'87 Hilux DC Re-build

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'87 Hilux DC Re-build

Post by Knuppel »

After the introductions viewtopic.php?f=137&t=39895&p=471501#p471293 I think it is time to start the build thread as things are going fast on some days :celebrate:

Once done this Hilus will be my daily ride so it needs to be reliable. At this stage i am thinking seriously about fitting a 1UZ but my mind is still investigating and pondering the thought and work involved.

I bought the vehicle knowing that the gearbox is buggered and that the engine may be blown, confirmed once I got it started at the yard :o:

This bakkie looks good from far but far from good, as stated before "a good base to work from".

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Re: '87 Hilux DC Re-build

Post by Knuppel »

And so the fun started

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Re: '87 Hilux DC Re-build

Post by Knuppel »

Some more pics of progress.......for those who battle to read

Sold the rims it came with, fitted 10" X 15" rims with 32 X 11.5 X 15 tyres

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Re: '87 Hilux DC Re-build

Post by Knuppel »

:dance1:

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Re: '87 Hilux DC Re-build

Post by MOFASA »

Fit a WL 2.5 Turbo Diesel

If fitted correctly its the BEST conversion for the price....
I have one fitted and WILL NEVER change it......
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
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Re: '87 Hilux DC Re-build

Post by Knuppel »

It had one in, not impressed with the conversion work but I believe the WL is not too bad. I need more power however. The one I stripped out has compression comming out the wrong holes :twisted:
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Re: '87 Hilux DC Re-build

Post by pampoen »

Can i suggest that if you're looking for a lexus v8, to go for the vvti with original ECU to keep things reliable and running as they should, also large gains can be had over the non vvti v8 with fuel economy. Google v8 solid, or lextreme.co.za, you can pick up a unit complete with gearbox controller and all the other stuff, lambda sensors, air flow sensor and all the wiring in a nice neat bundle to a water proof fusebox for R18500. It also comes with obd 2 plugs and a flash diagnostic for on the go info.
With each replacement of parts, a car slowly becomes Chinese.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Got your message on the other thread also, Thanks!
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Body getting a good scrubbing, the inside floor area is rubberised :aggresive:

I suspect something was hidden :twisted:

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Re: '87 Hilux DC Re-build

Post by Knuppel »

The problem.......

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Where the problem started, rust patch was cut and replaced, so no more water into cab :celebrate:

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Closing the inspection hole back up.

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Re: '87 Hilux DC Re-build

Post by Knuppel »

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Re: '87 Hilux DC Re-build

Post by JohanW »

Marius, consider enlarging that drainage hole. Also maybe remove the bottom lip. If you can stop leaves and all manner of rubbish collecting in there and having the water drain completely you will never have rust issues again in that area.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

I have been checking it from all angles there, metal fatigue is part of the problem and is caused by that drain hole not supporting the motion coming from the front cab mounting. Increasing the hole size will increase the flexing in that part. The way we have smoothed it out will ensure no water remains standing there. We also filled all the crevices and cracks with sikaflex. I was thinking about fitting a gause below the vent grid to prevent leaves from falling in. Good suggestion, thanks
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Re: '87 Hilux DC Re-build

Post by Mud Dog »

Nice work there! :thumbup:

The gauze is a good idea, some vehicle have it as standard and it certainly does help, but personally I think that the finer dirt that gets in there is just as much to blame if it's allowed to accumulate - it retains moisture. Ideally there should be no grooves, hollows / depressions, cracks or crevices where it can begin to accumulate.
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Re: '87 Hilux DC Re-build

Post by MOFASA »

Knuppel wrote:It had one in, not impressed with the conversion work but I believe the WL is not too bad. I need more power however. The one I stripped out has compression comming out the wrong holes :twisted:
Will you be rebuilding that WL or selling it?
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Re: '87 Hilux DC Re-build

Post by Knuppel »

I sold,it as is, on Friday, got R9k for it. Seems to be a saught after item.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Work comes first so progress accordingly
The bottom of the cab is done now, will focus on some surface rust on the chassis.
Then the cab will go back to the chassis. Still have to go buy a Lexus.

What colour to paint this little beasty, white it will not be.


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Re: '87 Hilux DC Re-build

Post by Reinart21 »

Marius, what Lexus are you looking to use? Going auto or manual route?
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Re: '87 Hilux DC Re-build

Post by The Legend »

Knuppel wrote:Work comes first so progress accordingly
The bottom of the cab is done now, will focus on some surface rust on the chassis.
Then the cab will go back to the chassis. Still have to go buy a Lexus.

What colour to paint this little beasty, white it will not be.


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I like that khaki colour very much
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Reinart21 wrote:Marius, what Lexus are you looking to use? Going auto or manual route?
Sorry, I missed your post, will be using the lexus vvti with auto box with adaptor to t/box.
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Re: '87 Hilux DC Re-build

Post by Reinart21 »

Sorry Marius, I think I meant to ask what ECU?
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Reinhart, will be using the original one intended for the engine, OEM!
I don't want to spend the next three years tuning, and tuning and tuning.................
Plug and play as far as possible. Even going to get the OEM Shifter.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Look what I got over the week-end. Small steps but they count a lot.
Replacement facia for the vent controls R50! :celebrate:
The old one is a bit perished.

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Re: '87 Hilux DC Re-build

Post by Knuppel »

Been playing with some colours

This first one is a definite NO-GO

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This one has my attention........and its a Toyota colour
What do you guy thinks.....or am I boring you?

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Re: '87 Hilux DC Re-build

Post by 4x4BEES »

That orange looks brilliant :thumbup: :thumbup:
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Swambo also likes the orange! so I am on the right track :D:

Toyota 86!! se kleur
It pops... I like

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Re: '87 Hilux DC Re-build

Post by 4x4BEES »

:drool: :drool: :thumbup: :thumbup:
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Re: '87 Hilux DC Re-build

Post by Reinart21 »

Great colour choice!! :thumbup: :thumbup: :clap: :clap:
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Progress is slow but the chassis is ready.

Will be fitting 1UZ vvti with auto box
Going to use OEM shifter so that ALL the electronics will be OEM.
Adaptor for 1UZ Autobox to Hilux T/box is being manufactured( Two week lead time)
When all the goodies are ready I will go collect in PTA.

All paint has arrived but still busy preparing the body


Chassis completed.
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The paint is amazing, depending on the angle to the sun it changes colour.
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Re: '87 Hilux DC Re-build

Post by MOFASA »

:drool: :drool: :drool:

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Re: '87 Hilux DC Re-build

Post by LouisZ »

Sjoe daai kleur gaan verskriklik mooi lyk. :thumbup:

As dit sal help kyk na die ene. Kan help met die uitleg op die 3UZ binne die enjin kompartiment.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Sjoe, maar daai is netjiese werk!!!!!! :drool:

Ek mik in dieselfde rigting vir onder die bonnet. Dit moet lyk asof hy so uit die fabriek kom.
1UZ & 3UZ is identies dieselfde, wat het jy gebruik vir engine mountings as ek mag vra, n prentjie sal duisend woorde spreek :beg:

Waar kom daai expansion tenkie vandaan?
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Re: '87 Hilux DC Re-build

Post by Reinart21 »

Ek sit met presies dieselfde probleem. Engine mountings...

Kom kêrels dis vir n goeie doel!! Help bietjie uit...
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Re: '87 Hilux DC Re-build

Post by LouisZ »

Die bottle is 'n VW golf sin :silent:

Ek neem fotos van die mounts vanaand vir julle.

Ignoreer die cone filter, die ordenlike boks moet nog in.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

:thumbup: Dankie Louis, dit gaan baie help
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Re: '87 Hilux DC Re-build

Post by LouisZ »

Fotos is op my thread van die mounts.

Nogals se as jou Hilux klaar is sal dit verskiklik koppe laat draai.
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Dankie Louis. Gaan probeer om haar te laat blink!
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Re: '87 Hilux DC Re-build

Post by Knuppel »

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Re: '87 Hilux DC Re-build

Post by Agteros »

Dit lyk regtig regtig amazing.... :clap: :thumbup:
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Re: '87 Hilux DC Re-build

Post by Pietman »

Lyk spogerig :thumbup: :thumbup: :thumbup: :clap:
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Re: '87 Hilux DC Re-build

Post by MOFASA »

When you done it going to be 1 of a kind.....

Please give us a breakdown of cost so far cos I am thinking maybe its time for MOFASA to get a rebuild
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Re: '87 Hilux DC Re-build

Post by 4x4BEES »

Agteros wrote:Dit lyk regtig regtig amazing.... :clap: :thumbup:
+1 :drool: :drool: :thumbup:
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Re: '87 Hilux DC Re-build

Post by Knuppel »

MOFASA wrote:When you done it going to be 1 of a kind.....

Please give us a breakdown of cost so far cos I am thinking maybe it's time for MOFASA to get a rebuild
I will give you a breakdown on the costs of the complete project so far but I have an unfair advantage that most people don't have!

+R40 000 Bakkie
-R 9 000 Engine
-R 2 500 Wheels and rims
+R 0 Wheels and rims I have had those for a while and are paid for
+R 6 000 Paint
+R 6 000 Adaptor
+R16 500 Engine & gearbox
+R 750 OEM Fuel pump
+R2 800 OEM Rear Sump
+R2 500 OEM Shifter
+R 0 Bodywork
+R 0 Metal work
+R 0 Cleaning
+R 0 Engine mountings (Made in house)
+R 0 25mm Lift kit ( Made in house)

R60 500 total
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Re: '87 Hilux DC Re-build

Post by Knuppel »

Thanks for all the compliments so far Guys!
Some days lots of progress and other days ZERO
As time allows. :boss:
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Re: '87 Hilux DC Re-build

Post by MOFASA »

Knuppel wrote:
MOFASA wrote:When you done it going to be 1 of a kind.....

Please give us a breakdown of cost so far cos I am thinking maybe it's time for MOFASA to get a rebuild
I will give you a breakdown on the costs of the complete project so far but I have an unfair advantage that most people don't have!

+R40 000 Bakkie
-R 9 000 Engine
-R 2 500 Wheels and rims
+R 0 Wheels and rims I have had those for a while and are paid for
+R 6 000 Paint
+R 6 000 Adaptor
+R16 500 Engine & gearbox
+R 750 OEM Fuel pump
+R2 800 OEM Rear Sump
+R2 500 OEM Shifter
+R 0 Bodywork
+R 0 Metal work
+R 0 Cleaning
+R 0 Engine mountings (Made in house)
+R 0 25mm Lift kit ( Made in house)

R60 500 total

Not bad if you take the price off the bakkie its good pricing.....

Whats your advantage do tell
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To 4x4 or not to 4x4 thats the question....
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Town: Empangeni
Vehicle: Toyota Hilux 4x4 98 SFA DC
Real Name: Ray

Re: '87 Hilux DC Re-build

Post by rayv »

Wow Amazing !

Gaan Amazing wees Marius !

Sal baie graag wil sien waneer klaar is.
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Knuppel
LR 4WD Full Lockers
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Town: Somewhere in Africa
Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Mofasa, My advantage is in the Zero amounts! I have the labour of a panel beater, spray painter, boilermaker, turner and mechanics of my choice available.
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Knuppel
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Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Ray, julle sal hom sien hier! ;-)
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niclemaitre
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Town: Stellenbosch
Vehicle: 99 IFS DC 4x4
Real Name: Nic
Location: Stellenbosch

Re: '87 Hilux DC Re-build

Post by niclemaitre »

Knuppel wrote:Look what I got over the week-end. Small steps but they count a lot.
Replacement facia for the vent controls R50! :celebrate:
The old one is a bit perished.

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Where did you get that please?
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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Knuppel
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Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Scrap yard in Nelspruit, Izuco, on the Barberton road, have a friend that lives closeby and fetched me one.

I will ask and see if they can find another one.
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niclemaitre
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Vehicle: 99 IFS DC 4x4
Real Name: Nic
Location: Stellenbosch

Re: '87 Hilux DC Re-build

Post by niclemaitre »

Thanks!

Did your bumper arrive?
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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Knuppel
LR 4WD Full Lockers
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Posts: 553
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Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

It arrived yes...........and they managed to break off the one corner piece :irate: I am practising to remain calm.
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niclemaitre
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Location: Stellenbosch

Re: '87 Hilux DC Re-build

Post by niclemaitre »

Knuppel wrote:It arrived yes...........and they managed to break off the one corner piece :irate: I am practising to remain calm.
Ag nee! As far as I know they are available as spares still.

Time Freight are not my favourite couriers...
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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MOFASA
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Location: Kempton Park

Re: '87 Hilux DC Re-build

Post by MOFASA »

Knuppel wrote:Mofasa, My advantage is in the Zero amounts! I have the labour of a panel beater, spray painter, boilermaker, turner and mechanics of my choice available.
That's luck.... Can I call on your services too please... :beg:
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP :yahoo: ..... You wouldn't understand....
ImageImageImage[rimg=206x128]
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Knuppel
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Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Tomorrow!

Tomorrow never comes
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MOFASA
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Location: Kempton Park

Re: '87 Hilux DC Re-build

Post by MOFASA »

Knuppel wrote:Tomorrow!

Tomorrow never comes
:lmao: :lmao: :laugh2: :laugh2: :lmao: :lmao:
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP :yahoo: ..... You wouldn't understand....
ImageImageImage[rimg=206x128]
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Knuppel
LR 4WD Full Lockers
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Posts: 553
Joined: Sat Aug 29, 2015 2:11 pm
Town: Somewhere in Africa
Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Some progress pics

Cab prepared, ready for painting, just got to hang the doors but need to rebuild the driver door's hinges first

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:shock2: Some body putty on the load body, I think the PO got putty for Xmas!!

Luckily I have a Panel beater and not a new part fitter

Load bin, we removed the panels so they can be repaired properly
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Crazy body putty! :silent:
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Putty removed
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Rubberizing hiding some rust

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Check the thickness :blackeye:
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Knuppel
LR 4WD Full Lockers
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Posts: 553
Joined: Sat Aug 29, 2015 2:11 pm
Town: Somewhere in Africa
Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Re: '87 Hilux DC Re-build

Post by Knuppel »

Some mechanical progress

Got my engine
Fitted gearbox adaptor
Mockup of engine into body
55mm lift on body

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Wikkels
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Posts: 77
Joined: Tue Oct 27, 2009 8:31 pm
Town: Kathu
Vehicle: 1997 Toyota Hilux 2.4 D/C SFA - 2013 Mitsubishi Triton 2.5 4x2 D/C
Real Name: William
Location: Northern Cape

Re: '87 Hilux DC Re-build

Post by Wikkels »

Dit gaan een awesome Hilux wees!! :thumbup:
The man who smile when things go wrong thought of someone to blame it on!


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Reinart21
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Town: Secunda
Vehicle: Toyota Hilux 3.0 D4D 4X4 D/C 2011 - ONCA Bullbar Dastek Unichip 76MM S/S Freeflow Leveling Kit. Hilux SFA '97 D/C OME Suspension extra long range tank', V8 coming soon!
Real Name: Reinart

Re: '87 Hilux DC Re-build

Post by Reinart21 »

Well done with the progress!

Where did you get your shifter?
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