CA18_Sean's HJ75 Troopy - Build & Restore Thread

[mongoose2231]

oh man, your truck is t**s! loving the troopy. Always wanted one. Had to settle for for a 60 diesel but maybe in the future. Keep going with the build, will be watching.

 

[andrewh]

COUGH UPDATE PLEASE COUGH!

 

[ca18_sean]

Soon! Ordered a full 2H diesel engine gasket kit that was somehow available in the US market... so that's cool almost done with my 4Runner, so my attention can shift to the troopy! First up is axle rebuilds and possibly a rear locker.

 

[ca18_sean]

Couple updates



Threw it on jack stands and pulled the front fenders to start rust repair and prep for axle rebuilds.



Sandblasted to reveal the previous owner's rust repairs. Rivets and glue with galvanized sheet metal.



Rust underneath.





Rusty sections cut out with a plasma cutter.

 

[ca18_sean]

Weld through primer applied to areas I won't be able to paint after the panel is welded



New piece of 18 gauge sheet metal cut and bent to fit. Welded it in.





Welds cleaned up and primed for now. Still need some slight body filler and sanding but good progress. One more fender and 4 more rusty spots to fix still...

 

[paynemw]

updates?!

 

[Stoffregen Motorsports]

Gotta love rust repair...

 

[ca18_sean]

Rust is terrible... been knocking it out slowly but surely. I haven't been updating this thread as much as I should, so here's some updates!

Sold my 4Runner. The new owner is in Iowa but he's already taken it to Colorado. Seems to be loving it, so that makes me happy

IMG_9202 by CA18 Sean, on Flickr

IMG_9195 by CA18 Sean, on Flickr

On to the troopy!

First thing I did, axle rebuild. Used Terrain Tamer kit with Koyo bearings.

ImageUploadedByTapatalk1441840664.929457 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1448321300.015576 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1448321416.823427 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1450301150.330965 by CA18 Sean, on Flickr

Decided I needed new hubs. The ones that came on it weren't OEM Aisin, and they had slight cracks. Found these on Amazon.

ImageUploadedByTapatalk1450301298.359693 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1450301337.594667 by CA18 Sean, on Flickr

Fit perfectly. Added spacers too.

ImageUploadedByTapatalk1451600847.015198 by CA18 Sean, on Flickr

 

[ca18_sean]

Went ahead and did new shocks too.

ImageUploadedByTapatalk1451600816.811023 by CA18 Sean, on Flickr

New steering components. 555 Japan.

ImageUploadedByTapatalk1451600783.725960 by CA18 Sean, on Flickr

Centramatic wheel balancers.

ImageUploadedByTapatalk1446414849.387721 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1451695446.693070 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1451695457.840719 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1451690468.429323 by CA18 Sean, on Flickr

 

[ca18_sean]

Added switches and wiring to the stock instrument cluster:

ImageUploadedByTapatalk1449186715.462421 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1449246410.927550 by CA18 Sean, on Flickr

Removed a ton of wires that the PO installed that weren't going to anything anymore.

ImageUploadedByTapatalk1449186760.397848 by CA18 Sean, on Flickr

Got the snorkel partially installed. Still need to build the connection to the factory airbox. I may try and get a hold of a factory snorkel airbox from Australia. Not sure how hard this is gonna be...

ImageUploadedByTapatalk1451950468.956737 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1451950480.756843 by CA18 Sean, on Flickr

Put a coat of the 058 White paint on the fenders to see how it will look. No clear, just making sure I liked it. I do

ImageUploadedByTapatalk1449010074.110807 by CA18 Sean, on Flickr

 

[ca18_sean]

Next up, roof rack! I want to hold my mats, some boxes of gear, and my roof top tent. And I wanted LED lights on the front.

ImageUploadedByTapatalk1451950649.206445 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1452027946.459866 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1452027955.308449 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1452461610.567648 by CA18 Sean, on Flickr

Built it at my shop, then took it home to test fit on the troopy. LOVE it. Still need to add a mesh floor to the front and possibly some sort of a ladder. I may end up running the Front Runner ladder on my spare tire.

ImageUploadedByTapatalk1452461620.885496 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1452463146.929193 by CA18 Sean, on Flickr

 

[ca18_sean]

Grabbed a couple new parts. Radio bezel, door seals, antenna, and knuckle studs with torx fasteners from a newer LC.

ImageUploadedByTapatalk1453913005.940771 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1453912975.103517 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1453912931.532083 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1453912916.551472 by CA18 Sean, on Flickr

Also did some rust repair behind the front fenders while I had them off. Since no one will ever see this I didn't bother making it as pretty

ImageUploadedByTapatalk1453304604.395887 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1453304614.065688 by CA18 Sean, on Flickr

ImageUploadedByTapatalk1453304623.449274 by CA18 Sean, on Flickr

 

[ca18_sean]

I decided I can't have a tough TJM front bumper and a beat up stock bumper. So again, sketched it up and made it!

IMG_9467 by CA18 Sean, on Flickr

Decided to use the existing trailer hitch as my base to attach to the frame. Turned out great.

IMG_9469 by CA18 Sean, on Flickr

IMG_9482 by CA18 Sean, on Flickr

IMG_9484 by CA18 Sean, on Flickr

IMG_9485 by CA18 Sean, on Flickr

rear bumper by CA18 Sean, on Flickr

 

[ca18_sean]

Went ahead and added a winch to the TJM bumper while I was making stuff. Just added a tray to the center to hold it. The bumper is aluminum but the brackets that attach to the frame are steel, so again this was pretty simple to do.

IMG_9530 by CA18 Sean, on Flickr

IMG_0109 by CA18 Sean, on Flickr

IMG_0113 by CA18 Sean, on Flickr

IMG_0112 by CA18 Sean, on Flickr

And now I think we're caught up!

 

[ca18_sean]

Here's how she currently sits. Actually not quite, I have pulled all the windows to do rust repair before heading to paint. I did have the bumpers sand blasted and painted, should be able to pick them up tomorrow. Plenty of other projects have been keeping me busy lately though, so who knows when I'll actually get around to finishing up the rust repair and going to paint.

IMG_9255 by CA18 Sean, on Flickr

IMG_9257 by CA18 Sean, on Flickr

If anyone is interested, this is my current project at work. I'm the mechanic/fabricator for a local geotechnical engineering firm. I was an engineer for them for 7 years, but desk work wasn't for me. Been running the shop now for 3 and I love it. Anyways, the project is mounting a soil sampling drill rig called a Diedrich D-25 to the back of an FLU-419 Unimog. It's fun stuff

IMG_9565 by CA18 Sean, on Flickr

This is a link to the build thread for that one:

http://www.benzworld.org/forums/unimog/2573250-flu419-diedrich-d-25-drill-rig.html