Hi-5, the 1972 Hilux Pickup turbo project

Thread in 'Project Cars and Builds Threads' started by james, Mar 15, 2017.

  1. MC2

    MC2 Active Member

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    I haven't enjoyed a post so much since the driftworks builds and some lad from the VW scene who bought a red S14. Love it.
     
  2. Threadmark: Front towers and manifold fit
    james

    james Administrator
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    Work continued with the front suspension towers. The Hilux has its damper top mounts onto the subframe and that's all gone now, so we need to make some strong suspension top mounts for the mx5 coilovers that are separate from the inner wings and mounted to the subframe and crossmember

    20170323_164712. 20170324_110901.
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    That should hold it! It'll get welded inside and some triangulation added in when things get taken apart again, but for now that'll do nicely :)
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    Also got to trial fit the turbo manifold and downpipe, just needed a slight tweak to clear the chassis, but otherwise a very good fit :)
    download_20170323_163620.
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    but now these bits are where they need to go, it needs pulling apart again and the cab dropped back on to see how it all interacts...
     
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  3. Threadmark: Cab chop
    james

    james Administrator
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    we have a rolling chassis!

    20170327_115357.

    no front springs fitted currently, so it's sat on the bump stops
    20170327_115416. 20170327_115640.

    Then the cab goes back on to see how it all fits. It's around this point of lowering the cab on that it's asked whether I should have made it into a jacked-up offroader...
    20170327_120022.

    So a quick trial fit of the engine reveals that we need a bit of bulkhead work. This was always going to be the case, we just weren't sure how much.
    Turns out quite a bit needs to come out :smash:
    20170327_150831. 20170327_151201. 20170327_151659.

    and it's in!

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    There's not that much of the engine poking into the cab, but the shape of the old bulkhead was wrong and the tunnel was teeny, so it needs to come out..
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    So there's still quite a bit to do, but it's progressing well :)
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    One issue that's come up is the gearstick location which is currently under the bench seat :smash:
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    So we're going to need to make this type of arrangement, but the other way around DSCN2306. metro43. metro44.
    and have a floor mounted gearstick like this
    s-l1600 (1).
     
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  4. Cruuz

    Cruuz New Member

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    Absolutely fantastic build! I'm doing much the same thing except with an '80 hilux and an awd Mitsu eclipse. Following this
     
  5. james

    james Administrator
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    no updates for aaaaages! I've been away then other projects here have got in the way, but we're back on the Hilux now.

    So with the engine in place, it wasn't looking like we can keep the pedals and master cylinders in place and keep the standard inlet manifold
    20170517_111855.

    So the old one was cut up
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    and fabrication started on a new one

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    We also had a slight interference issue between steering column and chassis rail :smash:

    20170612_145709.

    That was plated up so it's nice and strong again and the new subframe bolts either side of it so should add a fair bit of strength back in
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    So I've now got a steering column attached to the front wheels. won't be long before a nice Nardi makes its way on there...

    20170613_104722.

    Craig also turned up a cool boss so I can use a small modern Nissan brake master cylinder and servo alongside the original clutch master cylinder

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    Then the rest of the bulkhead can get made up and welded in place


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    once we have this next phase done, the cab will come off again so the tunnel and bulkhead can be welded nicely from both sides.
     
  6. james

    james Administrator
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    Hopefully this won't create an inception-style loop in the fabric of spacetime as these link to each other, but progress has been good lately, so here's our latest video showing where we're up to :)
     
  7. NYA

    NYA New Member

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    Just read all this after watching the video. I have to say, this is such a cool project, and one i'd love to have the time and space to do myself. The mating of an older shell, with a modern engine is just perfection, and give you the best of both worlds. Awesome stuff, keep us updated. :D
     
  8. james

    james Administrator
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    More build updates!
     
  9. james

    james Administrator
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    and more!
     
  10. james

    james Administrator
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    Got it 95% done for Matsuri!
     
  11. Drifter X

    Drifter X Member

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    Such an unbelievably cool car, are you happy with the power figures? Not tempted to put some forged rods in and turn it up to 300? :rolleyes:
     
  12. james

    james Administrator
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    I've still got a few bits to do to get it how I want, but I'm really chuffed with how it's turned out so far :)
    Just needs a few of the rough edges ironing out like stopping the windows rattling in the frames :wack: upgrade the engine mounts to stop the engine trying to escape, redesign the rear camber arms as they're hitting the chassis rails on full compression and going to try and transfer over to use the original Toyota clocks
     
  13. james

    james Administrator
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    I've still got a few bits to do to get it how I want, but I'm really chuffed with how it's turned out so far :)
    Just needs a few of the rough edges ironing out like stopping the windows rattling in the frames :wack: upgrade the engine mounts to stop the engine trying to escape, redesign the rear camber arms as they're hitting the chassis rails on full compression and going to try and transfer over to use the original Toyota clocks
     
  14. james

    james Administrator
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    cheers. As it is at the moment, it's definitely enough for it to be fun. It's running about 8psi on actuator pressure and getting 220bhp. I might knock it up a little as Doug from G19 was saying they really come alive around 10psi, but I won't go much more than that on this I don't think. I'd much rather have something where I need to work a bit harder to go fast, but is 100% robust and reliable and I can just concentrate on driving it and having fun.
    It was real cool at the weekend to set out from home, drive to an event, do a load of skids and drive it home again
    MVIMG_20171119_072717.
     
  15. Drifter X

    Drifter X Member

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    I've got the full G19 works on my 1.8 and he's right in saying 10psi is where the real fun starts. It might also be worth running a more capable ignition system if you're going to turn the power up, Toyota COPs are a common upgrade and are good for north of 300hp, at which point you'll start bending rods.

    I'm running a slightly bigger VF35 turbo on the same manifold at the same wastegate pressure you're on so I think I'm hitting around 230, albeit with a misfire and an incomplete map at the moment, once I solve that I'd expect it to hit 235-240hp at wastegate before I turn it up a bit, which is probably where the TD04 would sit with a few extra psi. It certainly is an absolute riot even at 230ish.
     
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  16. mad.matt

    mad.matt Well-Known Member

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    You thought about using Speedhut gauges in the original binnacle?
    I know Chay bought a set for one of his cars and they do have a HUGE amount of options :)
     
  17. james

    james Administrator
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    Ohh, I haven't seen those before, but they're pretty cool. As you say, fully customisable, plus they do options like GPS speedo which would save a bit of dicking about.
    I'll have a go at merging with the old clocks and treat that as option B :)
     
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  18. orange_beastie

    orange_beastie Pickup driftin

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    Looks awsome dude glad to see another mini truck being built! Just need to get mine finished.
     
  19. Nathaniel Taylor

    Nathaniel Taylor New Member

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    What pipping\hose are you using in order to fit an air filter to the td04.can't find any the correct size
     
  20. james

    james Administrator
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    Nothing special. I don't recall the sizes, but I can have a look when I'm back at the workshop in a week or so
     

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