HZJ75 Overland Build

[roscoFJ73]

Thanks for the suggestions. I actually spoke to N&J a few days ago, and they came up with a quote for me for an aluminium box, but it was very pricy (around £5k with the VAT), without any shelving or other bits and bobs. I may try and simplify the design and get them to re-quote though. I guess the fewer corners and angles the cheaper it will be. I've also spoken to a company called Anglesey Camper Conversions. Does anyone know anything about them? I'm going to ask them to quote for something like the last pic that rosco posted. They specialise in pop tops, although I'm not sure how big they are on metal fabrication. A pop top would be awesome tho.

Some of the slide on campers in oz are made from aluminium sandwich foam built over a steel frame. I havent worked with sandwich foam before,but it maybe easy and cheaper.

Some more ideas here
http://compare.ebay.com.au/like/110953805628?clk_rvr_id=389634189131

 

[johnnystrom]

I just haven't been able to find anyone who I would trust to do a really good pop top camper conversion in the UK (and given the cost involved I couldn't afford to have it done twice if it went wrong), so the set up I think I'm going for will be two aluminium boxes fixed side by side on the back, with a roof tent on the top. Each box will be 100cm high (so the same as the height of the cab), 235cm long and 90cm wide. So side by side they will cover the tray area on the back. One box will just be for two spare wheels and storage, with 2 top hinged doors on gas struts. The second box will be kitted out with shelves/drawer and cupboards, with a cooking area and built in compartment for the water tank and water purification system etc. The whole side of this second box will lift up on gas struts, and there will be an awning room on this side too. I'm just waiting for the quote back from NJ Aluminium... Once the boxes are underway, I can get on with the mechical preparations. Although the design is a compromise on the "camper" design I originally had in mind, the plus side is that is has a lot more storage space, which is important as we're donating supplies to some charities along the way. So the extra space will be useful

 

[TonyS]

Hi Jonny,

That's pretty much what I have done with Betsy,my HJ47 in Australia, look at the pictures in the travel pages, Oz trip oct,nov dec 2011.


It works really well, was thinking of a roof top tent too, but just put down a swag if I'm On my own, or pitch tent if Becky is with me.


Cheers,

 

[TonyS]

Look here,

http://www.landcruiserclub.net/forums/showthread.php/43582-Oz-tour-Oct-Nov-Dec-2011

 

[johnnystrom]

That looks great Tony. It seems a practical set up, and looks the part too.

Hey Rosco, what shocks did you have on your 75? I'm thinking of upgrading, but not sure which ones to go for. I've seen Koni Heavy Track ones on eBay (item number 271036919975), but PRICY at nearly £300/pair!!

Then there are some cheaper ones on there from Australia (eg item number 120858660092) but those are a brand I don't know and the postage pushes the cost right up. I don't really know anything about suspension set up to be honest, but at the moment the ride is pretty hard and unforgiving, and I'm wondering if new shocks would be a good investment. The roads in northern Kenya where we're headed are supposed to be as bone shaking as anywhere, and I'll get brownie points from the wife if I can do anything to make the ride a bit more comfortable... (and it's her birthday today so maybe I can buy them for her as a "present"

 

[TonyS]

Hi Jonny,

On Betsy I have EFS suspension, with airbags on the rear. As she is old, and leaf front and rear, this set up is superb. The airbags help no end, and give a great ride, along with the EFS shocks. If you are interested in the airbags, Derek at LRS Offroad is worth contacting.
Devon 4x4 used to be able to get EFS, but not sure now, but there is a dealer in Europe somewhere. Put it along side Old Man Emu, it looks so much stronger.
I have the Konis on my hilux, cant fault them either, certainly up there with the best but they are pricey.

Come along to the cruiser weekend here next week, you can pick up heaps of ideas.

Cheers,

 

[johnnystrom]

Thanks for the info Tony. Until a week ago I thought air bags only lived in the dashboard But I'm slowly catching up. I do like the sound of your set up. I have leaves all round too. I think it's running on the original leaves, which I'm guessing are fairly heavy duty, but would you change those anyway if you were changing the shocks? From what I've read, the airbags sound like a great upgrade. My only concern would be if they go wrong. But am I right in thinking that they only complement the existing suspension, rather than replacing it, so even if the airbags broke the suspension would still work? I'll speak to Derek at LRS, but do you have any idea what I should be paying to have airbags supplied and fitted on the rear? Sounds like an expensive job..?

 

[TonyS]

It's always such a debatable job suspension, and like most things budget is the major player.
As I travel mainly on dirt roads in Australia, I try to keep as outback as I can, then the suspension needs to be right. For your trip, if you are on original suspension looks well used,I would change it all, but if the leaf packs look pretty good, then shocks, rebush, and airbags. The airbags should be a twin bellows type, mine are black Firestone ones, manually adjusted. You can get a fancy set up to adjust in cab, but I wouldn't bother.
The great thing with bags is that you can adjust to the weight you are carrying. If the truck is empty or carrying a light load most of the time, then they can have a minimum psi. Start to add weight for a big trip and pump them up.
They are the same as trucks and buses use, so strong as hell, and the ride really is great.
I don't know why they aren't used more here, as the the majority of vehicles would only be loaded up for a few weeks of the year for a holiday, and to have a heavy duty set of springs to run empty all year isn't the best ride. Likewise only using a light,medium spring when loaded, won't give you the best handling.
Down under they are so popular on any commercial pick up, when weight carrying changes regularly.
Keep us posted, this is an interesting build.

Cheers,

 

[johnnystrom]

Cheers Tony. I'm waiting for a call back from Derek. He sounds like a nice guy. And he knew exactly who I was talking about when I said someone with a Landcruiser pick up had recommended him! I'd love to come along to the Cruiser weekend, but unfortunately it's the same weekend as the Overland Show, which I need to get to. I'll definitely keep you all posted. Things should get more interesting next month once work starts on the aluminium storage boxes, and the baselining of pick up begins.

 

[Chas]

but unfortunately it's the same weekend as the Overland Show, which I need to get to..

Look out for my Green 80 with the Land Cruiser club sticker on the back, I'll be there Sat morning on my way to Lincomb. Probably at Julian Voelkers stand.

 

[TonyS]

Just a quite thought on the storage boxes. In one of mine I have a 50lt Waeco fridge, and second battery. The gull wing doors work well, and that fridge opens the same way. If I got them again I would have gone a few inches taller, so just go as big as you can!
I also have the small Waeco 15lt that acts as an armrest too, in between the front seats. Great for the chocolate and cold drinks?

 

[johnnystrom]

So it was a busy few days back with Julian Voelker at Overland Cruisers last week. First up was draining all the oils and then checking the axles. The CV joints and bearings (which looked and felt like new) are cleaned and repacked...
View attachment 4271

Then shiny new discs and pads are fitted. This cured the bad judder in the brake pedal on braking......View attachment 4272

And new rear brake cylinders. The old ones were almost completely seized up, and with worn pads on the front it's not surprising it wasn't stopping very well...
View attachment 4273
Then a neat little trick to bypass a defective seal between the gearbox and transfer case. When the seals fail the oil ends up filling the transfer case so the level is too low in the gearbox and too high in the transfer case. What Julian did was link the fill/level plugs on the gearbox and transfer case and then blocked the breather on the transfer case. As the transfer case heats up, any surplus oil is pumped back in to the gearbox. Once the levels have evened out the two boxes breathe happily through the gearbox breather. A very simple solution to what could be an expensive problem, particularly running a gearbox with low oil levels...




Next step will be the custom built rear and fit out!

 

[johnnystrom]

Just a quick update. I've now dropped the truck (or "Tonka" as my wife and I now affectionately call him) off with Roger Young Fabrications in Plymouth (http://www.ryfabrication.co.uk/quadtechs.html). No prizes for spotting that Roger Young are Land Rover dealers, but that aside I felt very happy leaving Tonka with them for the construction of the rear body. After looking a several "budget" options, I eventually decided to just bite the bullet and get a full Quad Tech rear body built. They are eye-wateringly expensive, but 1) look a lot more factory fitted than bolt on aluminium boxes, and 2) have incredible rigidity and strength. So the old tray comes off and the new body gets bolted directly to the chassis on a custom built cradle. The rear light cluster will also be replaced and incorporated into the new body. Roger Young impressed me with their coach building heritage, and I had no doubt that they know what they're talking about. All being well I should be picking it up in 4 weeks, and then loading it with the overlanding goodies that I've been storing in my office...

 

[TonyS]

Going to be a great overlander with the full back on it. Keep the pics coming. What have you decided on the suspension? Any thoughts on the airbags?


Cheers,

 

[roscoFJ73]

That looks great Tony. It seems a practical set up, and looks the part too.

Hey Rosco, what shocks did you have on your 75? I'm thinking of upgrading, but not sure which ones to go for. I've seen Koni Heavy Track ones on eBay (item number 271036919975), but PRICY at nearly £300/pair!!

Then there are some cheaper ones on there from Australia (eg item number 120858660092) but those are a brand I don't know and the postage pushes the cost right up. I don't really know anything about suspension set up to be honest, but at the moment the ride is pretty hard and unforgiving, and I'm wondering if new shocks would be a good investment. The roads in northern Kenya where we're headed are supposed to be as bone shaking as anywhere, and I'll get brownie points from the wife if I can do anything to make the ride a bit more comfortable... (and it's her birthday today so maybe I can buy them for her as a "present"

Currently Im using a full ARB(OME) lift kit fitted by the previos owner and Im quite happy with it. My female companion has given it the thumbs up,in her expert opinion,"it feels like a normal car". Well I think thats approval.

 

[johnnystrom]

Hi Tony/Rosco. For some reason all but one of the pictures I posted above are now showing as invalid attachments. Hopefully the next ones will work ok. As for suspension, I'm thinking OME shocks. The jury is out on the airbags. Partly because Derrick at LRS hasn't been able to get hold of the importer, and partly because the upgraded rear leaves are such monsters that they don't really need any help. They give a pretty harsh ride at the moment, but it should be a lot better when the rear is properly loaded.
On a separate note, I'm thinking of switching tyres from the Hankook Dynapros to BF Goodrich's all round. The Hankooks will be the spares, so I want to stick with the same size (33 12.5 15). I have a chance to buy a couple of good used BFG All Terrains in that size, but I was originally thinking of going with Mud Terrains as there may be quite a few muddy river bed crossings. So my question is whether it would be a bad idea to have 2 x BFG all terrains on the front and 2 x BFG mud terrains on the back? What do you think?

 

[TonyS]

Hi Jonny,


For me if I was going on a serious trip like you are , then I would not buy second hand tyres, but would put four new and have two spares.
Also I wouldn't mix ATs and MTs, but would probably go for a good AT, as your mileage will be high, and MTs do use more fuel, and some all terrains now are pretty good in the rough stuff. I am not a fan of the BFG AT, (but really like the KM2 mud), but have driven all over Australia with Cooper STs, without a single puncture. Now I would opt for the stronger side walled ST Maxx.


Tyres are a personal preference. One other option someone told me of was to actually use proper truck tyres, but not sure of their sizes, as they are so much stronger! Chris from Boab knows more on this subject.


Keep us posted, hope you sort out the pics.


Cheers,

 

[roscoFJ73]

If I was going to Africa(I think thats where you are heading) I would be looking at tyres that can be replaced enroute. Truck tyres that suit the small Japanese 2-3 ton trucks are a 16 in tyre.
They are also fitted to the japanese buses made by toyota and nissan.
These tyres come in a multitude of tread types.Everything from quarry lugs to high speed highway ,sand and mud terrains.
The 235x85x16 will fit the 16x6 rim size or a 16x7 and maybe a 16x8.

On the road these tyres can be inflated to over 60 psi and the narrower width means better fuel economy.
I you do need to replace them,they are less than half the price of the big offroad tyres.
The ones I had were equivalent to 32 inches in height.

Deflated they are almost as good as the A/T 4WD tyres in thick sand.

I started using tyres like these in 2007 when driving from Perth to Alice Springs via Great Central Road which is a dirt road approx 1100 klms long.I blew 2 BFG A/T near the WA/NT border and limped into Alice with no spares left.
I was then told it would take 1-2 weeks to get replacements for the BFGs.
So I bought 2 split rims and 235x85x16 tyres and drove home with them

 

[johnnystrom]

Thanks guys. I was considering moving to a 16 in rim, but as I already have 6 of the 15x7 rims that are currently on the truck (see pics at the start of this thread), I'd quite like to stick with them really. I've heard that these 15x7 rims with their 33 12.50 15 tyres allow a lot of deflation if necessary too. Having said that, I did see these 16 in tyres and rims on ebay, which seem pretty good if the description is accurate...

http://www.ebay.co.uk/itm/271103507853?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

I think the 6 stud rims from the 80 series should fit the 75 series, right? Do either if you have experience with these Cooper STT's? Tony, I see you were using the ST's, which I think are slightly more on road oriented version of the STT's? If I did go with these 16s, I calculated that I lose some lift (about 3/4" inch I think) as the overall diameter is less than the 33 12.50 15s that I have on now. Hmmmmm.

I agree with what you say about not mixing A/Ts with M/Ts, and have ruled that out. If I do stick with the 15 in rims (I have room for a 3rd spare so am not too worried about having to source tyres out there (famous last words tho...)) I'm thinking of going either with the Cooper STT's or BFG M/Ts. I hear what you're saying about A/T's giving better fuel consumption, but I'm expecting to be driving a lot of dirt roads, sometimes in the wet, and never at any great speeds. So I thought thing there will be enough times when an M/T might perform better to make them worthwhile. The Cooper STT sounds like it might be a bit better on road than the BFG M/T tho.

 

[johnnystrom]

Right, having read some more about it, and considering the rims I already have (which in their 7 " size are too small for the 33 12.50 15s that are on them now I think), I'm looking at changing to BFG 33 10.50 15 KM2s. I can't find a bad word about them on or off road, and it sounds like they will have more bite than the 12.50s. But they'll still pressure down well off road, and give a bit better fuel consumption on road. So maybe the best compromise?