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Welcome to the Garage

For about two decades now I have been tinkering on random things in various ‘garage’ spaces to keep myself sane. Starting out with computers and case modding, and then moving to cars, bikes, microcontrollers, and now 3D printers, it has been a rather long journey.

Lots of this journey has been documented on various forums over the years, but with the forum platform now going the way of the dodo I thought it was high time to migrate a bunch of build threads and other garage threads over to a blog.

Occasionally in these builds there will references to other threads or to people from the forums, and it may not make entire sense. But that is a price I’m willing to pay for not having to rewrite everything from scratch.

Here goes then, an attempt to collate all the random garage stuff I have done in the past 20 years.

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The Impulse Buy Nugget – PH1 Echo Sportivo

So I haven’t made any car related ill advised impulse buys recently, and after turning 40 last year I was due for some sillyness. A mate of mine has been hassling me to get my butt into gear and buy a Nugget to run in Nugget Nationals with him, and I kept putting it off by saying I would finally get the MX5 going etc.

During all this period my dad was passing away with terminal cancer (which is another thing in and of itself) and I wanted to make sure that I had enough time to spend doing stuff with the kids. Well, after watching Chasing Midnight with my kids at Christmas it kind of sealed the deal as my eldest and middle wanted to start to play with cars, and the eldest can start to do Junior Motorkhana in a year or so. Plus with the quite restrictive regs for Nugget Nats there shouldn’t be too much scope creep on this thing. Less scope creep == more driving time.The spark was lit.

After that the only questions were what to get, and how to get nopics to sign on. Settling on a car was actually the easy part. Because of the regulations for Nugget Nationals the base price of the car has to be under $3000, basically stock (i.e. no non-factory engines), and maximum 1.5L engine capacity. The engine capacity limit and no non-factory swap meant that a lot of older cars were instantly out of contention, such as Corollas or Civics. Some of the newer cars are rather more spritely (my dad’s 2016 Mazda 2 manual would have been good) but too expensive. The sweet spot was about early 2000s, and being a Toyota guy the option of an Echo Sportivo was a no brainer. The only question was whether to buy an off the shelf Sportivo, or get a base model Echo and swap in the 1.5L 1NZ from the sedan. Getting nopics to sign on was a bit harder, but with dad’s cancer we had become accustomed to having two cars for a lot of the running around, and combined with a summer of multiple kids birthday parties on the same day as well as weekday sports in different locations having a second car was becoming a must. Nopics signoff came with a condition though, it had to be running and kept running 99% of the time… i.e. no engine swaps. Fine, Sportivo it is.

With that it was off to find a car. I had a look at a couple of different ones, as well as the usual Marketplace and Scumtree searches. Quite a few were from dreamers who were wanting $7-8k for a clean but basically stock vehicle, or a few people who were misrepresenting their 1.3L “swap” as a Sportivo (one still had the 1.3L 2NZ in it). In the end I found this nugget, and managed to work out a deal.

Its a 2001 Toyota Echo Sportivo, 220k km on the clock, but with a supposed 110k km engine swapped in late last year. The guy had been running it in Nugget Nationals over the last couple of years, but gave up to go camping instead.

[IMG]http://images.plebeians.net/_data/i/upload/2024/02/18/20240218225350-dbd44de3-xl.jpg[/IMG]

Has the prerequisite clearcoat and paint fade on every upper surface that all non-white Toyotas have, along with a bunch of dings and scrapes which the guy hadn’t bothered to do anything about.

This photo with my mate’s PH2 shows a bit more of the paint fade “patina” along with the dents
[IMG]http://images.plebeians.net/_data/i/upload/2024/02/18/20240218212724-aa73ab0e-xl.jpg[/IMG]

Driver’s side foglight was found in the glovebox…

Engine bay is stock as a rock:
[IMG]http://images.plebeians.net/_data/i/upload/2024/02/18/20240218225331-8506f226-xl.jpg[/IMG]

Currently it has some CSA wheels on it which foul on the guards a bit at full compression, and has a GC8 seat in it, which I’m undecided about keeping or taking out.

First thing to do though is to return it to mostly stock and put it through RWC so it can fulfil its other function as a runabout. Then the (super limited) modding can begin.

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Camper Trailer – Another one?

Right, now that the Hilux is almost finished, it is time to start thinking about the other projects again. First cab off the rank was going camping this year, where we took the camper trailer above. Nopics and the kids got the bug for it, so we bit the bullet and bought a camper trailer off some relatives who are moving overseas. Its roughly the same, but has some advantages over the one i got from Sloth.

This is it when we picked it up:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208171149-bd23af88-xl.jpg[/img]

Plus packed up:
[img]http://images.plebeians.net/i.php?/upload/2022/02/08/20220208171221-8d1be185-xl.jpg[/img]

This one has both electric brakes and independent suspension:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208171231-2c96089b-xl.jpg[/img]

Plus external pole tubes, stone deflector, and a slightly longer drawbar:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208171715-d2da6131-xl.jpg[/img]

On the flipside, it doesnt have the front storage box, nor any drawers, or a kitchen. So all of those need to be remedied. 

First cab off the rank though is this ORAC hitch:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208171529-927ddce1-xl.jpg[/img]

While in some universe this is a good idea, as it separates vertical and horizontal movement, and places it on a double shear pivot. There are some significant issues with it.

Firstly, the shank of the trailer side has had the adjusting nut welded on, so that there is no way to set any preload for fore-aft travel:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208191506-daaaf35e-xl.jpg[/img]

This means it just knocks back and forwards.

The second is that the left-right pivot point is a sleeved bolt that is slightly longer than the tongue:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208190539-1b3a4c6f-xl.jpg[/img]

Now while this allows for lateral location, there is no vertical locating of the tongue to the towbar, and so it uses the tongue/towbar interface surfaces as bearing surfaces… neither of which are designed for that
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208172523-5788cdac-xl.jpg[/img]

This mightn’t be an issue if there was a way of continually keeping it greased, but there isn’t. Instead its just left to grind back and forth on the towbar.

Instead i ended up replacing it with a basic polyblock hitch, that should do much better, and added a new jockey wheel while i was there:
[img]http://images.plebeians.net/_data/i/upload/2022/02/08/20220208191556-585cdbf6-xl.jpg[/img]

Next up for the camper is a kitchen and water tank, and then draw bar box and electrics.

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Hilux – Finishing Touches

Bit more of an update. Had some time to cut down some tray sides i bought off Gumtree:
[IMG]http://images.plebeians.net/i.php?/upload/2022/01/11/20220111145710-df2a7871-xl.jpg[/IMG]

Then added a bunch of Raptor to them. Really highlights how short the tray is, but its workable enough.

I then bolted on a bunch of accessories so it looks cool while crawling down the mall, and been driving it around. Stopped to take some happy snaps on my way to a conference last week… of course i took the dirt road to get there.
[IMG]http://images.plebeians.net/_data/i/upload/2022/02/07/20220207191628-f4c2cafa-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2022/02/07/20220207191404-7c1d9ef8-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2022/02/07/20220207191410-4f5de422-xl.jpg[/IMG]

It has come a long way since i first saw it in the paddock:
[IMG]http://images.plebeians.net/_data/i/upload/2020/04/29/20200429005438-95b0b3ae-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2020/04/29/20200429005502-2dfc207b-xl.jpg[/IMG]

Lots more little things to do with it. Canopy fitout is next, plus need to wire up the accessory lights etc. But all of that can be done while it is driving.

Next big thing for it will be rock sliders, and then turbo…

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Hilux – Wiring

Not a huge amount of progress over the summer, mainly because of being away and it being too damn hot to do much. But got the wiring finished, although it needs a slight tidy:
[IMG]http://images.plebeians.net/_data/i/upload/2022/01/11/20220111145804-e7347a96-xl.jpg[/IMG]

Plus finally got around to redoing the latches on the rear drawer. From factory the central latch didnt fit properly, and was attached with only two screws to the body of the drawer. That is ok, because i was going to replace it with side compression latches instead. So out came the TIG and welded in a plate and then cut holes for the two side latches:
[IMG]http://images.plebeians.net/_data/i/upload/2022/01/24/20220124205228-379a7f93-xl.jpg[/IMG]

A lick of paint and it looks like this:
[IMG]http://images.plebeians.net/_data/i/upload/2022/01/24/20220124205248-ff3256a6-xl.jpg[/IMG]

It will get raptor coated at some point when i build the side steps, but until then our finest Australian Export $2 can will do. Not sold on the gunmetal grey fascia for the drawer too, so will probably repaint that in black at a later point.

And finally I rewired the winch solenoid to a plate, so it will fit on the side of the battery:
[IMG]http://images.plebeians.net/i.php?/upload/2022/01/11/20220111145723-2d6b0d20-xl.jpg[/IMG]
Much better:
[IMG]http://images.plebeians.net/_data/i/upload/2022/01/11/20220111145705-1ba43cc9-xl.jpg[/IMG]

Thats about it for now. Ive been driving it around a bit to get some kms on the engine, and all has been well so far. Except the front diff is leaking like a sieve.

Need to tidy up the tray sides and mount them, and then I can do the interior and canopy

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Hilux – Getting the Funk On

Havent had as much time to work on the HIlux as before, but still plugging away and getting stuff done in the background. I had been putting off the wiring for as long as possible, so instead I fitted the under tray pods:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021322-e5b4e6ec-xl.jpg[/img]

Then I regreased the winch:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021251-f1f60a8e-xl.jpg[/img]

And finally fitted up the bullbar:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021424-93903f64-xl.jpg[/img]

Need to sort out a plate mount and stuff, but that will come.

Eventually i resigned myself to needing to sort out where everythign was going in the car, and so after my new battery arrived I mocked everything up:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021158-58ed1227-xl.jpg[/img]

Renogy 50A DC-DC charger, 1000W inverter, and a slimline 170AH battery.

Then it was time to get the funk on. Hole punches and dimple dies make life easy

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021541-330a3351-xl.jpg[/img]

But had a delay courtesy of a small leak in the gas line on the TIG which was causing a venturi and sucking air in:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021551-95423b3c-xl.jpg[/img]

That took way to long to figure out, but once it was sorted the welding could continue as normal.

Which in the end leaves me with this:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021700-2f9b0d56-xl.jpg[/img]

Need to tighten some bolts with assistance (I’m not stretch Armstrong), but that will be easy enough shortly.

Plus i built a new battery tray, because the old one was sized for a smaller battery than the larger truck unit that they had fitted it with:

[img]http://images.plebeians.net/_data/i/upload/2021/12/12/20211212021649-d67405bf-xl.jpg[/img]

That gave me the ability to add a mounting plate for something too…

For now though i just need to get my crimping on and sort out all the wires.

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Hilux – Dirty dirty dirty

The process of screwing all of this back together has been really slow. Although part of that is because i keep getting distracted by other things. First up was getting the drawers in, which i mounted up using a ton of M8 stainless hardware and sandwiched 3mm rubber sheet in between, got it all together and it fits well:

[IMG]http://images.plebeians.net/i.php?/upload/2021/11/24/20211124160316-e3bd0654-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160329-183138f6-xl.jpg[/IMG]

Then i started running the wiring for the rear battery and realised how filthy the cabin was, which led to pulling out all the interior to clean it:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160527-5cff47e2-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160635-22fe4d45-xl.jpg[/IMG]

And it truly was filthy:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124163620-31bc9015-xl.jpg[/IMG]

But i did find some interesting things when doing automotive archaeology. True to form there were a few casings under the vinyl:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160504-726f4015-xl.jpg[/IMG]

Plus some ski club tickets from 1998, the same year as the Hilux was made
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160341-df0826d7-xl.jpg[/IMG]

Anywho, i also found this big dent under the clutch pedal:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160554-4c8ef36c-xl.jpg[/IMG]

Which after a hit with a hammer gave:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160601-876a5b03-xl.jpg[/IMG]

That spot is here, high up under the car between the chassis rail, torsion bar and gearbox. I have absolutely no idea how it could have even been hit.
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160606-9e1affe6-xl.jpg[/IMG]

Completely bizarre. Ohwell, it got a bit of a beating and then some sound deadening added over the top…. then one thing led to another and suddenly the entire rear of the cabin was covered in sound deadening:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124163605-56167ee9-xl.jpg[/IMG]

While all that was drying I got around to refitting the flares, after the flare mounting rubber finally arrived:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124163714-2496d9dc-xl.jpg[/IMG]

Then after refitting all the interior i figured out why it was all so filthy.
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160511-4f1883de-xl.jpg[/IMG]

That is the rear cabin vent to allow pressure to equalise when opening and closing doors. The one on the left was what was in the car, and the one on the right is what it should look like. Basically had none of the flaps or dampening chamber, so little wonder the cabin filled up with mud and junk.

Anywho, I decided that I should actually make some progress on getting it back together and built a bracket to mount the battery isolation switch and manual override:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160537-94f3e15e-xl.jpg[/IMG]

Was all pleased with myself before promptly realising that I had completely forgotten to add space for the circuit breakers. So then i had to build a new one. Take two:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160542-bc3cf807-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124160549-44abc6bd-xl.jpg[/IMG]

Its made out of 1.6mm sheet steel, so a bit of an overkill, but I didnt have any 1.2mm or 1mm around.

Finally my Deutsch plugs arrived so i did the wiring for the rear tail lights with my new crimper. Its so good having a nice crimper for this stuff:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124163659-674d9e02-xl.jpg[/IMG]

And I also finished off the grille that was munted by the previous owner, and gave it a bit of a paint job:
[IMG]http://images.plebeians.net/_data/i/upload/2021/11/24/20211124163706-d3a88db6-xl.jpg[/IMG]

Thats about it for now. Currently waiting for new slim AGM to arrive so i can finish the rear seat wiring and then I can get a move on with mounting up the canopy properly and doing all that sort of stuff.

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Hilux – Getting my paint on

So at some point last week the treadplate sheet arrived and i was able to figure out how much i needed:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164736-73a12705-xl.jpg[/img]

After that I was able to put some left over KBS onto the “closed” faces of the tray:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164812-c912c369-xl.jpg[/img]

With that done I jumped at the opportunity of a couple of dry days and got stuck into prepping the cabin for paint.

Before:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164841-088751bb-xl.jpg[/img]

Set up a cheap gazebo as a “spray booth” and prepped and masked:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164924-c6d6b9fa-xl.jpg[/img]

One nice dark maroon (3K4) ready for mixing:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164943-011f67b1-xl.jpg[/img]

First coat of Raptor:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102164949-bc3786f1-xl.jpg[/img]

Then done:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102165854-c7236c3c-xl.jpg[/img]

Would have been better with 6L of Raptor rather than just 4L, but it still looks decent in person. Lighter coats under the flares, but that will all be hidden anyway. Need a new aerial too, as the locking nut sheared in two when i was removing it…

Then back to the tray. I had wondered how i was going to trim the tray, and decided to give it a go with the router and a flush trim bit. Worked a treat:
[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102165434-5f6bf56d-xl.jpg[/img]
Sikaflexed it on with a bunch of rivets after that.

Riveted and sikaflexed on the drawer mounts, so i could then set it all up and drill the mounting holes.

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102165827-4a178fc1-xl.jpg[/img]

Cut out some 2mm alu sheet for the light mounts and sikaflexed in place:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102165838-c86816cf-xl.jpg[/img]

Finally I used Bully Liner for the underside of the tray:

[img]http://images.plebeians.net/_data/i/upload/2021/11/02/20211102165911-01b82829-xl.jpg[/img]

I figure that the rubber in the Bully Liner will deaden down the tray a bit especially with stone hits etc. Plus being water based and UV curing it is a lot better for touchup than Raptor.

Its now raining for a few days, so i wont get much of a chance to do anything else. But need to prime and paint the drawers, the tray sides, canopy, and tray bed. Plus bull bar at some point i guess too.

Hopefully be able to work at it in the “spray booth” gazebo later in the week… so long as it doesnt tear itself to bits in the wind.

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Hilux – Frustrations and Tray

Another week, another update.

Didnt get much of a chance to do much until the weekend as it basically lashed down all week here, but got back into it after it dried out. Well after the weather did anyway.

Fitted up the radiator and the rest of the pipe work, and filled the radiator, only to find that the water pump gasket had pinched at some point in the fitting, and was just pissing water out of the side of the pump:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018040941-2ec933f0-xl.jpg[/IMG]

That necessitated pulling the entire front of the car apart again to try and figure out what has gone on. Replaced it with RTV and bolted it all back up, but had to wait for the RTV to dry, so set about doing other things… namely moving onto the tray. Got the ute through into the back yard:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018041119-41a92c30-xl.jpg[/IMG]

Then set about pulling the tray apart. But thought I would document just how bad it was before i started. First up was this terrible roll hoop/ladder bar/spotty bar that was bolted and then welded to the tray because they had used bolts that had a longer non-threaded shoulder than the tray thickness.
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018041240-9f610b5b-xl.jpg[/IMG]

Oh and everything is rusty, so needed to be cut off:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018041802-86ca0df9-xl.jpg[/IMG]

All of the bolt heads on the tray mounts were rounded off, probably some redneck security measure. Out comes the grinder:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018041933-6ebee5a0-xl.jpg[/IMG]

Every 6″ or so there were these really badly drilled holes for side marker lights. EVERY SIX INCHES! Would have been at least 50 of them on the car:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018042059-92151fdc-xl.jpg[/IMG]

Anyway, after an hour or so it finally looked like this:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018042234-85fa868c-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018042351-e6ebe145-xl.jpg[/IMG]

At which point I was able to clean out part of the accumulated mud… yes only part of it. Still a ton more to go, the chassis rails were almost full:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018042729-dcba8575-xl.jpg[/IMG]

The next day I got stuck into making the new tray. Firstly set it up with clamps to get some measurements and levels.
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018043016-e3cfc901-xl.jpg[/IMG]

Make the noise:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018043247-e7ea53dc-xl.jpg[/IMG]

Managed to get it all square and within +/-0.1deg of deflection, which I figure is good enough for a ute tray…. You can also see in that picture the mounts i built for the tray with random 3mm square plate washers for spacers.

Then weld on some bars, and take it off for trimming up the cab end:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044354-299f8918-xl.jpg[/IMG]

Go back to the trusty mitre bandsaw and start chamfering ends:

[img]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044329-b5455933-xl.jpg[/img]

Then the outer bars get tacked in place:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044412-8340689e-xl.jpg[/img]

After that it is time for the main hoop, measure measure measure then cut:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044428-66c9cbba-xl.jpg[/IMG]

Do a bit of maths and measuring and you end up with one main hoop:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044227-175fd1f9-xl.jpg[/IMG]

Looks a bit weird, but thats because its the same profile as the canopy.

Finally, do a bit of trimming where you screwed up and forgot that the under tray drawer has to go in the space that you just filled with the rear bar:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/18/20211018044531-c82573bf-xl.jpg[/IMG]

All in all decent for a half day of work on the tray. Still need to build the light plate, and start to weld up a bunch of mount pieces for the behind rear wheel boxes, plus some gussets etc, and then have to weld up the entire thing. But its getting there, not too long now.

All in all decent for a half day of work on the tray. Still need to build the light plate, and start to weld up a bunch of mount pieces for the behind rear wheel boxes, plus some gussets etc, and then have to weld up the entire thing. But its getting there, not too long now.

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Nugget Hilux First Start

Another week and certainly invoking the 80:20 rule here. But the box of heater hoses finally arrived and so it became a process of mix and match to figure out where everything went:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010194310-4ed0834d-xl.jpg[/IMG]

Not terrible, but a pain as a bunch of them were too long and needed to be trimmed shorter, or joined in two for some reason. Plus the entire heater hose catalogue doesn’t include the feed and return to the oil cooler or the throttle body. Minor annoyances, but they are both absolutely painful to get into and I hope they never burst, as the old ones had to go back on there. The oil cooler ones will be fine as in the long run they will be replaced when i do the turbo.

Plus i put on my new Jaaaaag alternator, only to realise that it had the old style of plug, which required a plug adapter:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010195302-2255eeda-xl.jpg[/IMG]

Mercifully they are available off the shelf, but another couple of day wait.

Then I started bolting it all back together and one of the fuel pressure regulator bolts sheared off… Mercifully it came out with the application of a sacrificial torx bit
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010195424-2527d9a1-xl.jpg[/IMG]

After that I made up a hideous overkill of a fuel line to replace the damaged one, because getting a new fuel hose crimped up in lockdown was all but impossible, so a 200 series -6AN line it is:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010195716-a015c3a8-xl.jpg[/IMG]
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010200035-0939e23c-xl.jpg[/IMG]

But hey, bling bling.

At which point you get to here:
[IMG]http://images.plebeians.net/_data/i/upload/2021/10/10/20211010201038-7cb3484d-xl.jpg[/IMG]

And so late one afternoon

[MEDIA=youtube]27JWDLb26NQ[/MEDIA]

Still has a slight exhaust leak as the secondaries were only finger tight, and I now need to bolt together the rest of the random bits and pieces, but its pretty much good to go.

Posted on

Hilux – One Engine in One Engine Hole

On Saturday i pulled my finger out, took a teaspoon of concrete, and figured i could work in the rain if need be. So managed to get the engine out of the garage with a bit of pendulum trickery and no small amount of good luck:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181700-4dc0aefe-xl.jpg[/img]

That meant i could get access to the back of the engine to put the rear main seal and carrier on, and then the flywheel:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181727-1894a1a3-xl.jpg[/img]

Add some pink bits, and then a fresh release bearing to the gearbox.

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181753-1354ef98-xl.jpg[/img]

Then its time to gingerly wheel it all over to the ute to offer up:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181802-e63586b8-xl.jpg[/img]

Lift engine into engine bay, and spend a while trying to line up the input shaft with the clutch. Remember part way through that you forgot to remove the clutch aligning tool (yes, note that above). Wiggle the engine back and forward until you can get your hand into the bellhousing and pull that out.
Funnily enough it is much easier to get into place without an alignment tool in the way….

Manage to get it lined up and then add the bolts in and pull down on the dowels:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181812-2dda1524-xl.jpg[/img]

Took a bit of effort to get the bellhousing bolts in, but managed to do that. Much easier without the intake and exhaust manifolds in the way.

Then it was up to test fitting the dynamic compression ratio modification device:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181820-1c0903c3-xl.jpg[/img]

Spent a bit of time checking out clearances and taking measurements for the eventual spoolyboy install:

[img]http://images.plebeians.net/_data/i/upload/2021/10/03/20211003181847-a3adfe44-xl.jpg[/img]

After that there was a bunch of boring bolting up of ancillaries. But im waiting on heater hoses to arrive, because they are a pain in the arse to replace with the manifolds in place, so i thought I should actually do it now. But that will delay most of the rest of the bits. Hopefully they will arrive this week and I can get it screwed back together next weekend and then start on the tray soon after.