LJ70 Build Thread!

[Paddler Ed]

Here you go Steve:

 

[froggy Steve]

sweet
Steve

 

[Ben]

Thanks guys.

No I havent come across inch ants or paralysis ticks yet.

Fingers crossed I don't!

This week has gone so quick! I've been working on LJ everynight till 10pm and shes finally ready for my 4 day Otways trip.

No time for an update tonight as I'm exhausted and have to be up for the gym at 5am tomorrow.

Got loads of pics to update you with when I get chance though.

 

[AndyCook]

Amused you are going to Otway
since one of the Geological/geophysical seismic projects I use for software demo's is from cape Otway
an onshore/offshore oil field!

screenshot attached - Port Phillip Bay on the right


I look forward to seeing what the place looks like - take a photo if you see any Rigs!

 

[Jimbo4x4]

Here you go Steve:

I see your offensively titled Australian product and raise you:

In the UK though we're all prudes and need to * out the offensive bits...:

 

[Ben]

Amused you are going to Otway
since one of the Geological/geophysical seismic projects I use for software demo's is from cape Otway
an onshore/offshore oil field!

screenshot attached - Port Phillip Bay on the right


I look forward to seeing what the place looks like - take a photo if you see any Rigs!

Thanks Andy, I will see what I can do.

The plan was to drive back along the great ocean road but I dont think Michael is going to want to do that while running the 37"s. Hes trailering them to one of the guys houses who lives nearer the national park, as he doesnt want to wear them out on the road or risk getting pulled by the police.

I see your offensively titled Australian product and raise you:

In the UK though we're all prudes and need to * out the offensive bits...:

 

[Ben]

Amused you are going to Otway
since one of the Geological/geophysical seismic projects I use for software demo's is from cape Otway
an onshore/offshore oil field!

screenshot attached - Port Phillip Bay on the right


I look forward to seeing what the place looks like - take a photo if you see any Rigs!

Thanks Andy, I will see what I can do.

The plan was to drive back along the Great Ocean Road, but I don't think Michael is going to want to do that while running his 37" tyres.

Hes actually trailering them to one of the guys houses who lives nearer the national park, to save wearing them down on the road or risk getting pulled by the police.

I see your offensively titled Australian product and raise you:

In the UK though we're all prudes and need to * out the offensive bits...:

 

[Ben]

Well guys I'm finally home after yet another epic adventure!

The trip to the Otways was absolutely awesome! Loved every minute of it!

I took far too many photos as always.

+ I got all the pics that 3 of the other guys had taken so I've ended up with 1200 pics to sort through, resize, upload and write about.

Also got some great videos.

So the trip report is going to take a while, but I'm sure it will be worth the wait. It was a really tough trip and we drove the hardest tracks in the area.

Before then theres one little update about what I did last week.

Work first.............................

I've been making more battery trays.





These are some special order 40 series ones I made.



I got sick of not having a completely empty bench and not having enough room to lay all the trays out when I weld them all up, so I made a shelf to put all the stuff off the bench on.





Back to the Frankenzuke build next.......................

I'd filled in the rear arches where I'd cut them to clear the big tyres, but still needed to do the fronts.















Arches done I could fit the new front shocks that had finally arrived from ARB.











It was then time for another test drive. As Micheal needed his 37" Trep's back for our trip we put a set of 34" Interco Trexus's on.

Even without diff locks the Jimny drove up and over all the rocks and was very stable and didnt feel tippy.















We drove it and around and even at 70-80 kmh it felt safe and drove just like a normal 4x4. Which is pretty amazing really considering I welded all the axles, trailing arms, panhard rod, steering bars etc all up myself.

Obviously the geometry of the suspension must be reasonably good.

Since fitting the new auto box the engine occasionally goes into limp mode and throws up engine warning lights. So its now going off to an automotive computer wizard who will fix it!





This is the rubber flare we've bought to try and cover the huge tyres. The widest one available.





OK back to LJ....................................

I needed to replace all 6 bushes in the trailing arms. So I found the part numbers and called the Toyota dealer we use for parts. Even with my 40% discount they still wanted $90 per bush and the ones which mount the arms to the chassis were out of stock and would have to come from Japan which would take a few weeks.

So I spoke to my boss about my options. As LJ gets used hard off road and twisted up a lot he recommended that I fit rubber bushes like the originals and don't go for the easily available polyurethane bushes like Super Pro sell.

So I gave him the measurements and the next day he gave me these, $20 each.



I hoped the press at work would press them out.





Got one out.





I managed to press one bush out but the press wasnt powerful enough to press the others out.

So Michael took them to a local garage and used there 65 ton press to get them out. Apparently one of them went up to 64 tonnes before it finally started to move.

He also pressed the new ones in.





After work on Thursday I pulled LJ in the workshop and began changing the arms/bushes.





The only bushes I had to press in were the genuine Toyota ones on the chassis end. The 20 ton press pushed them in perfectly.





They wernt quite the right size bush in that the tube in the middle was 10mm too long. But for the price of them and the fact we couldn't get any others I decided to use them and cut the tubes down.

So I cut 5mm off each side.



On the band saw.



And then cleaned them up with a file.







One side done.



After removing the bolt on the chassis end of the other arm it was clear this side was even worse than the other side. I could move the arm up and down a lot, the bushes were that worn.









I developed an oil leek on the last trip but couldnt trace exactly where it was coming from.



So we put LJ outside and Michael steam cleaned the engine bay and underneath for me.



With the new bushes fitted we needed to do some electrics under the bonnet. The terminal I'd crimped on the power lead from the battery to the starter had come loose and recently I tried starting the engine and just got a click click click.

So Michael crimped a new terminal on, this time using the proper tool.





After heat shrinking the new terminal he fitted some rubber covers over the battery terminals.





I still needed to replace the rear window that I put one of the forklift tines through.

Michael picked me one up from one of the local wreckers yards for the bargain price of $60.



Cleaned the glass and removed the old sticker.



Tint next.









I then got one of my work mates to help me pop the new piece of glass in place.



I got the modified rad cowl and electric fan fitted.

Whilst lying on my back under LJ bolting it in place Spot came and kept me company.





I got it fitted but it didnt have quite as much clearance as I'd have liked between the pulley on the front of the engine and the motor on the fan.







With the engine running at full throttle the engine didn't move forwards so I hoped the small amount of clearance I'd got would be enough.



I got the camping gear loaded in the back of LJ.



And then greased all the UJ's on the prop shafts.





Then I was ready for my Otways Adventure.

More on that soon.

I've been out today and invested my tax rebate in a big tool box for work. I've always wanted one and now I'm doing a job where I need one.

 

[warrenpfo]

Another great update, can't wait for the trip report. How do the tools compare to say halfords professional range over here. It looks a nice setup.

 

[Paddler Ed]

What grease did you use for the UJ's; I've got to do ours (and the cardon joint) on the 4Runner at somepoint soon - ideally before I drive 500km+ down to Sydney.

 

[Ben]

Another great update, can't wait for the trip report. How do the tools compare to say halfords professional range over here. It looks a nice setup.

Thanks mate.

Id say there easily as good as the Halfords pro range if not better.

The mechanic at work has the same tool box and hes had it a few years and its a good quality box. He didn't get the tools with his, he just bought the empty box.

One thing I liked is that its come with some good tools, but I've still got loads of empty drawers to put all my own tools in so I can have all my tools together in one big box and then just wheel it to where ever I'm working in the factory.

What grease did you use for the UJ's; I've got to do ours (and the cardon joint) on the 4Runner at some point soon - ideally before I drive 500km+ down to Sydney.

I got it from the local bearing place. Its high temp, high pressure waterproof grease. Basically the same marine grade waterproof grease I use in my wheel bearings but in a grease gun cartridge/tube.

 

[Paddler Ed]

Oh on the tool box Ben, make a couple of flat bits of steel with a bend in the bottom and a hole in the top, so that you can lock the drawers shut.

Imagine a tyre lever but in 1" wide steel... that's the sort of idea.

Couple of the guys I used to work with had those on their tool chests in the workshop for when they weren't in.

 

[Ben]

Closing the lid pushes down on 2 rods at the back which lock all the drawers. You then turn the key in the cylinder to lock the lid down.

Definitely well designed.

 

[fridayman]

I'm really enjoying seeing all the fabrication. We're looking for somewhere to live now and I've add a very large shed to my must have list (just below swimming pool).

I've decided its time for an intercooler on mine - have you looked into this yet? Although I already have most of the parts for a stock setup, I'm leaning towards an aftermarket top mount with a bonnet scoop and electric fan.

 

[Ben]

Finally Melbourne is having great weather!

6pm and still 29 degrees!



I took the new tool box to work today and then spent most of the morning sorting my tools out.



Just about to start on the trip report!

I suspect this one is going to take me the longest yet.

I've got far too many pics to go through.

Will be worth it though as it was an awesome adventure!

I'm really enjoying seeing all the fabrication. We're looking for somewhere to live now and I've add a very large shed to my must have list (just below swimming pool).

I've decided its time for an intercooler on mine - have you looked into this yet? Although I already have most of the parts for a stock setup, I'm leaning towards an aftermarket top mount with a bonnet scoop and electric fan.

Thanks mate, I'm really really enjoying my job. I love designing and fabricating stuff.

Yes I'm seriously thinking of fitting an intercooler to LJ soon. It well help lower the EGT, something which is especially important in a hot country.

If you go down the top mount and electric fan route I'd very much like to see which kit you buy and what you think of it.

The best systems are the water to air intercooler systems, there a lot more efficient and effective. I know Michael runs one on his 12v 80 series and my boss runs one on his 24v engine in the 79 series ute.

 

[fridayman]

I looked into the intercooler setup a bit more today, and now I'm not sure anymore. If I could move the aircon pipework and modify the grill mount, a front mount could be an option. I think I could fit a larger front mount than top mount and then I wouldn't have to worry about heat soak or messing about with fans.
I still need to look into what a water to air setup would cost.

 

[grantw]

Now that's a tool box!

 

[Ben]

OK Trip Report Time....................

I dont normally like splitting the trip reports into sections, as I find it can become a bit disjointed when people read day 1 and then have to wait a few days/week until the next bit is up. But its too big to post as one so here goes.......................................

Day 1.

I stayed the night at Erins so we wouldn't have to set off quite so early in the morning.

So 2 classic Toyotas together.



We soon hit the road for the 1 hour drive to Danny's house. Danny works for 4WD TV and is friends with Michael and had kindly said we could meet at his house and that he would show us all the best tracks in the Otways.



A quick 7am ice cream stop on the way.



We got to Danny's house and Justin soon turned up with passengers Andre and Ben. He had a bad steering shake/wheel wobble so wanted to change a wheel.





We soon hit the road and headed to the Otways National Park.





We stopped at a bakery on the way for breakfast and last minute supplies from the supermarket.



Michael stopped to get fuel and I had a quick look under LJ's bonnet as the engine was still over heating.



We were soon back on the road.



And soon turning off it.





A brand new 200 series LandCruiser in front of us.



He had just bought it and had the owners manual out and was working out how everything worked.



We passed him and carried on.



We soon got to a very big steep hill with multiple tracks running up it.



We stopped and aired down, locked the hubs in and clipped mudflaps out of the way.









Michael told me I was going first, so with 1st low engaged and both air lockers flicked in we crawled our way up to the top. We had a few nervous moments as we lifted front wheels while driving over a few large steps, but we got to the top.



Everyone made it up and we continued with our journey.





We could see a mine and/or power station below, but more on that later.





















Next to the power station they were mining coal. Talking to Justin he told me that they mine coal there purely to feed the power station and the power station is there to feed electricity to a big aluminium foundry in South Australia.



It was a gorgeous day and we were driving on sandy tracks, and not the mud I was expecting, but that would come!

















Past a few motorbikes.











Past some old cars.





And onto some more challenging tracks.

















Passed a few nice houses.





We pulled up at a camp ground to use the toilets. We were thinking of coming back to stay here later.











We soon hit the tracks again.



The next track was very washed out with deep ruts and soon LJ was on 3 wheels again!







It actually felt quite close to going over, so I asked some of the guys to weigh down that corner for me.











A short distance later the guys behind radioed to say I was dragging a branch underneath me.





It had split the sidewall but the tyre wasnt leaking so I decided to leave it.



While stopped I explained to the guys that LJ was still overheating and the electric fan didnt seem to be working. I said Id fix it that night at camp as I didnt want to delay everyone, but they said I should fix it now.







The fan was too close to the engine and the bolts on the bottom pulley had severed the wires. So the plan was to pull it off and try and fix it.






















The fan was soon off.











We worked out that by removing 2 of the plastic spacer rings we would be able to mount the fan a lot further forward and so away from the bottom pulley on the engine.







I needed to remove some of the metal on the cowl to make it work.



Luckily Mr Gadget man Michael now carries a 240v angle grinder.

















We decided to test that the fan still worked ok as id taped around the frayed wires.



Bloody thing wouldn't work.



I tried opening up the motor on the fan to investigate what the problem was but it was a sealed unit and I couldnt get it open.



We were all discussing where we might be able to get another fan from and the fact it was now mid day on a Saturday and everywhere would be closed when Justin ver kindly said "I've got an electric fan on my intercooler you can use".



A bit smaller but a working fan all the same.



We bolted my fan blade onto the motor and the motor bolted straight up to my mount.







Poured the lost coolant back in.





Im very grateful for Erin for taking all of the above pics of me working on LJ. While working away I happened to ask Erin to take a pic as it was a "significant moment".

Well for the benefit of any of you guys reading this who haven't spent much time in the company of Ozzies, their the biggest piss takers I've ever met! Great people but love to take the piss out of each other all the time!

So for the rest of the trip from then on whenever I got my camera out or something happened they would all be like "ooh is this another significant moment"?

I told them its for the fans, and they were like what fans and I was like the thousands of people who read my blog!

Well then they were like "oh you mean you view it 999 times and Erin was the other person to view it"!

And I would hear them say that a lot over the next few days.

Anyway back to the story..........................

With LJ's fan fixed we hit the tracks again.

















Justin was soon winching.













As I was driving along I could hear air gushing out of the front tyre.

We pulled over and it was clear that there was crap between the sidewall and the rim.



We tried cleaning it out with a tyre lever and screw driver.



But it was no good so we had to take it off and do it properly.







We used the highlift jack and the back of Michaels 80 to break the bead.











We cleaned out the one side and then re-seated the tyre.



Then popped the other bead and cleaned out all the mud.







And finally we hit the tracks again.











Michael got stuck and had to winch.



Then it was my turn in LJ.







I gave it my best shot and for a moment it looked like I might get through, but I ended up getting stuck and I too was soon winching.









With the 2 LandCruisers up it was Justins turn in the mighty Patrol.







I love how blue the sky is over here. Quite often there isnt a cloud in the sky and the sky is such a vivid beautiful blue!



Sorry....back to the story...............

After Justin had winched himself to the top we had to wait while a guy in a near standard Patrol got stuck and then proceeded to try and winch himself free. He clearly didnt know what he was doing so the guys helped him out and got him moving.







The next track was insane!

Huge washed out deep ruts, and big rock steps!



Michael went first.























Through the little creek and up the other side.



It was my turn next in LJ.













Safely down and through the creek at the bottom.







I started driving up the other side with both lockers engaged and the passenger wheel came off the ground and due to the angle LJ was now on I was convinced I was going over! Luckily it all happened very slowly and I was ready to hit reverse at any second.

But I held it and waited to see if it would go over or not.







The guys quickly came over and jumped on the front for me.











By the time LJ was safely up the other side, Justin was almost down the first section.







We drove to the start of the next track and when we got there we found there was 2 entrances to it. A steep technical one and an insane one!

Michael tried the insane one.









With all 3 lockers engaged trying to scale the near vertical climb he suddenly lost drive to his passenger front wheel.

He had sheared all the bolts off holding the flange on.













Michael and Danny decided to drive a few k's to the nearest place with phone reception to try and source a replacement hub, and me and Justin continued onwards and upwards along the track.





The following pics dont do the track justice for how steep it is and the crazy angle we were on. We could see nothing but sky and couldnt get over a particularly large rock step on the steep climb.















Ben pulled my winch rope out and hooked it to a nearby tree and I winched LJ for the next 20-30 meters.

We made it to the top and I had a look at the map Danny had lent me.



We managed to get Michael and Danny on the radio and worked out where they were and drove to them.



Danny had posted an SOS on the 4WD TV facebook page and they had had a few offers of 80 series front hubs. So they set off to get a hub and get the 80 fixed while the rest of us headed for camp.



We passed a pond at the side of a track which some one had put a sign up which had clearly been taken from a town center some where.





We headed to the camp site we had stopped at earlier in the day, but when we got there there were quite a few people there and there were a few families with young children.

Now one of the reasons we come away on trips is to get away from people, and I knew wed want to stay up late drinking and chatting round the fire, so I decided we should find some where better and I had just the place in mind!

We passed a lovely green grassy area in some woods on the last track so we headed back over there and set up camp.









Andre decided to be anti social and do his whole Bear Grylls thing and sleep in the forrest.











Awesome end to a great day! Roaring fire and ice cold beer!





Andre killed the fire!





But fortunately I had some used engine oil with me!







I cooked dinner for Erin and I.

Steak, mash and tinned veggies!



We then sat around the fire till the early hours drinking beer and chatting.

So thats day 1. The other 2 days of the trip were just as eventful and fun and I will get the trip report written asap.

 

[clivehorridge]

Great report Ben, as usual 11 out of 10

As a (very) distant observer, I can't help thinking that airing down may be giving you more problems than advantages. I know the theory is sound, but wouldn't it be more appropriate to air down when you need it rather than a matter of course? I've done the same, and without beadlocks I've had the same problems with debris between rim and tyre. Only my opinion in the comfort of my living room, of course!

Did fixing the fan fix the overheating problem? I hope so!

I know what you mean about the bluer than blue sky, it's like that here! Amazing!

Now looking forward to day 2

Thanks Ben, a lot of work posting, but great entertainment!

Cheers!

 

[Ben]

Thanks Clive.

With these tyres your right I shouldn't be airing down, as Chris pointed out theirs no advantage as they don't bag out and flex like normal tyres anyway as the sidewalls are too stiff.

In hindsight I shouldn't have aired down, but I thought I would be ok just airing down from 30psi road pressure to 20 psi.

I used to air down to 10psi in the past.

Nah still overheating.

Ended up driving home with the bonnet slightly open to try and get more air flow, did even consider taking it off completely!

The general consensus is now that I need to get the viscous fan put back on as the electric fans just cant suck enough air through the rad.

When I fitted the electric fan I knew that 2 other members in the club had fitted electric fans on their KZJ70's. But then they didnt have accurate after market temp gauges fitted, they didnt have a big bull bar on the front and they didnt drive the most extreme off road terrain they can find.