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At last I have had some time to finish off the roof rack. Here's the final product:

GRRRRRRRRR...... The right hand side knuckle that I rebuilt 2 weeks ago is weeping oil/grease again. D@mn. Either the breather is blocked, or the small groove worn in the drive shaft where the oil seal fits is worse than I thought. I've disconnected the breather, to be sure. I'll test it over...

Even with the 4 feet currently, I've had a spare wheel and 5 bags of wood up there with no problem. I don't really plan to have too much weight up there - a few jerry cans of diesel, some equipment, the side awning and the swag bags. Probably 100kgs at most.

Yeah maybe next time..... I think I need to learn how to weld aluminum and make the feet and flat bar out of that, or else it will end up being too heavy. Has anyone successfully welded aluminum with a MIG? Or is TIG the answer?

Yeah, I've seen those designs. The problem is that there is a slight curvature in the gutters and I don't trust my fabrication skills yet to match the curve. :-)

Did the other knuckle today. looks like who ever did it before me did a little of a bodge job :icon-cry:. They used a chisel to tighten the BIG nut. Swivel bearings were dry and needed replacing. Anyway, all grease up now and should be ok for the next few years.

I've just used a whole tub (500grams) of CV grease, and about a third of a 500g tub of wheel bearing grease for one steering knuckle.

Got my back seat back, on Monday too. Got them covered with grey canvas. Should give some protection against the kids and dog.. Hopefully the front seats are done soon.

Over the last weekend I rebuilt the front left steering knuckle, put a new studbolt in where the old one had broken off and glued all of them in place. Although its a relatively straight forward its a real PITA to do - not to mention the cleaning required. I also took the opportunity to paint...

Tomorrow I'm gonna get these fixed up. The upholster will replace the leather on the front seats and make a canvas cover for the back ones.

Ok thanks - I'm a great supporter of keeping things simple and reliable, rather than going full out and overloading with every single available gadget. I suppost you've just got to go along with what you're comfortable with. Water, food and Fuel being most important.

Hi, great trips you have had. What kind of equipment did you carry around with you? Both for camping, emergency, tools etc and also mechanical spares

Also to note from the StopTech site: "One last note on the DOT ratings: Systems designed for a particular type of fluid (especially prior to the wide distribution and use of DOT 4 fluids) should continue to be filled with that fluid. For example, in a car that was delivered with DOT 3 fluid...

I think the bolt has actually broken off, I tried pushing a skrewdriver in to check but it only goes about 1cm in. I hope there is a bit of the bolt sticking out on the other side which would make it easier to remove...

Clive I've got that T-shirt too and damaged paint work under the reservoir on the Volvo - not going to repeat that mistake again. Thanks for the tip on draining the brake fluid Chris. I'm planning to replace the oil seals on the from axle in a few weeks time (not looking forward to the mess) -...

Good point there Clive, I'll check the pads. Cheers

Yeah - I figured the seals needed replacing. In preparation of stripping the front axle I did some cleaning today.. hmmm arn't there supposed to be 4 bolts holding the steering arm :think: Are they just stud bolts or something else? Anyway I'll head over to the dealer some time and find out...

This is what I did - lets see how it goes....

Thanks that might be it - the break fluid is about half way between the min and max marks, which is triggering the warning light as the fluid sloshes around. I was thinking the light meant something to do with the hand break...

The warning light next to the parking brake light, looks like (!), comes on intermittently. What does it mean and how do I make it go away?

I made my feet 130mm high and gives a gap of about 30mm between the roof rack and the center of the roof. This allows me to fully tilt my sunroof open with about 10mm to spare.

I found this interesting article on wikipedia: http://en.wikipedia.org/wiki/Exhaust_gas_recirculation My main concern from the article is that EGR introduces carbon particles into the cylinders which cause additional wear on the parts. How do you disable the EGR? Do you just pull off the...

Hey Chuggy, welcome - we're practically neighbours. I'd love to do a tour of Bots some time.

Thanks, whats the advantage of the EGR system ( other than reducing emissions)? And what are the consequences disconnecting the egr?

There was a lot of crud buildup in the intake manifold section which stretches over the engine - it looked like oily soot :think:. I presume this comes from the EGR system. Is this normal?

I thought I would start a thread documenting the progress on my 1996 80 series, 24 valve. She's in a generally good condition, just the usual oil seal leaks etc. I'll post some pics of her shortly I've already fixed some oil leaks on the valve cover. The next jobs I plan are: - Seats to be...

Ok, I finally got some time to take the valve cover off. Why on earth did Toyota place a bolt right at the back behind the cover... :eusa-snooty: Anyway, it seems that a rivet worked a little loose resulting in the pipe moving around a bit. I just used some metal glue on the inside and outside...

Hey Blown80, Great looking truck there --- I like the wine rack --- a good way to justify all the "repairs" to the missus. I'm looking building some removable drawers to place in the tent for those longer stays. Do you mind posting some more pics of them and how they work. Cheers James

Thanks for the advice - I'll build accordingly. I'll probably add another 2 pairs since I have already half finished them, and that it gives better weight distribution.

Thanks . I'll let you know how I get on.

Morning Has anyone got any experience using one of these to drive a big relay for split charging or for an auxiliary power outlet (eg for a fridge). http://www.towbex.co.uk/100230/info.php?p=3&pid=619845&ack=9 Ive got one lying around the house and would like to use it if its suitable...

Thanks. I saw that post and it inspired me. I made 4 of them feet and stuck them on the rack - nice and sturdy. I want to make another 4 so that I've got 8 feet holding it up. Heres a pick of me testing them: Still need to finish them off and tidy them up a bit

Lol, yeah I was thinking that it would make a good sleeping place.. just need to build a tent, or just sleep under the stars

Then a few licks of paint I have some old roof bars which I used just to see what it looks like on Betsy (my cruiser): Tomorrow I'll get some aluminum sheeting from the wind deflector. And I need to get some ideas of how to make the feet - I'll appreciate any ideas or tips on building feet...

Then came the top frame and the vertical upright supports: I used a 25mm hole saw to cut the coping at ends of the tubing to form a snug fit.