So this has been in the build for quite a while, will start this build from the start of this year. For the build details prior to that look here -
http://forums.minitruckin.co.nz/viewtopic.php?f=12&t=69

Engine fitment into dummy shell -

Cleaned up the crossmember ready for engine mounts, which were cut off the crossmember from the RX7. Will see how well they line up, may need to start from scratch if they aren't close enough. Sump should be here in the next few days, then its all on.


Sump being fitted up to engine -

Got busy late this afternoon once it cooled down a little, bolted together the W55, adaptor plate and 4V auto bellhousing. Fitted up the sump and pickup to the motor and then slotted them together. Found a few goodies in the motor that confirmed it isn't standard, looks like a set of Ross forged pistons. Got some measurements off the flywheel too so will see if I can find what its from.




Trial fitment -

Then I thought I should see how it fits in the engine bay, took a bit of jiggling but I got it in.



Seeing how it sits -

Clearance isn’t bad, will need to cut a bit of the tunnel to get the motor sitting a bit higher. Starter will be tight on the steering but may be able to offset the motor a little to help. Will pick up some cutting discs for the grinder tomorrow and get it sitting in a better spot. Looks like I will need to use the remote filter setup which came with the motor and look at an AE86 sway bar from Whiteline, supposed to give a little more clearance for the sump.




A bit of cutting -

Got the angle grinder out and dealt to the tunnel, basically just need to lift it up a bit to suit the bigger auto bellhousing. Gearbox is pretty much in the same spot as with the 18RG, maybe 10mm back. Engine is sitting approx 35mm above the factory crossmember which sets the sump basically level with the bottom of it. Factory starter is a no go, so either a smaller starter or reverse mount one on the passengers side through the bellhousing. This would mean either moving the clutch fork or I will probably go for a hydraulic release bearing as the simpler option (although more costly).



Mounts will come down straight onto the crossmember, will probably need to look at some sort of pedalbox arrangement as well and maybe ditch the booster unless I want to offset the motor a little. Height wise will definitely involve some sort of bonnet scoop, will probably go for a factory style look and just increase the height of the standard hump. The other option is to cut the hump from the spare Hilux bonnet I have here.

Engine mounts made -

Mounts tacked up, will be final welded once the crossmember has been mounted into the proper car. Should have more pics Thursday.


Callum

 

Fitted into the proper shell -

Game on.


Engine in and mounts fully welded. You may note that the drivers mount on the crossmember is further forward than the passengers, this is due to the block mounts being the same each side but with the V8 the second bank is offset rearwards from the first.

Dropping off a spare bonnet tomorrow to get cut up for clearance checking, then we can make a decision on what sort of bonnet scoop based on the height I need. Currently the aircleaner is sitting against the bonnet framing so it shouldn't stick through too much, will need clearance for the distributor cap as well.

Bonnet clearance -



Holes cut in the bonnet, front edge of the aircleaner is around 60mm above the bonnet. No luck trying to find a steel BA Falcon bonnet bulge so need to resort to fibreglass. May need a little modding to get it high enough but my panelbeater has a lot of glassing experience so will be no problem.



Bonnet finished -



Bonnet bulge is on and front guards are finished, very happy with how it came out and how it blends into the factory body lines. Should have pics with the front bumper on tomorrow evening.



Prepping for primer -

Getting prepped for a quick coat of primer before taking it to Auckland next week, should have assembled pics tomorrow hopefully.




Ready for 4 and Rotary Nats 2010 -

Picked the ute up tonight, got it home and swapped on the proper rear wheels. I think I need to raise the front, but for the Nats I'm just going to drop the back instead.








Loaded up for the long tow -



All loaded up to head off to the Nats tomorrow, going to be a LONG trip.

Callum

 

Pulling it all apart again -

When last seen, the ute was tucked away in Hamilton looking a little sad.



Finally got it and my trailer home so talked to my panelbeater and its going in for the chassis bracing this week so needs to be stripped right down. Time for a reverse jigsaw.







Ran out of daylight but have only got the steering column and the fuel and brake lines left to come out. Have to leave the diff in so I can move it around.

Hanging it upside down -

Rotisserie time.




Most of the underseal has been stripped off ready to start welding. Will be starting on the bracing next week then onto fitting the swaybar and traction brackets as well as recessing the diff head bumpstop to suit the new ride height and the larger diff.

Bracing started -

A start has been made on the bracing.




All the bracing is folded up from 2mm panel steel so it adds a lot of strength without too much weight. Will brace right along the sills and tie into the leaf mounts. Will also brace across to form the mounts for the traction brackets. Where the gearbox mounts are is going to be extended rearward to tie it all together and provide a good mounting point for the driveshaft loop. Tunnel needs altering at the rear to lift up the diff head bumpstop as well as provide a bit more driveshaft clearance.
Certifier is supposed to be in town next Wednesday so want to get of it done by then if we can so he can have a good look and make any recommendations.

More bracing work -





More bracing work done, will get more pics on Wednesday.

Getting strong now -

More progress, really starting to take shape now. Definitely no worries about flexing any more.





Will get more pics tomorrow.

Cleaning up -

A little more progress, cleaned up the extra bracing and working on tidying up a few bits on the towbar mounting and where the Surf rear bumper mounts tie into the Corolla floorpan. Also found a spot of rust in one sill that has been fixed up.






Traction brackets -
Certifier didn't show up today, apparently will be next Friday now. Diff is back in though and work is starting on the traction brackets using adjustable Camry rear arms. Also test fitted the AE86 swaybar and should be pretty easy to mount.







So while we wait for the certifier the panelbeater will get the traction brackets all finished, mount up the swaybar and clearance the tunnel for the diff head by raising the bumpstop.

Callum

 

Undersealed -

My first set of quads has shown up now just waiting on the second.


Underseal all done, forgot to clearance for the diff head though so still need to cut and weld a small section.






So should be back on its wheels some time next week, then I can take it home and re-assemble it so they can finish the outside and gearbox tunnel off.

Since then, I have got the underseal stripped from the inside and the front suspension and engine back in. It has been dropped back to the penelbeater and he should be back on to finishing the gearbox tunnel this week. Then it's start from the back and work forward until the bodywork is all finalised.

Callum

 

WOW ive never seen anything like this done before and i cant wait to see it finished. i'll definitely be following this build thread closely

 

Eat your heart out picture whores!

Crazy build you got going on there mate! I just started to burn metal, got some ideas running thru the head now.... Thanks!

 

WOW that thing is so dope

 

very cool ..


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Work has started again, did a deal on my Hilux for panel work as well so saved me dealing with dropkicks with no money when trying to sell it. It has now become a shop hack.



So tunnel all tacked up, will be getting final welded now we are happy with the clearance. Then starter motor to be relocated when the motor is back out to tidy up the engine bay side of the firewall.

Callum

 

sweet! progress is lookin good

 

So tunnel is now finished and I need to drop off a bunch of body panels to be fitted up, will be starting at the back and working forward so need rear bumper, tailgate, doors and seats at this stage. Also re-doing the clutch setup using AE86 bits as I wasn’t that happy with the ratio on the modded cable pedal. Ordering a smaller clutch master cylinder to give plenty of clearance to the motor, will probably run a remote reservoir. Looking for a smaller booster too, or may offset it for more room.



Callum

 

Very nice work ..

I would sure like to see some pics of the transition between the box and cab .. rear window work ..

do you have any pics of this ?


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I will dig some out for you and post them, as it was originally a stationwagon they basically cut the roof off, capped the sides, pillars and back of the roof. A section of the roof was used for the back wall of the cab but will be changing as part of the electric rear window setup, using a stamped toyota section for a Hilux tailgate.

Callum

 

Many of the older photos are hosted here -
http://hackedcorollaute.shutterfly.com/
If you look in the folder called re-inforcing it shows a bit more detail of the back of the cab.

Callum

 

that my friend .... is some seriously dedicated work .. I'm not sure if your a genius or just stupid !! NICE work ..

what has your time line been on this project , how many months/years now ?

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The original conversion was actually done by a friend of mine who had it on the road for a few years before pulling it apart for a rebuild and larger motor (was running a 3T, he upgraded to an 18RGEU). He ended up selling it to another friend part way through in order to finish his V8 2WD Toyota Surf, they also lost interest and I picked it up very cheap. Took me about 8 months to get it all back together and driving, then it sort of snowballed after we pulled the screen to do some rust repairs before getting it legal. Got screwed around on a sodablasting job before we painted it and decided there was no point doing a half assed job. I think I've owned it for about 5 and a half years now, want to be driving it again by January. There were a lot of gaps in the build, big delay while sorting the sodablasting, changing paneebeaters, saving money etc.

Callum

 

I get it totally .. check out my build .. 3 years now !
I look forward to more pics ..

again .. nice work and cool build


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Saw an auction I couldn’t resist so now have some bigger brakes to play with. 4 pot calipers and 315mm discs from Toyota Celsior/Lexus LS400, should do the job and fill out the wheels a bit better than the Altezza stuff and are actually very light too. Now I just have to make them fit.




Callum

 

I always wondered about the 4 piston LS400/430's calipers. (like how heavy they are)

My 95 2 piston ones are heavy like you wouldnt know. Good luck mounting them. The issue is getting the rotor centered on the hub. The rest is easy.

 

Yeah I currently have Toyota Altezza RS200 discs on it but haven't sorted caliper brackets yet, using Crown 5 stud hubs that have already been machined down to suit the centre bore of the disc which is the same as the new ones. The two piston calipers are definitely pretty chunky. Looking to change struts at the moment just to make the caliper bracket easier to fabricate.

Callum