Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

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Kensykatro
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Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good day,

I just bought this Front Runner Roof Rail Kit 99 FRXH02 for my Toyota Hilux 1999 D/c 2.7i.

I am planning on fitting the Rooftop Tent or a rack on it. But first I need to install it on the roof. Does anybody have some helpful information and tips on how to remove the ceiling of my bakkie and best to install this Kit.

Thanks and cheereo,

Kensy
Last edited by Kensykatro on Wed Aug 29, 2012 8:49 pm, edited 1 time in total.
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by OOOOMS »

Welcome here :thumbup:

Have a look here: viewtopic.php?f=41&t=13862&hilit=roof+rack" onclick="window.open(this.href);return false;

and follow the links :thumbup:
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by 4x4Maniac »

Welcome to the forum! If I may ask what did you pay for the roofrack?
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by Kensykatro »

Dankie for welcoming me.

OOOOMS unfortunately I could not find the information I was looking for. But thank you in any case.

4x4Maniac, I haven't bought a roofrack. I just bought the Roof Rail Kit from Frontrunner to install a Rack on it or Rooftop Tent. For the Roof Rail Kit I paid 1850.- ZAR @ Safari Center in N1 Motor City, Goodwood, Cape Town.

Kind Regards

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Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good day everybody,

The weather at the west coast was not that great the past weekend. This ended up in the following:

I started to remove the ceiling of the bakkie. Which is actually fairly easy. Remove the Handles, Blinds, Mirrors, Cabin light, Column A Cover LH & RH and a few plastic screws and off comes the ceiling. To manoever it out of the cabin I decided to remove the passengers seat ( just helped not bending the ceiling to much ). Since it is out I will probably uholster it. Unfortunately ( or rather fortunately ) I did not came to the point of installing the FRONTRUNNER rail system yet.

But let me tell you that this is only the start of what ended up with what you see on the pic attached :dance1:.

First let me give you some background information :

The Heat exchanger in the cabin was defect from when I bought it, obviosly it was leaking ( leaving quite a stain on the passenger side ). The previous owners just bypassed it by disconnecting the pipes ( I do understand now, why they did so and who in Africa needs heating and wants to go through all this troubles...;o) ?? ).However, this made me buying a second hand Heat Exchanger from CARYOTA. At this point of time I was not really aware of what the replacement of this item involves. My Hayenes Repair Manual ( which I call my Toyota Bible ) helped a lot. As I got some spare time and I love to work on my bakkie I decided it to do it myself. Therefore I startet with what I call " Bakkie interior Renovation" which involves the following:

1. Removing all seats. They are still in a fairly good shape, therefore no plans to upholster them.
2. Remove the whole dashboard.
3. Remove the Crashbar. Which shows some surface corrosion. So I decided to Sandblast, Spraypaint and clearcoat it ( what I am busy with now ;-) ). Some of you might think it being unnecessary since the crash bar will ( hopefully ) never be seen again. But I just like doing thins to its best as possible. And it gives me a great peace of mind knowing it has been done properly ( well to my best expertise and skills ).
3. Remove the Fan, Aircon, and Heating Unit. These Units and the ducts are incredibly dirty. All will be perfectly cleaned prior installation.

That is where I stand at this point of time. Todays schedule is clearcoating the crashbar and start with the dissassembly and cleaning o the Fan, Aircon and Heater unit. This will probably take some time.

Let me complete me with what I would like to call Project X. Prior to the above the following has been done already:

1. Bullbar Removal ( in order to service the winch ). Since Bullbar is removed it was sandblasted and Powdercoated in black matt.
2. Winch and the Solenoid Pack. Solenoid Pack is rewired, the winch is serviced and will be fitted with new electrical and tow cables.
3. The Fuel Tank Protector. One hole was torn ( probably hooked on somewhere while 4x4 ) and the Fuel Tanks strip was corroded. Both is repaired.
4. The old bakkie lining. There were little chip marks and I feared corrosion underneath. Old lining was taken off, the corrosion removed ( had very little corrosion ) and new Rhino lining ( Rhino Lining Vredenburg ) put on. The guys did an excellent Job.

You've may seen that the Subjects name was changed. I believe it is rather going into an renovation/upgrade project than just a roof rail installation. Therefore I deem it justified to change to subjects name to Project X :cooldude:

Any tips and comments are more than welcome.

Next update to follow soon.

Kind regards

Kensy
Attachments
Powder Coated Bull Bar
Powder Coated Bull Bar
Fuel Tank Protector
Fuel Tank Protector
New RHINO
New RHINO
Load bin corrosion
Load bin corrosion
Bakkie before Projext X
Bakkie before Projext X
Bakkie interior Renovation Status 28.08.2012
Bakkie interior Renovation Status 28.08.2012
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by FJCruiser-ZN »

Matthias, I hope you can put everything together again.

T
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by Kensykatro »

Good evening Tony,

I hope so too..;o). No worries yet, I am pretty confident. Got everything documented.

Fan, Aircon and Heater Assy is dissasembled and ready for a big clean up. And Crash bar is painted ( satin black two layer ) and clear coated ( 1 layer ).

The Fan Assy got a metal support built in which is I would say heavily corroded. Toyota unfortunately does not sell this part alone, only the Fan Assy. It is quite thin, would like to avoid sand blasting. Anybody a good Idea how to clean it ?



Cheers Matthias
Attachments
Fan Assy Metal Ring
Fan Assy Metal Ring
IMG_1201.JPG (90.27 KiB) Viewed 8004 times
Crashbar Spray painted and Clear coated
Crashbar Spray painted and Clear coated
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by Scorpion »

Well done! You've still got a lot to do, but the start of any project is exiting! Watching with interest... :thumbup:
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Re: Front Runner Roof Rail Kit 99 FRXH02

Post by FJCruiser-ZN »

"Anybody a good Idea how to clean it ?"

I would suggest " bead blasting" it is not as harsh as sand blasting.

I have used pool acid in the past to eat the rust, but you need to be very careful and work in a well ventilated area away from other metal parts.

Get a deep dish, big enough to submerge the item, put enough pool acid in the dish and submerge. Continually check, and once clean, rinse with clean soapy water and force dry with compressed air. Undercoat and paint without delay.

Ensure there is no acid in joints, folds, etc.

Do not get acid on yourself or in your eyes. Keep fresh water handy in case of accidental contact.

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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Some progress has been done over the weekend.

The Steering column and the center Dashbord support brackets showed some surface corrosion. Steering column surface corrrosion was sanded ( by hand ) and clear coated with three layers. The center Dashboard brackets were acid treated and get clearcoated this afternoon. Heater Unit Covers, all air distribution ducts and the Aircon Heat Exchanger were cleaned with Green Clean and High pressure cleaned.

Next step is cleaning Aircon Covers, Fan Covers and putting back the High density foam which were fitted to the flaps of the Fan Unit and the Heater Unit.

Fan Assy Metal Ring was bead blasted. The corrosion was quite severe. The blasting deformed the part, it will be beaten into shape and painted ( just for corrosions sake ).
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Rooikappie »

The weather at the west coast was not that great the past weekend. This ended up in the following:


I did'nt know that the weather is that BAD on the West Coast>>>
Hope the weather stays BAD long enough to finish your Project X.

Voorspoed !! Sal graag die eind resultaat wil sien.
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Rooikappie, there certainly won't be enough bad weather but more than enough time....

Find attached the pictures of the Steering column and Center Dashboard Brackets before and after...
Attachments
Corrosion Dashboard Center Bracket ( after treatment )
Corrosion Dashboard Center Bracket ( after treatment )
IMG_1286.JPG (80.44 KiB) Viewed 7901 times
Corrosion Steering Column Bottom ( after treatment )
Corrosion Steering Column Bottom ( after treatment )
Corrosion Steering Column Top ( after treatment )
Corrosion Steering Column Top ( after treatment )
Corrosion Dashboard Center Bracket LH OS
Corrosion Dashboard Center Bracket LH OS
Corrosion Dashboard Center Bracket RH IS
Corrosion Dashboard Center Bracket RH IS
IMG_1242.JPG (86.01 KiB) Viewed 7901 times
Corrosion Dashboard Center Bracket RH OS
Corrosion Dashboard Center Bracket RH OS
IMG_1244.JPG (63.11 KiB) Viewed 7901 times
Corrosion Steering Column Surface Corrosion Top
Corrosion Steering Column Surface Corrosion Top
IMG_1241.JPG (88.41 KiB) Viewed 7901 times
Corrosion Steering Column Surface Corrosion Top
Corrosion Steering Column Surface Corrosion Top
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by JJBotes »

:thumbup: :thumbup:
:thumbup:
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

;-) Thanks JJ
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Hiluxfan_111 »

Looking good Matthias! :thumbup:
How did you remove the old lining from the loadbin so neatly?
I also want to re-do mine, but that old stuff is really tough!
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good morning Roelof,

That staff is indeed really tough. My old lining was actually in a very good condition. It had a few chipmarks. Therefore I decided to open those and repatch them. This was done with a carpet knife cutting around the chipmarks and removing the lining with a screwdriver and my hand acing as a Hammer ( was not pretty well equipped that time :o) ). The lining comes loose pretty easy where the corrosion sits, BUT that stuff sticks on to the loadbin with no corrosion !! There were about 20 chimparks with little surface corrosion underneath, therefore I decided to do a proper job and redo the whole lining and remove the corrosion. The removal of the whole lining was not done by myself as it would have taken to much time. Rhino lining Vredenburg was willing to do the job ( which I really appreciate ) for 500.- ZAR. It took them almost a week with chisel and hammer. This is basically your answear.

Hope this helps. Good luck and kind regards

Matthias
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Gents, my winch lays now in pieces..... :D: .

Decided to disassembly the Warn Winch M6000 and service it. Gears and housing were washed and cleaned with petrol. As this is not enough, I decided to paintstrip the housing for a nice new repainting. Had powdercoating in mind, but the housing is to complex. Layer of primer and spray job will do, or any suggestions ? I am looking for a good, sustainable paint. To paintstrip the housing TURCOL and Thinner V21 was used. The gears will eventually get a nice new grease.

Heater Assy flabs were cleaned and are now ready for a new foam application.
Attachments
Heater Assy Flaps before cleaning
Heater Assy Flaps before cleaning
IMG_1211.JPG (85.74 KiB) Viewed 7833 times
Heater Assy Flaps cleaned and ready for foam
Heater Assy Flaps cleaned and ready for foam
IMG_1300.JPG (63.3 KiB) Viewed 7833 times
WARN M6000 Dissassemly after paintstripping
WARN M6000 Dissassemly after paintstripping
WARN M6000 Dissassemly before paintstripping
WARN M6000 Dissassemly before paintstripping
IMG_1291.JPG (82.62 KiB) Viewed 7833 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Here some pictures of the primered winch Warn M6000. After paint stripping some little corrosion surfaced and was blead blasted prior to paint application.Aluminium housings ( Gear Train Drum Support, Motor Drum Support, End Housing Carrier Stage 1 & 2, S / P Motor cover ) were epoxy primered, steel parts ( Drum Assembly , S/ P Motor, Gear Ring )
Attachments
WP_000732.jpg
M6000 Gear Train Drum Support
(96.49 KiB) Downloaded 2025 times
WP_000731.jpg
M6000 Motor Drum Support
(68.52 KiB) Downloaded 2025 times
WP_000730.jpg
M6000 Drum Assembly
(58.47 KiB) Downloaded 2025 times
WP_000729.jpg
M6000 S / P Motor
(43.64 KiB) Downloaded 2025 times
M6000 Gear Ring
M6000 Gear Ring
WP_000728.jpg (49.59 KiB) Viewed 7744 times
M6000 End Housing Carrier Stage 1 & 2
M6000 End Housing Carrier Stage 1 & 2
WP_000727.jpg (30.35 KiB) Viewed 7744 times
WP_000726.jpg
M6000 Gear Train Drum Support
(91.15 KiB) Downloaded 2025 times
WP_000725.jpg
M6000 Motor Drum Support
(85.28 KiB) Downloaded 2025 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Heat Assy flabs were paintstripped ( Thinner V21 ), corrosion treated with POWAFIX DEOXIDINE, spray painted with three layers satin black and two layers clear coat. Rubber Sponge ( 3mm in thickness from Rubber Products & Moulding Cape Town ) was reapplied to all three flabs. The Boarder of the in- and outlets were sealed with 5mm Rubber Sponge.

Flab linkages were cleaned and greased with silikon grease.

The Fan Assy Metal Ring was redesigned, manufactured out of Aluminium ( and signed by manufacturer, a friend of mine ;-) )and spray painted with two layers of clear coat.

The Heat Exchanger is second hand from CARYOTA CPT bought for 650.- ZAR. It ( Heat Exchanger ) is actually the culprit which made me dissassemble to whole interior. In that sense, baie dankie ;o). It was submerged in a bucked of water and air pressure tested with 6 bars. NO BUBBLES !
Attachments
Heat Assy Heat Exchanger
Heat Assy Heat Exchanger
Heater Assy linkage
Heater Assy linkage
Heater Assy Heat Exchanger and Windscreen Flab
Heater Assy Heat Exchanger and Windscreen Flab
Heat Assy Feet and Cabin Flab
Heat Assy Feet and Cabin Flab
Heat Assy Flabs after Rubber Sponge Application
Heat Assy Flabs after Rubber Sponge Application
Heat Assy Flabs after Rubber Sponge Application
Heat Assy Flabs after Rubber Sponge Application
Heat Assy Flabs and Fan Assy Metal Ring after paint job
Heat Assy Flabs and Fan Assy Metal Ring after paint job
Heat Assy Flabs and Fan Assy Metal Ring after paint job
Heat Assy Flabs and Fan Assy Metal Ring after paint job
Last edited by Kensykatro on Thu Sep 27, 2012 10:55 am, edited 3 times in total.
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

The Roof was sound proofed means of Aluminium Antidroin Foil and Rubber Sponge 6mmm.
Attachments
Roof with Aluminium 6mm Rubber Sponge
Roof with Aluminium 6mm Rubber Sponge
Insulation & Antidroin (9).JPG (56.33 KiB) Viewed 7693 times
Roof with Aluminium Antidroin Foil
Roof with Aluminium Antidroin Foil
Insulation & Antidroin (8).JPG (62.88 KiB) Viewed 7737 times
Roof Before Soundproofing
Roof Before Soundproofing
Last edited by Kensykatro on Thu Sep 27, 2012 9:54 am, edited 2 times in total.
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

The Floor of the bakkie was freed of all sand and dust and thoroughly washed and cleaned out.

What was very much surprising ( in a positive way for sure ;o) ) to me was that the cabin shows literally no corrosion.
Attachments
Rear Cabin
Rear Cabin
DSC_0032.JPG (96.56 KiB) Viewed 7739 times
Floor Rear
Floor Rear
DSC_0031.JPG (98.5 KiB) Viewed 7739 times
Floor Rear
Floor Rear
DSC_0030.JPG (101.51 KiB) Viewed 7739 times
Floor Front
Floor Front
DSC_0029.JPG (109.07 KiB) Viewed 7739 times
Floor Dashbord Front
Floor Dashbord Front
DSC_0033.JPG (74.56 KiB) Viewed 7741 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Since the old Carpet is badly stained and carries some smells to my dislike I decided to go for a brandnew original Toyota Carpet. The carpet's insulation seems to be improved.

Upholstering of the carpet was considered but had a few contras:

1. It would have been quite difficult to get around all the obstacles on the Floor.
2. Cost was 1700.- ( New Carpet 2700.- )
3. The upholstery would have sticked the new carpet to the Floor. For a few reasons I do not want a carpet glued to the Floor. The Floor should be accessible all time for Corriosion Inspection, rewiring etc.
Attachments
DSC_0028.JPG
DSC_0028.JPG (65.02 KiB) Viewed 7737 times
DSC_0025.JPG
DSC_0025.JPG (60.17 KiB) Viewed 7737 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Airconditon Assy housing and Aircon Evaporator has been cleaned thoroughly inside and outside. New Sealing ( 5mm Rubber Sponnge ) has been applied with contact adhesive.
Attachments
Aircondition Evaporator (18).JPG
(127.6 KiB) Downloaded 2017 times
Aircondition Evaporator (14).JPG
Aircondition Evaporator (11).JPG
Aircondition Evaporator (10).JPG
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Fan Assy has been cleaned thoroughly inside and outside. Each blade of the fan was cleaned seperately, was a little mission. But a least its clean now.

The inlet/outlet flab was sealed with new rubber sponge 5mm. The flab linkages were cleaned and greased with silikon grease.
Attachments
IMG_1413.JPG
Fan Assy Flab Linkage
(170.48 KiB) Downloaded 1982 times
IMG_1412.JPG
Fan Assy
(169.15 KiB) Downloaded 1982 times
Fan Assy Inlet Circulation / Fresh Air Flab
Fan Assy Inlet Circulation / Fresh Air Flab
IMG_1409.JPG
Fan Assy Inlet
(167.49 KiB) Downloaded 1982 times
IMG_1408.JPG
Fan Assy Circulation Flab
(165.92 KiB) Downloaded 1982 times
Fan Assy Flabs new seal
Fan Assy Flabs new seal
Fan Assy (4).JPG (76.56 KiB) Viewed 7736 times
Fan Assy Flabs new seal
Fan Assy Flabs new seal
Fan Assy (3).JPG (65.52 KiB) Viewed 7736 times
Fan Assy Fan
Fan Assy Fan
Fan Assy (2).JPG (23.84 KiB) Viewed 7736 times
Last edited by Kensykatro on Thu Sep 27, 2012 9:59 am, edited 1 time in total.
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by george »

Well done mate. :clap: Awesome job you are doing
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Thank you George. Nice comment and very appreciated, keeps one going ;o).

But as it goes with some Projects you have little up and downs. And guess I just had a down one. Not too bad after all but still. It puts ones feet back on ground now and then :cooldude: .

With regards to the Front Runner Roof Rail installation i made a booboooooo....But will put a post at a later stage when sorted out.

" There are no Problems, ONLY SOLUTIONS!"

In that sense, have a lovely day.

Cheers

Matthias
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Mud Dog »

Great job meticulously done, Matthias!! :thumbup: :thumbup:

A word of advice ...... don't even try change the spark-plugs yourself, because you might end up stripping and re-building the whole motor!! :twisted: :lol: :lol: :lol:
When your road comes to an end ...... you need a HILUX!.

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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good morning Andy,

:o), I appreciate your advice.

To be honest, I am scared to even touch the sparky, cause I see myself hoisting out the engine...hihi.

No, no...No worries, Engine was partially overhauled so it should not be necessary to lift it out.

Have a lovely day,

Cheers

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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Mud Dog »

TKS! you too! :thumbup:
When your road comes to an end ...... you need a HILUX!.

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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Gents, your opinion is required...

A friend of mine ( thank you.... ;o) ) planted an interesting seed which I try not to get growing.

Since the bakkie is at this stage of renovation why not give it a new paint ( exterior ). The cost involved is roughly 8k to 10k ZAR. The new paint would give it another 10 years lifetime. Not that she urgently needed a paint, but being at this stage.

I mean she has got 270k on the clock with an partially overhauled engine...What do you folks think ? Will she one day hit the 500k mark...?
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Pora »

Kensykatro wrote:Gents, your opinion is required...

A friend of mine ( thank you.... ;o) ) planted an interesting seed which I try not to get growing.

Since the bakkie is at this stage of renovation why not give it a new paint ( exterior ). The cost involved is roughly 8k to 10k ZAR. The new paint would give it another 10 years lifetime. Not that she urgently needed a paint, but being at this stage.

I mean she has got 270k on the clock with an partially overhauled engine...What do you folks think ? Will she one day hit the 500k mark...?

dam sure she will i rate 1mil km will be a breeze :P
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Family_Dog »

Yep, and then after that it will hit the 800k+ mark as well, with regular servicing!


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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

:o) sounds good. But serious gents. Is it worth it ???

Go or no go ?
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Family_Dog »

Rhetorical question. It's a Hilux, go for it.

Do a search for "Bulldog gets new clothes", it might help you in deciding.


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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Mud Dog »

Kensykatro wrote::o) sounds good. But serious gents. Is it worth it ???

Go or no go ?
"Go" .... It's worth it, Matthias. The guys sound like they're joking, but seriously, with proper servicing that vehicle hasn't even hit the halfway mark. ;-)
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Here comes the winch with a new cloth.

Gearbox is already greased and assembled :cooldude:. Once the sealed bearing on the Motor Support is replaced it will be assembled as well. Ha, can't wait.

Assemblyyyy I am coming...Ha :yahoo:

This is very exciting times.

PS: Some may realized that the drum is missing. Had a little run which is sorted out.
Attachments
Gear Casing Rear
Gear Casing Rear
Gear Casing Front
Gear Casing Front
Motor Casing Rear
Motor Casing Rear
Motor Casing Front
Motor Casing Front
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by pietpetoors »

Looks good, will be better than new when you are done
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Mud Dog »

Looking really good!! :thumbup:
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by MOFASA »

Mud Dog wrote:Looking really good!! :thumbup:

That it is...

UPDATE PLEASE and more piktchas... :thumbup:
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Ahari »

What a great job! You got a lot of time to burn!

I like your attention to detail.

My only suggestion, although it is too late now is to electroplate all those little bits and pieces - even the nuts and bolts if you want! No paint, no rust, easy!

Can you do mine now? ;-)
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Hi everybody and thanks again for all the nice feedbacks.

Please find attached the Pics of the assembled and serviceable WARN M6000. The paint run on the drum was removed and the whole drum spray painted with another black layer. Certainly I could not wait to test run it. A dry run by directly connect the terminals to the battery worked out perfect. We will se how the winch works in the field, but this is another story.

Regarding getting her new a new dress...well I am sure she looks beautiful in a new outfit. But I decided the old one fits her still perfect, she is really in a good condition. The decision is based on a few quotes and some talkings to friends. If I want to have it properly done it will cost me around 13 K. I found a guy in vredenburg which got a pretty good reputation but does not have time now. I am pretty sure he would do a professional job as I would expect. Therefore I told myself should I still be in the mood next winter will be lots of time again. I would like to get her ready now and I am pretty sure that the 4x4ing this summer will surface some mods to be done for summer 2013.

Thank you guys anyways for all your inputs in this matter. In all likelhood I will approach you again Winter 2013.

Unfortunately I had only little time the past few weeks to carry on. Besides the winch assembly I decided to put new Electrical tape on some of the bakkies Dashboard wiring. The old sticky tape was removed and new tape neatly applied.

The Center Dashboard supports are fitted as well. Next step will be to install the Fan-, Aircon- and Heater Assy and then the Crashbar and Steering wheel Column...Can´t wait. Target time of 1st of November still in mind but might need some shifting to the right.
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WARN M6000 Reconditioned and Serviced
WARN M6000 Reconditioned and Serviced
WARN M6000 Reconditioned and Serviced
WARN M6000 Reconditioned and Serviced
WARN M6000 Reconditioned and Serviced
WARN M6000 Reconditioned and Serviced
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Ahari wrote:What a great job! You got a lot of time to burn!

I like your attention to detail.

My only suggestion, although it is too late now is to electroplate all those little bits and pieces - even the nuts and bolts if you want! No paint, no rust, easy!

Can you do mine now? ;-)
Thanks for the Input Alan, electroplating would have been great. Unfortunately I am too far now and summer is on its way. But will keep it still in mind for Winter 2013.

Will do yours in Winter 2014 ;o).

Cheereo, Matthias
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Ahari »

Kensykatro wrote: Will do yours in Winter 2014 ;o).
Ha haa! I await your call!
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Hiluxfan_111 »

Hi Matthias.
Looking great so far!
Just one word of warning! Make sure your winch is properly earthed when you re-fit it.
I made the mistake when doing mine. While winding the cable back onto the drum, the electrical current somehow found its way into the earth wires of the vehicle harness. Needless to say those wires are not made for that kind of current and completely melted.
It was not a pretty sight! I had to replace the complete harness! :oops:
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good day Roelof,

Thank you for your valuable input. I will make sure earthing is properly established prior fitting.
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good day,

It's been just about 3 month since I last posted. I have been quite busy and the bakkie is assembled and alread made a trip to Namibia. But this is just a brief info. Let me give you the details on about what has been done since may last post.

First lets have a look at the winch. It is fully rebuild and operational. The wires have been replaced by new 35mm cables and routed in a protective hose to the battery. The cable has been replaced with a new one. The pins and cables of the remote control connector which is mounted to the bullbar have been replaced.
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Warn M6000 rebuild
Warn M6000 rebuild
IMG_1662.JPG (84.05 KiB) Viewed 6242 times
Warn M6000 solenoid pack rebuild and rewired
Warn M6000 solenoid pack rebuild and rewired
IMG_1661.JPG (75.03 KiB) Viewed 6242 times
Warn M6000 before rebuild
Warn M6000 before rebuild
IMG_1036.JPG (84.54 KiB) Viewed 6242 times
Warn M6000 before rebuild
Warn M6000 before rebuild
IMG_1035.JPG (88.51 KiB) Viewed 6242 times
Warn M6000 Solenoid pack before rebuild
Warn M6000 Solenoid pack before rebuild
IMG_1034.JPG (84.48 KiB) Viewed 6242 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

With regards to the Roof Rack installation I still owe you an update. As mentioned earlier in the post I made a little boboo.

When I was about to install the soundproofing to the roof the Roof Rack Rails were not installed yet. I thought I have to make provision for the bolts and made cut outs on the soundproofing. But well, not only cut outs were made but pilot holes drilled. Soon later I realized that the location is completely wrong. The Rails have to be mounted on the reinforced roof structure. Well the 3mm pilot holes were repaired with counter sink rivets and to prevent future corrosion protected with seal. This procedure is called wet rivetting.

The Roof Rack rails are fitted with four 6mm bolts each. The nuts and the drills have been sealed off on the inside of the ceiling with Windscreen seal.

The ceiling itself has been upholstered and looks brandnew.
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Ceiling upholstered
Ceiling upholstered
Ceiling (10).JPG (117.28 KiB) Viewed 6241 times
Ceiling upholstered
Ceiling upholstered
Ceiling (11).JPG (130.29 KiB) Viewed 6241 times
Ceiling Soundproofing & Roof Rack bolts
Ceiling Soundproofing & Roof Rack bolts
Ceiling (3).JPG (116.89 KiB) Viewed 6241 times
Ceiling Soundproofing & Roof Rack bolts
Ceiling Soundproofing & Roof Rack bolts
Ceiling (1).JPG (129.31 KiB) Viewed 6241 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Dashboard and all covers have been thouroughly cleaned. Event the heater outlets were disassembled and cleaned. The inside of the interior covers were soundproofed with 3mm rubber foam.
Attachments
Side Covers Front LH & RH soundproofed
Side Covers Front LH & RH soundproofed
Interior Covers (2).JPG (126.42 KiB) Viewed 6241 times
Side Covers Rear LH & RH soundproofed
Side Covers Rear LH & RH soundproofed
Interior Covers (1).JPG (120.92 KiB) Viewed 6241 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Well and eventually the following pics is the result of this whole project. She got fitted with a Howlingmoon rooftop tent and a canopy. She made a two week 4'500km trip to Namibia with out any Problems. Only the one Tyre gave me some Problems, but beside that all 100%. She has got 275k km on the clock.After the trip the Front and Rear Diff Oil, Motor Oil and Gearbox Oil was replaced. The last Motor Oil Change was done at 269k km. I am very excited about the engines performence and happy to tell you that the engine literally uses no oil at all.
Attachments
Namiba 2013 (754).JPG
Namiba 2013 (754).JPG (95.04 KiB) Viewed 6240 times
Namiba 2013 (433).JPG
Namiba 2013 (433).JPG (104.81 KiB) Viewed 6240 times
Namiba 2013 (307).JPG
Namiba 2013 (307).JPG (123.75 KiB) Viewed 6240 times
Namiba 2013 (299).JPG
Namiba 2013 (299).JPG (121.53 KiB) Viewed 6240 times
Namiba 2013 (43).JPG
Namiba 2013 (43).JPG (107.98 KiB) Viewed 6240 times
Namiba 2013 (6).JPG
Namiba 2013 (6).JPG (132.84 KiB) Viewed 6240 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Dzombo4 »

Awesome job, wish you many happy Km's
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Damaruri »

Kensykatro wrote:Good day,

I just bought this Front Runner Roof Rail Kit 99 FRXH02 for my Toyota Hilux 1999 D/c 2.7i.

I am planning on fitting the Rooftop Tent or a rack on it. But first I need to install it on the roof. Does anybody have some helpful information and tips on how to remove the ceiling of my bakkie and best to install this Kit.

Thanks and cheereo,

Kensy
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Damaruri »

I think this is what you need
You can get it for free
Regards
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DSCN0221.JPG
DSCN0221.JPG (16.91 KiB) Viewed 6239 times
DSCN0222.JPG
DSCN0222.JPG (17.86 KiB) Viewed 6239 times
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Good day all.

My days are becoming less in this beautiful land of yours. Since these posts a Howling moon Rooftop and a Aluminium Canopy was added.

Unfortunately I have to leave my bakkie to the place she belongs....

Please ref.: viewtopic.php?f=129&t=33620" onclick="window.open(this.href);return false;
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Thabogrobler »

Mattias,

Did the roof insulation make a big difference, and if so what, noise, heat?
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Re: Project X ( Front Runner Roof Rail Kit 99 FRXH02 )

Post by Kensykatro »

Hi Thabo,

To be honest, I can't really tell you. Since the noise is transferred from botthem through the tires on to the chassis, I do not think it made a big difference. Heatwise it would probably help, since it burns on t the roof ( without rooftop ). But I didn't drive the bakkie long enough before the modes to make out big differences.
Warthog : 1999 2.7i DC Raider 4x4
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