Buildup Thread: "Project 'Melon"

[60seriesguy]

I've never had a centralized buildup thread before, so I thought this time I'll post all pictures in one spot!

The goal is to build an expedition vehicle capable of traveling safely and reliably to remote areas, primarily in North America. I mostly travel solo or with my best friend, but as my boys (currently 3.5 and 1 year old) get older, I expect to do a lot more traveling with the family.

I grew up on expeditions all over South America, but flirted heavily with rock crawling and heavier wheeling for the last decade and a half (since moving to the US). I tried my best, but never truly enjoyed the type of wheeling that results in heavy damage, too many years of indoctrination around preservation of the vehicle's integrity to enable the return home prevents me from doing so. As a result, my previous buildup was a compromise between an expedition build and heavier wheeling, with mixed succcess. This time, I'm going for a dedicated expedition rig and it's my intention to avoid "experimenting" and focus on the modifications that I *know* work. Time will tell if I am truly successful...

The platform is a 1999 UZJ100 Land Cruiser that I purchased about 8 months ago in Scottsdale, AZ. It was clearly a lightly-used commuter car and it's in excellent mechanical and cosmetic shape. I don't particularly care for the color, but I couldn't pass on the deal and I can always hose it down with a better color later.

This is an intimidating project to me from a technical standpoint, because it's the first of eight Land Cruisers I've owned that's automatic, fuel-injected, or depends on electronics to run. But I'm trying to learn as I go and look forward to the challenge.

The plan, in no specific order, is to add:

* Steel wheels with BFG AT/KO 285/75R16s
* OME suspension + Slee diff drop kit
* Front ARB Locker
* Front bumper
* Rear bumper with spare tire/ladder
* Custom skid plates
* Sidebars
* INTI roof rack
* cargo management solution
* Safari snorkel
* Warn M10000 w/synthethic rope
* Extra foglights
* air compressor/Co2 tank
* onboard shower
* Seat covers
* extended range fuel tank
* dual battery management system
* 2M/CB radios
* GPS

Although not technically part of the buildup, I will also be adapting my current expedition trailer to better match the new truck. Another work in progress, the trailer features a MARE roof top tent and provisions for extra fuel, water and coolers. More on this later.

I'll be adding to this thread periodically as the buildup progresses.

 

[60seriesguy]

I already have the Warn winch, a leftover from my previous buildup. I intend to overhaul it and replace the steel cable with synthethic rope and use a hause fairlead instead of the roller (which is frozen from rock rash anyway).

I also already have the INTI roof rack, it's a 3/4 length rack with light/antenna/sand ladder mounts and a custom storage box. I plan to replace the original gutter clamps with AO rail mounts, I'm pretty sure I can make that work cleanly.

 

[60seriesguy]

I had planned to start this buildup much earlier, but the first obstacle I encountered was formidable and even made me second-guess my choice of the 100 Series as a platform...I couldn't find steel wheels!

I don't want this thread to turn into a discussion about the merits of alloy vs. steel. I am not questioning the strength and weight advantages of good-quality alloy wheels, I am merely stating that it's my *very personal opinion* that an expedition vehicle should have steel wheels. I've seen too many cracked alloy wheels in the bush before, and I've seen an equal number of steel wheels getting pounded back into a workable condition at a campsite. This isn't about logic to me, it's about experience and personal preference. So I set out to score a set of steel wheels, only to hit a stone wall. There are currently *zero* aftermarket steel wheels available in the US with the 5x150mm bolt pattern of the 100 series, and the extreme backspacing needed to match the OEM wheels (6 and 7/8") made most custom wheel sources balk at the prospect. I explored the possibility of sourcing OEM wheels out of my native Venezuela (a logistical nightmare under the current political climate) or even sourcing a used set of OEM wheels from another country and shipping them here (an expensive proposition). Nada, no progress.

Months went by and I spent hours searching online, checking and cross-checking seven different Toyota parts microfiches. I reached out to my small network of non-US parts sources (I drove a non-US truck for 11 years), and still couldn't get a straight answer. Toyota NA has recently clamped down on the activation of non-NA parts into their system (despite earlier successes), and the wheels I'd identified (16x8" steel wheels) clearly fell under that category. I was getting discouraged, but kept up the effort, I considered it a personal challenge.

Finally, after sourcing not only the production code of an HDJ100 that met the trim specs needed, coming up with the VIN numbers and production dates of three different Land Cruisers (don't ask...), and waiting patiently (OK, going nuts next to the phone), I got the word that a set of wheels had been sourced!

Now came the risky part. I had to place one order without knowing 100% if the wheels were the right ones. I was fairly confident in my research, but still, this would be a costly gamble if they turned to be the wrong wheels. So I placed the order, was told I'd had to wait around twelve weeks, but less than two weeks later, I got word that the six wheel I had ordered had arrived....

And here they are! Toyota OEM 16x8" steel wheels with the same exact dimensions and backspacing as the OEM alloy wheels on US-spec UZJ100s. They're plain, they're heavy, and to me, beautiful!

 

[Desertdude]

Looking forward to following your build.

Any need or plans for updating the suspension?

 

[HongerVenture]

Henry,
I'm really looking forward to following your build. However, this thread needs pics! I won't say its worthless without pics because I've enjoyed reading so far... but I'd LOVE to see the simple, steel wheels you managed to source.

And the 100-series as well.

Or are pictures excluded for future-publishing in OJ?

Joel

 

[60seriesguy]

Whoops! Thanks for bringing it up, I totally forgot to mention the suspension, probably because I already have portions of it. I plan to do a combo OME + Slee diff drop kit, maybe add some trim packers to balance the stance with the trailer hooked up.

 

[60seriesguy]

Here are some pics of the wheels. The comparison is with an OEM alloy 16" wheel. As you can see, the dimensions are the same. I like how the hole for the valve stem is tucked in behind the flange.

 

[60seriesguy]

Here's a couple of poor shots of the backspacing measurement for both wheels. Interestingly, the steel wheels have a DOT number stamped on them (?), you can see it right to the right of the measuring tape. The last shot shows a closeup fo the wheel on my workbench.

 

[60seriesguy]

I need to order tires this week so I can get rid of these "bling" chromies...gag!

 

[60seriesguy]

Here are a couple of shots of the Land Cruiser, prior to any significant mods. All I've done so far is "de-bling it" by removing the offending gold emblems! The last shot is from the day I took delivery of it, parked next to my old rig.

 

[60seriesguy]

And just for the heck of it, here's a couple of shots of my little expedition trailer, in it's latest iteration.

 

[Willman]

^I like it!

What type of RTT is that?

:chowtime:

 

[Sgt Grunt]

Henry,

Can't wait to see your progression...

I have sold my 80 and am looking for it's replacement... I am thinking Tacoma or 100, so this will help in my research.

 

[upcruiser]

Sounds like a great project, I'll be into following it as well. Each year that passes I find myself lusting for a 100 more and more. I like that color too.

 

[60seriesguy]

^I like it!

What type of RTT is that?

:chowtime:

MARE, made in Venezuela. Similar in build and style to the earlier Eezi-Awn.