Not So Modest 2000 (Gen 2.5) Montero Build

[zerodrift]

where did you get front Fog lights? is that pretty much plug and play?

Fog lights were acquired on eBay as an OEM replacement. I believe the brand was Depo and the pair of lights were around $130. Direct fit, however I'm not impressed with the overall light output of these units. For the price I think I'd go an aftermarket looking back on it.

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[newworld2004]

Fog lights were acquired on eBay as an OEM replacement. I believe the brand was Depo and the pair of lights were around $130. Direct fit, however I'm not impressed with the overall light output of these units. For the price I think I'd go an aftermarket looking back on it.

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Thank you !

 

[zerodrift]

The interior is coming along, but I'm waiting for seat brackets, so I've taken the project to a different direction for the last week. I've taken steps to resolve the fading paint finally! It's still curing, but it's looking promising so far! It's tinted Raptor Liner in the factory color! It looks good in the garage light, but I'm keen to see what it looks like in the sun once fully cured.

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[PacS14]

Nice progress! The liner instead of paint was one of those things that I planned on maybe adding to the to do list, now seeing pictures it looks promising, but I think I will keep the silver, if I ever do pull the trigger on it. Thanks for sharing!

 

[zerodrift]

Thanks- It's certainly a different look, but it's extremely durable from what I'm told and my limited experience setting tools down on the hood. Looking back at the finished product I'd suggest sticking to a matte finish, and if going with a red- opting for something a little more bright. The factory burgundy color is neat, but I'd honestly like it to be a little more red with the texture... That said I'm really enjoying the skid feel of the doors now! They feel substantial and close with a very solid and quality feel.

New parts have arrived! The exterior is mostly buttoned back up and my attention is back on the interior. More to come later!

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[zerodrift]

Progress has been made and I'm really enjoying seeing everything go back on the car. Snorkel is back on, as are the wipers and new window visor things! The other main success is the status of the electrical install, which is mostly complete now. Getting everything to fit was a task, but honestly one well worth doing right. Stitches are in process and will go in when the center console is reinstalled. Once the electrical project is 100% finished, I'll put together a guide of what I've done so others can follow if they are keen on a similar setup.

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[Swank Force One]

I swear we had already had this discussion before, but the search function doesn't really work on this forum anymore with the new update.

Where did you get those rain visors? Just install with double sided tape or is there an actual securing mechanism on the front ones at least?

 

[zerodrift]

I swear we had already had this discussion before, but the search function doesn't really work on this forum anymore with the new update.

Where did you get those rain visors? Just install with double sided tape or is there an actual securing mechanism on the front ones at least?

I picked up the visors from eBay. They are from a company called WellVisor and the quality seems good/average. Certainly worth the price point in my opinion. I'll get some close up pictures later on.

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[zerodrift]

To answer the other questions- yes,there are physical clips in addition to 3m double sided tape. The clips go underneath the rubber trim and is a fairly solid connection, but honestly seems to me it's just a secondary support to the tape. See pictures...

Other projects include prep work to the differentials. Thanks to a forum member (JeepandMontero) I've a set of 4.63 differentials and the rear is a factory air locker. These still need a little attention, but are nearly ready to install!

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[MrGalantguy]

Heck yeah man...great progress. Love what you done with the electrical work...very clean!

Where did your source out your projector retrofit lens? This is a project I am looking to tackle in the near future.

 

[zerodrift]

Heck yeah man...great progress. Love what you done with the electrical work...very clean!

Where did your source out your projector retrofit lens? This is a project I am looking to tackle in the near future.

Thanks! I picked these up on Amazon. The name was DDM Tuning retrofit mini H1 2.5" projectors. These are a snug fit but it seems to be ok so far. I didn't check alignment when I did the install and they are angled down a bit too much currently. I'm in the process of adjusting these but the mechanical adjuster is skipping a bit. If you try the setup sure it's closely aligned before putting it back together.

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[zerodrift]

Recent progress has been made installing the stockpile of parts. I'm currently installing the front differential and hit a few snags.

First up- the new poly bushings from Adventure Driven Design for the transmission mount have a smaller width than the factory mounts. Are people just using washers to shim the bushings or is there another preferred solution?

Next up- the passenger side cv-joint mounting flange on the new housing has a slightly larger bolt pattern than my old unit. Based on a rough estimate when measuring the two opposite bolts, the new (older) unit measured 123mm whereas the unit that came out of my car measured 120mm. What is the best solution to fix this? Swap cv joints, or the half shaft itself? I'd prefer not taking the whole front differential assembly out at this point, but certainly will if needed.

Here are some picture of the progress. New bushings were a task to install, but went in fairly well! The quality seems great compared to some of the other poly bushings I've experienced in the past.

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[tlr]

Did you swap to the ADD front diff mounts also? Rig is coming along great!!

 

[zerodrift]

I did swap the diff mounts. I ended up using some washers to shim the new mounts as they are a little more narrow than the oem units.

I have everything buttoned up in the front and installed the new torsion bars that just arrived! I'll install the remaining skid plates after I tackle another oil change and general maintenance.

The rear differential swap was attempted yesterday, though my attempts were ultimately futile. The axle shaft and brake shield bracket were really stuck and all attempts to separate were unsuccessful. I'll likely be outsourcing this to a shop that has a larger press.

More progress to come!

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[tlr]

Awesome thanks. You'll have to report back on the ride of the torsion bars. How's the electrical write up coming along?