looked at many options for the motor replacement and even picked up a PE courier XLT 4x4 dualcab from a local as a donor vehicle. Sadly the engine in that wasnt great as they had tinkered (sic) with it. But it wasnt a total loss as I scored a safari snorkle and many extras like electric windows etc which will turn the standard GL ute into XLT.

Was doing some think tanking one day as started to consider changing the original 2WD to the 4x4 chassis (donor vehicle) which I much preferred. Naturally I wanted to keep the awesome service body and single cab so needed to firstly find out if that could be achieved onto a 4x4 dual cab chassis. One thing I learned about fords they thankfully kept a lot of things unchanged and after finally tracking down the factory line drawings I discovered that yes indeed I could do the conversion as the cab mounts and body mounts were basically identical, with a few mods as expected.

First step was stripping out the dual cab 4x4 and removing the cab and body, engine, trans...everything, right back to bare chassis. At this point I made some chassis stands to support it in the workshop. Did some final checking of dimensions and confirmed it could be done. Removed the rearmost cab mounts and left the six front mounts as is, the single cab will drop on perfectly. Thankfully all other considerations were spot on also, gear shifters etc match up identically so the cab conversion side will be easy. even the electrics have no issues, it appears they basically used universal looms. I might add, doing a major project such as this is so much easier when you start off with a bare chassis, so easy to work on.

Then I did the same with the original ute, stripped it down, cab and body off and onto castor mounted stands. Carefully removed the two front pairs of body mounts as these got welded to the 4x4 chassis so as to keep it 100% factory. Whilst the 4x4 chassis is bare I will basically go right over it, new suspension bushings, heavier torsion bars, upgrade rear springs with 40mm lift, boss air bags, shockies, the works! Will add some more tomorrow which will take me up to current status and include lot of pics....catch you then!
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #2  
Old 2 Weeks Ago
Nab Nab is offline
Valued Member
 
Join Date: Mar 2012
Location: Perth
Posts: 1,376
Default

Sounds like a cracker of a project, can't wait to see the pics!
__________________
SOLD 2004 NP 3.2 auto
NOW 2014 Ranger XLT auto
Reply With Quote
  #3  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

As far as the engine goes I knew the head was history and was confident the bottom half should be ok. Bought a brand new head and stripped the engine down. The bottom end wasnt too bad and still had good honing marks which I expected from an engine that had 200,000 clicks. My only concern was a few minor heat marks from the rings on the bores but considering the cost I plan on going over the bottom end regardless. End of the day, set rings and bearings and it will be a pretty good engine. Once overhauled It will get new injectors, glowies and an upgraded turbo not forgetting a nice paint job. Then once its in chassis and before the cab goes back, I will be building a new custom exhaust, full on 3" dump pipe and split system culminating each side into polished stainless drop boxes under the service body, in front of the rear wheels. Should look sick and sound cool. For now the engine goes on the back burner as there is a huge list of other works that need doing first. Few pics showing the cab and body on stands, the frame i made for safely lifting them and couple of engine.
Attached Images
File Type: jpg lifting frame 2.jpg (70.0 KB, 14 views)
File Type: jpg on stands.jpg (81.8 KB, 14 views)
File Type: jpg head2.jpg (115.6 KB, 13 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #4  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

I carefully removed the rearmost dualcab cab mount and front body mount, then removed the two front pairs body mounts from the 2wd chassis and after making a jig based on the line drawings, I was able to reweld the body mounts onto the 4x4 chassis. Its now setup to accept the single cab and service body and still retain factory mounts. When I first got the ute I fitted a set of 50mm lift blocks under the service body which helped get it to a better height for access (ole back needs looking after) With the 4x4 conversion I went one huge step better. I wanted to be able to add extra mods under the body so I decided on building a subframe as a platform firstly to secure extras such as water tanks, air tanks and extra fuel tank. The frame also doubles extra support to the chassis as Im fitting Boss airbags which are a great thing but have a history of damaging chassis as they introduce a pressure point that was never allowed for in the first place. The frame was originally going to be 50mm but i figured what the heck, whats another inch, so body gets 75mm lift.
Attached Images
File Type: jpg mounts removed.jpg (79.1 KB, 14 views)
File Type: jpg chassis stand 2.jpg (87.8 KB, 16 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,

Last edited by blackdragon; 2 Weeks Ago at 10:37 AM.
Reply With Quote
  #5  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

more pics
Attached Images
File Type: jpg body mount.jpg (124.4 KB, 8 views)
File Type: jpg bodyframe.jpg (124.9 KB, 8 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #6  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

Ok getting the hang of this, picture size was too big, make em smaller
The big planned mod was my custom rear step bumper/ rear body frame/towbar/twin swing out tyre carrier and jerry can rack. Obviously a structure that will have some weight in it but as it has a multitude of purposes I had to be clever on the engineering side and build it to purpose whilst still retaining strength and staying in the lower confines of weight. Primary importance was the need to have a stable base for this to hang from so I incorporated fish plates under the rear of the subframe that ties in both the subframe and end of chassis and spread the load as good as possible, terminating at the rear spring hangers/40mm lift.

Then it was onto the rear step bumper that served the base of the rest of the rear frame/towbar etc. One of my favorite means of keeping weight down and still retain strength is drilling hole saw holes where largely unseen. You would be surprised how this lowers weight. Once its finished I will use 50mm plastic plugs to fill the holes. The whole concept of this bumper and rear frame will enable 100% concealment of all electrical wiring which creates a really neat professional job. And if you need to ask, yes it was a painfully slow job drilling those holes (ive lost count) but on serious note, its not that hard, use plenty of coolant and you breeze thru them. I think I used two holesaws which isnt too bad. For those that dont know, Im a boilermaker/motor body builder by trade and enjoy challenges like this custom work.
Attached Images
File Type: jpg rear chassis and 40 lift.jpg (89.1 KB, 9 views)
File Type: jpg stepbumper1.jpg (186.7 KB, 9 views)
File Type: jpg stepbumper2.jpg (185.8 KB, 9 views)
File Type: jpg step bumper3.jpg (84.2 KB, 9 views)
File Type: jpg stepbumper4.jpg (82.7 KB, 8 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #7  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

You should be getting the idea where this frame is going, it matches and protects the rear of the service body and is all encompassing as its a solid rear bumper (capable of hilift jacking points) twin swing out tyre carriers, towbar/recovery points (including recessed small/large trailer plugs, anderson plug, 12v acc socket and water outlet. As always, I do like my lights and there will be standard LED tail lights across the bumper plus duplicated on the top frame with high level strobing stop lights, LED reverse lights, full width slim line LED light bars at top (work lights) plus extra small red LED marker lights up both sides of the vertical posts. Provision of course for number plate in the middle. Where poss they are all recessed and protected, again, all wiring 100% concealed.
Attached Images
File Type: jpg sb5.jpg (99.5 KB, 8 views)
File Type: jpg sb6.jpg (73.8 KB, 7 views)
File Type: jpg sb7.jpg (79.4 KB, 8 views)
File Type: jpg sb8.jpg (73.6 KB, 6 views)
File Type: jpg sb10.jpg (95.6 KB, 6 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #8  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

At this point I needed to mount the service body and then align it all with the stepbumper frame and get it tacked in position, dry fit so to speak. Made the drop down side plates and attached with small jigging bolts, these will eventually be 16mm HT bolts. Mounted the stepbumper frame and corrected alignment as required, tacked in position and ran few welds to maintain position. Once its all nutted out, it will be removed for full welding. Again, holesaw holes to keep weight down. Once I was happy position was secure, continued on with the spare wheel mount towers and other framework required to mount the brackets that will house the four 10 litre jerrycans. I went with 10 litre jerries as much easier to lift up and empty as well. Added benifit, if one leaks, you only lose 10 litres, not 20.
Attached Images
File Type: jpg sb11.jpg (78.5 KB, 8 views)
File Type: jpg sb12.jpg (166.0 KB, 6 views)
File Type: jpg sb13.jpg (179.3 KB, 6 views)
File Type: jpg sb14.jpg (193.4 KB, 6 views)
File Type: jpg sb15.jpg (151.9 KB, 8 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #9  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

The pics give you some idea of how great those LED tail lights fit in. Also one showing the low profile plastic plugs filling the holesaw hole...neat hey.
Attached Images
File Type: jpg sb16.jpg (174.2 KB, 7 views)
File Type: jpg sb17.jpg (182.0 KB, 6 views)
File Type: jpg sb18.jpg (83.5 KB, 6 views)
File Type: jpg sb19.jpg (50.8 KB, 7 views)
File Type: jpg sb20.jpg (191.6 KB, 5 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
  #10  
Old 2 Weeks Ago
blackdragon's Avatar
blackdragon blackdragon is offline
Member
 
Join Date: Apr 2014
Location: tennant creek, NT
Posts: 206
Default

More pics, showing the primary over centre latches for the tyre carriers which will be supplemented with secondary latches above the two tower posts, even thou the swing outs are solid enough and pivot on those awesome stub axles, you still get movement, vibrations etc, so i like to add secondary anchor to minimise that. You may have noticed the two recessed holes on the main bumper, these are again support points for the swing arms as there are coned shape urthene bumpstops that mate into the holes when the arms swing closed.
Attached Images
File Type: jpg sb21.jpg (53.7 KB, 6 views)
File Type: jpg sb22.jpg (49.4 KB, 6 views)
File Type: jpg sb23.jpg (66.2 KB, 5 views)
File Type: jpg sb24.jpg (72.5 KB, 6 views)
File Type: jpg sb25.jpg (181.2 KB, 6 views)
__________________
'91 NH SWB (import) intercooled turbo 4D56T, Manual, factory mags 31x10.5 15's, alloy bulbar, snorkel, UHF, Rhino alloy rack, sunroof, bonnet bug deflector, LED light bars, driving lights, air bags, new shockies, polished stainless rear ladder, GPS, on board air, telescopic rear light, 60ltr fridge/freezer, dual battery system plus aux batteries, comprehensive set gauges, security system, air horns, on board solar panels, roof lightbar/spotties, worklights, towbar, rear bumper lights,
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Pajero long term storage Travel Tragic Generation 4-4 Pajero 10 30-04-20 08:11 PM
Dobinson's MRR long term review sharkcaver Where the rubber hits the road. 23 19-01-19 02:59 PM
Long term Chip users westward Generation 4-3 Pajero 32 10-02-14 04:49 PM
Long term plans TC.Barky Generation 2 Pajero 22 18-09-12 08:01 PM
Long Term Storage justcruizin Generation 4-1 Pajero 8 20-02-11 08:47 PM


All times are GMT +10. The time now is 08:18 AM.


Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2020, vBulletin Solutions, Inc.