Author Topic: Chris's 2004 2wd Hilux Workmate build #CrawlMate  (Read 7125 times)

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Aus_Mallcrwlr

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Chris's 2004 2wd Hilux Workmate build #CrawlMate
« on: Jun 09, 2016, 01:23:54 AM »
Some of you on here may know me from Facebook, recently deleted it, sick of the Bs. So thought I'd throw a build up thread on here of my Hilux. It was an old work ute from the family business I purchased for cheap and moved all of my parts out of my old unreliable crawler into.

Basic specs are:
2004 2wd Hilux Workmate
2.7 3rz with 200,000kms.
Currently g52 manual but plan to go R151 in the future.
Dual 2.28 transfers with Trailgear adaptor and Twin sticks.
Fj80 front diff, lock rite Auto locker, custom double shear steering setup, Braced housing, Psc 8" single ended ram.
2010 Hilux rear Diff with full spool. 4.88 gearsets.
Box front shaft, Pto tube rear shaft.
2wd rears up front Spring pack, 2010 Hilux rears, rear springs Inboarded 3" each side.
Tm Fabrications plate shock towers in the front, F250 towers drenched into the chassis in the rear.
Chassis had had 240mm taken out of the centre to shorten the wheelbase. Current wheelbase is 104".
Full hydraulic steering using 8" Psc ram, Psc resovoir, inline finned cooler, High flowed V6 commodore pump, Eaton orbital.
Front and rear winches and suck down winch in the rear. Most likely other stuff I've forgotten.

Basically built it to be a fairly capable but basic setup, reliability being the key. It runs the stock fuel setup, moved around to work with the shortened chassis, all accessories wired to a separate dual battery to keep the original wiring intact.
Engine is left Stock apart from the commodore steering pump.

37x12.5r17 Blue label Krawlers on 17x9-30 Dynamic steel wheels with DesignFab beadlocks.

All stock interior, still running the 3/4 bench seat and has working Air con.

Future plans are to Exo cage it and run a seamless internal cage.










Aus_Mallcrwlr [OP]

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The old crawler, had engine and wiring issues. Was parted out and kept all the axles, transfers and various other pieces for the new build.



After being stripped.


Aus_Mallcrwlr [OP]

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The 2wd as I bought it.





Chassis cut, shortened and fish plated back together.








Aus_Mallcrwlr [OP]

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Boxed in the rear of the chassis using a towbar I had and added recovery points and a winch mount.





Rear tube work.



Standard fuel tank mounts reused with the stock tank.




Dimpled rear tray made for space case/toolbox and can also see the rear inboard Spring mounts on the inside of the frame. They bolt through a crush tube in the chassis and tie the whole lot together.





Tire mount added.



Rear all mocked up with axle under.


Rear ended welded off and painted.

[I[URL=http://s1198.photobucket.com/user/Chris_Yarrow/media/FC3F6C0B-7957-4F3A-872D-0107AEF7FF1F_zpstnycyrnz.jpg.html]MG]http://i1198.photobucket.com/albums/aa455/Chris_Yarrow/47222AF9-F5C1-4CDD-83F5-9DB87AAFA614_zpsrqpnb4sc.jpg[/IMG][/URL]


RATCATCHER38

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Hey mate! I was following your build on FB. So glad you have moved it onto here. This is a safe place to share your rig haha. Looking forward to seeing more updates!

Aus_Mallcrwlr [OP]

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Rear end all back together. 2010 Hilux rear axle installed, this matches an fj80 front for width and is also an 8" third member.



2wd suspension all removed and frame cleaned up, shackle tubes installed.



Front shock towers modified to clear the steering column.



Shock towers installed.



Painted.


Aus_Mallcrwlr [OP]

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Hey mate! I was following your build on FB. So glad you have moved it onto here. This is a safe place to share your rig haha. Looking forward to seeing more updates!

Cheers! Yeah figured I should put an actual build thread somewhere for it

Aus_Mallcrwlr [OP]

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Factory 3rz-w series bellhousing on the g52.



Dual transfers installed, unfortunately I didn't flat belly it. I didn't want to hack the body up to much. Will be building a solid belly pan on it to protect the transfers.




Aus_Mallcrwlr [OP]

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Thought I would throw some pics up of the FJ80 Axle and my double shear steering setup.

Housing was shaved and had leaf perches added, I made it a bolt on deal with one u bolt on the pumpkin side and a normal setup on the other.





Then the double shear was doing using a rhd lower arm and a lhd lower arm to have the tierod in the front. Made my own top arms with a press fit pin to locate the trunion bearing. The lower arms have been tig welded to the knuckles.




Aus_Mallcrwlr [OP]

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Few pics of the Full hydro setup.

Orbital mounted above the frame so I could use the standard steering shaft and keep the orbital out of the interior.





Power steering pump mount on the 3rz, it uses a high flowed v6 Holden commodore pump, these are easy to find here in Aus and simple to high flow. I keep a spare in the toolbox. I also added a brace afterwards to stop the mount flexing under high revs.



With Psc Ressy mounted and brace added to pump.


RATCATCHER38

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Cheers! Yeah figured I should put an actual build thread somewhere for it
Yeah it is great having it on a forum as you can scroll through it down the track and remember all work you've put into it haha.

Sing out if you every bring the bus down to Tassie.

OVRAROK

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nice build. I like seeing these "other continent" build threads  :thumbs:
Even the most primitive society, has an intimate respect for the insane.

Aus_Mallcrwlr [OP]

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Knocked up some sliders before dinner this afternoon. Mini kick style with a dimpled sheet. Yet to weld off fully and make mounts.








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Aus_Mallcrwlr [OP]

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Got the sliders tacked on to work out mounts. Welding fish played to the chassis with tube and a gusset.






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Aus_Mallcrwlr [OP]

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Reworked my f250 towers in the rear as they were limiting travel with the 12" shocks. It was using all the stroke of the shock on both up travel and down travel but still had more left in the leaves. I swapped the 12" 5125's for some 14" stroke 5125's. I cut the top of the f250 tower off and flipped them and remounted them to the under side of the rear stays on the rear cage. It's now using all of the 14" shock but I'm happy with the travel, I'll be adding bumpstops and limit straps yet. Anyway pics-













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OVRAROK

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looks great, I like how you stuck some "c" channel into frame to gain some inward clearance
Even the most primitive society, has an intimate respect for the insane.

 
 
 
 
 

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