Brakkenjan's change from Ordinary to Custom

Post by **JohanM** » Tue Aug 03, 2010 12:30 pm

During the early stages of this year, I had planned to slowly turn my SFA into the Overlander that I need. I Decided that it would be done in Phases as to allow the vehicle to be on the road when needed, and modified when not used.

So here follows a brief breakdown of the Stages that thus far has been completed.
Stage 1 was to sort out the wiring inside and under the bonnet of the vehicle and to fit a new alarm system. Also I needed to get the Cab noise lower as doing 1400km in one day does become tiring when driving a noisy vehicle.

Stage 2 was to remove the rubberrising on the loadbin, replace the broken tailgate latch and redo the loadbin with something more vehicle friendly.

Stage 3 involved the canopy being modified with Alu side doors and to build my own loading/kitchen/overlanding system. I needed it to be able to be removed when needed to, but also be lightweight, robust and able to be added onto as the requirements grow.

So below is the story of Stage 1.

I had erratic starter problems during the late stages of last year, and also lost a battery do to a 45AMP Alternator not being able to charge more than 12.4 Volts.
SO I managed to trace the starting problem to the Faulty immobilser. So I got a new system and decided to fit it myself in a different way than the standard fitment centre's use. Also the Alternator was changed to a 90 Amp unit sourced from a VW Golf. Made some minor changes to it and now it charges at 13.8 Volts - 14.3 volts depending on the state of charge in the battery.

I searched high and low for some decent sound deadning material and managed to get some via my Nephew. SO out when the inside, and the wires have been fixed, fitted the alarm, added the sound deadning material after I cleaned the floor of some old glue stuff that was left behind by the first owners attempt of sound deadning. I spent a long time sorting the basics out and managed to get everything working as it should and also sorted some rattles in the dash out.

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Post by **JohanM** » Tue Aug 03, 2010 12:41 pm

Here is the special sound deadnin pads fitted to the floor and they do make a tremendous difference. My sfa only starts to become noisy and tiring to drive when pushing above 130km/h or above 3800 RPM. Up to this speed it compares with an IFS in road noise.

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This is what you call a nightmare. This is a VESA approved installation on my vehicle. Well I removed it and decided to fit the new one in a different way.

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I spent a lot of time redoing the wires to the headlights, fitted new connects to match the H4 Night breaker globes I bought. I also decided it was time to tidy up every wire I could find, made sleeves and or integrated and made new harnesses as needed in order to make sure that everything runs smoothly when out in the far reaches of the bush.

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I also decided that it was time to let the old Jensen Radio go, and replace it with a Decent robust Sony CD player.

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Here is the proof of my new ALternator giving the required juice....

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OOOOMS · Post by **OOOOMS** » Tue Aug 03, 2010 12:46 pm

Lyk goed Johan

Here is the special sound deadnin pads fitted to the floor and they do make a tremendous difference. My sfa only starts to become noisy and tiring to drive when pushing

Dis baie interessant!!!

Post by **JohanM** » Tue Aug 03, 2010 12:48 pm

Stage 2 was the worst part of it. It really is not giving you a good feeling when you start to take to the loadbin with a hammer and a chisel to remove old busted rubberrising.

It took me 4 days to clean the old stuff off before I could apply the undercoat and prep the vehicle for its new load liner.

I masked the vehicle because i also used the grinder to remove some of the hard rubber with that.

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While i was busy with the loadbin I added some extra dust proofing to the tailgate. I tested it with letting water into the bin, and nothing comes out the tailgate now.

Spartan · Post by **Spartan** » Tue Aug 03, 2010 12:51 pm

Jy was omtrent lus vir werk, nice report

Post by **JohanM** » Tue Aug 03, 2010 1:01 pm

Stage 3 was the most pleasing but also the most frustrating and difficult part of the changes thus far. Having to plan for most things upfront, doing simulations and drawings is where the rest has come from. I uses 4 & 6mm Plywood and laminated it between aluminium angle iron to gie the wood the required strength. I decided that using large flange pop rivits (4.8mm) washers and sikaflex it would provide the strength and sealing capability that I required.

I cut the wood to sizes, and then paint them in order to give it a sealing layer before the work started.

I popped the side windows out, bought Aluminium treadplate and square tubing, and set off to make my own side windows. I also opted to keep the Aluminium frames of the windows and use them as the support for the doors.

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I also made a toolbox which would hold all the stuff that was in my ammo crate, and also the compressor and recovery gear.

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OOOOMS · Post by **OOOOMS** » Tue Aug 03, 2010 1:12 pm

What can I say......impressive!!!

Spartan · Post by **Spartan** » Tue Aug 03, 2010 1:17 pm

Dit is mos hoe jy dit doen

Bosfebok · Post by **Bosfebok** » Tue Aug 03, 2010 1:26 pm

Ek is mal oor werk... ek kan ure daarna staan en kyk

Dit lyk baie goed en lyk of dit baie prakties is ook... well done

Post by **george** » Tue Aug 03, 2010 1:37 pm

Geluk Johan.Dit lyk sommer bakgat

Post by **JohanM** » Tue Aug 03, 2010 1:44 pm

Baie dankie, dit is baie werk maar dit is lekker om dit self te doen.....

Hier is die Kombuis en die toolbox in die SFA. Nou moet ek hulle net mooi gaan vasmaak en dan gaan ons die kleinere details klaarmaak. Ek wil Saterdag die Voertuig weegbrug toe neem met alles in en kyk wat weeg die Trok.

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Ek het 'n dustcover gemaak wat oor die kombuis pas, net om die meeste stof weg te hou en ook sommer net om dit bietjie afterond.

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Daar is nog baie dinge wat moet klaarkom maar sover is die ergste in en daar is nog lekker baie pakplek agter in die voertuig vir alles wat moet saamry.

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Post by **CasKru** » Tue Aug 03, 2010 1:52 pm

Post by **Family_Dog** » Tue Aug 03, 2010 4:08 pm

Nicely done Johan! Professional, as usual.

-F_D

kfxnando · Post by **kfxnando** » Tue Aug 03, 2010 4:38 pm

yep very impressive!!!

yep those Golf alternators are great, however those Golf alternators properly modified are even better!! 14.4 under load, with lights, spots aircon, and what ever else one can find to switch on, at Idle!! hehehe!!

agree, the wiring that most figment centers do, leave a lot to be desired!!

looks like a great job on every thing!!

FUDGES · Post by **FUDGES** » Tue Aug 03, 2010 4:48 pm

Baie mooi gedoen!!!

sabiankahn · Post by **sabiankahn** » Tue Aug 03, 2010 9:52 pm

Dis 'n dem netjiese job! Veels geluk!

Post by **JohanM** » Tue Aug 03, 2010 10:06 pm

Vir die wat wonder, nee ek het nie niks gedoen van middag nie. Die groot werk om die kaste te fit is klaar, nou begin die detail werk van al die kleinere fitments van elke ander los ding wat moet saam ry.

Van die verdere fitments wat ek moet doen, is 'n slide rail vir ammo boxes om saam te ry asook 4x Jerry kanne en dan die pale vir die tente, warm shower, en ook die braai rooster wat altyd 'n pes is om te pak en te vervoer.

Ek sal die res opsit soos ek dit klaar maak. More moet ek gaan friction pads koop vir die OME vere. Myne is glad en dit is stage 4 van die veranderinnge is om die vere te strip en skoon te maak en weer nuut te ghries en terug te sit sodat hy lekker kan flex en sag ry..

Die wat Thabazimbi toe gaan sal kans kry om van nader te kan kyk hoe die nuwe opset werk, op die vuurdoop naweek....

OOOOMS · Post by **OOOOMS** » Tue Aug 03, 2010 10:09 pm

Johan, ek sien nie 'n drie-poot pot nie....

Post by **JohanM** » Tue Aug 03, 2010 10:12 pm

OOOOMS wrote:Johan, ek sien nie 'n drie-poot pot nie....

Mark, watse driepoot praat jy van??? Kamera driepoot of die swart driepoot pot??

OOOOMS · Post by **OOOOMS** » Tue Aug 03, 2010 10:23 pm

Toro-Adventures wrote:
OOOOMS wrote:Johan, ek sien nie 'n drie-poot pot nie....
Mark, watse driepoot praat jy van??? Kamera driepoot of die swart driepoot pot??

Vir die pap en sous

Post by **JohanM** » Tue Aug 03, 2010 10:33 pm

Mark hy kom tussen die ander dinge agter in. Hy is lomp en ongemaklik om te pak so die kombuis se ontwerp het dit uitgesluit om rede dit so moeilik is om te pak.

OOOOMS · Post by **OOOOMS** » Tue Aug 03, 2010 10:36 pm

Reg so, jy moet hom net nie vergeet nie....as ons einde van die maand gaan kamp nie...

Post by **JohanM** » Tue Aug 03, 2010 10:38 pm

OOOOMS wrote:Reg so, jy moet hom net nie vergeet nie....as ons einde van die maand gaan kamp nie...

Ek sal nie, maar jy gaan die pap moet maak dan.....

Yes please, ek's mal oor pap en sous

Spartan · Post by **Spartan** » Wed Aug 04, 2010 6:22 am

Toro-Adventures wrote: jy gaan die pap moet maak

Jong ek weet nie of jy dit moet waag nie

OOOOMS · Post by **OOOOMS** » Wed Aug 04, 2010 8:27 am

Spartan wrote:
Toro-Adventures wrote: jy gaan die pap moet maak
Jong ek weet nie of jy dit moet waag nie

Lekker pap met 'n warm sous....yummmmmmy :!: :!: Jaco, Ouma se chilly sous, hou julle van warm sous?

Spartan · Post by **Spartan** » Wed Aug 04, 2010 9:05 am

OOOOMS wrote:hou julle van warm sous?

Nee nie regtig nie

OOOOMS · Post by **OOOOMS** » Wed Aug 04, 2010 9:09 am

Spartan wrote:
OOOOMS wrote:hou julle van warm sous?
Nee nie regtig nie

Tyd dat julle bietjie kom kuier....dan kan ek julle bietjie leer!!!

Spartan · Post by **Spartan** » Wed Aug 04, 2010 9:25 am

Hey ons is off-topic

OOOOMS · Post by **OOOOMS** » Wed Aug 04, 2010 9:28 am

Spartan wrote:Hey ons is off-topic

Sorry....man

Johan, waar pak jy jou chillies....?

Post by **JohanM** » Wed Aug 04, 2010 2:18 pm

OOOOMS wrote:
Spartan wrote:Hey ons is off-topic

Sorry....man

Johan, waar pak jy jou chillies....?

Mark ek sit hulle gewoonlik by die beker in van die een wat die stoutste is in die groep.....

OOOOMS · Post by **OOOOMS** » Wed Aug 04, 2010 2:50 pm

Bring dit saam

Post by **JohanM** » Thu Aug 19, 2010 7:53 pm

SO vinnige update.

Ek het vandag die nuwe speaker mountings gebou wat agter in die voertuig kom. Ook het ek plek gemaak om my verwysings boeke saam te ry daarso asook die kaarte ect.. Ek sal die naweek foto's neem sodra hy in is op sy plek. More moet hy ge-upholster word en Saterdag sal ek hom dan fit op sy plek bo in die dak bo die agterste sitplek.

Ek sal die naweek begin met die roof console sodat die ook klaar is voor die naweek wat kom.

swartvark · Post by **swartvark** » Thu Aug 19, 2010 8:54 pm

Baie netjies.
Ek kan nie wag om die res te sien nie!

Post by **JohanM** » Sat Aug 21, 2010 7:10 pm

Hier is die nuwe agterste roof console waaring die Speakers pas asook dan 'n lekker groot plek om my Verwysings boeke & Kaarte te sit sodat ek dit darem kan bykom sonder om die binnekant om te keer.

Ek sal Maandag die draade na die speakers in sleeving sit en wegsteek in die hoeke sodat dit netjies lyk.

Verder het ek die voorste roof console amper klaar gemaak vandag. Moet maandag gou gaan scrapyard crawling doen opsoek na 'n dakliggie asook mapreading lights van 'n Vigo/Fortuner, en dan sal ek dit ook upholster en fit.

OOOOMS · Post by **OOOOMS** » Sat Aug 21, 2010 9:15 pm

...eks bly ek sit nie agter nie....

Post by **JohanM** » Sat Aug 21, 2010 9:21 pm

OOOOMS wrote:...eks bly ek sit nie agter nie....

Ja dit is nou maar knap daarso.

Ek het ook nie agterste saftebelts in nie, so wil nie he daar moet iemand verkieslik saam ry nie.

Post by **JohanM** » Mon Aug 23, 2010 7:51 pm

So today I went scrapyard crawling and found some new things to finish the project off before heading down to the coast in 4 weeks time....

So I got a extra dome light from a Venture but no lens cover. Also found Complete undamaged mapreading lights from a Isuzu, and 2 near perfect Corolla seats to reupholster & Fit to my SFA.

SO I spent the day finishing off the roof console.

It has 2x Interior lights that works on the normal door triggers & then I wired the Map Reading lights to work seperately via their own switches.

Also the console was not designed to keep a radio up there but rather things like Cd's Wallets ect when travelling. It has two similar sized pockets where you can put things in, one on each side.

Here is the pictures..

Here is the seats I got today. All the covers are there and everything works 100%. Even got to test it before I took it....

Now it is time to remove the seat coverings, and have new Two tone Canvas covers made for it. The Once colour will be the same as the new consoles that I have fitted already. Then its time to fit them in the place of the Bench seat and Lastly I will make a floor console that will it from the front to the back of the front seats.

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Traveler · Post by **Traveler** » Mon Aug 23, 2010 8:24 pm

Interesting thread.

Post by **JohanM** » Mon Aug 23, 2010 8:33 pm

Traveler wrote:Interesting thread.

Heinrich, most of these mod's and changes was planned a long time ago, but then when I got the quotes to have everything done I left it STD for a very long time. SO most of these changes are actually long overdue.

I am now nearing the end of a long road of changes and once this is done I shall start getting other goodies again for the Hilux...

OOOOMS · Post by **OOOOMS** » Mon Aug 23, 2010 8:52 pm

Hi Johan, dit lyk goed

Ek gaan nou bietjie jou planne omkrap.... kan jy nie plan maak om daai roof console te modify nie? .....om daai boks te bou net vir liggies en CD's in te bere klink vir my na bietjie van 'n waste?

Jy gan jou kop teen daai console stamp

Post by **JohanM** » Mon Aug 23, 2010 8:58 pm

OOOOMS wrote:Hi Johan, dit lyk goed Ek gaan nou bietjie jou planne omkrap.... kan jy nie plan maak om daai roof console te modify nie? .....om daai boks te bou net vir liggies en CD's in te bere klink vir my na bietjie van 'n waste?

Jy gan jou kop teen daai console stamp

Mark ek kan 'n Radio wel mount daarin as ek wou, maar nou is die varkie eers bietjie maar, so vir eers sal hy so moet doen. :shifty:

Ek mag dalk die naweek my kopstamp, maar nie daarna nie want dan kan ek my seat recline met die aparte bucket seats in......(Lees Luxury SFA...

)

OOOOMS · Post by **OOOOMS** » Mon Aug 23, 2010 9:02 pm

OK, ekke verstaan nou beter! Dog nou net jy het 'n maase CD versameling wat jy daar gaan wegsteek....

Post by **JohanM** » Mon Aug 23, 2010 9:07 pm

OOOOMS wrote:OK, ekke verstaan nou beter! Dog nou net jy het 'n maase CD versameling wat jy daar gaan wegsteek....

Ek het een en hy word al grooter. Ek nou al by 56 Gig se MP3's wat ek moet sort en write. Hulle gaan daarbo ry....

Post by **JohanM** » Wed Sep 08, 2010 12:21 pm

So I bought tent canvas for the recovering of the seats, and then took the seats for recovering. I went to collect it this morning, and now the fun starts with getting to fit those seats to my SFA.

Here they are. Now I have water resistant seats and much easier cleaning of them.

The light colour is so that i can see if someone has been leaving skidmarks on the seats when driving with me....

A closer view of the work done. I am very happy with the outcome seeing that tent canvas is not the easiest material to use to recover bucket seats.

And a picture of the inside. Now I just have to level the seats and bolt them down accordingly..

At last I can now sit really comfortable in my SFA...

Jaco Versfeld · Post by **Jaco Versfeld** » Wed Sep 08, 2010 1:23 pm

Hi Johan,

The seats look really nice. How difficult is it to mount them?

Which model Corrola do they come from (pre 1998)?

Toro-Adventures wrote:So I bought tent canvas for the recovering of the seats, and then took the seats for recovering. I went to collect it this morning, and now the fun starts with getting to fit those seats to my SFA.

Here they are. Now I have water resistant seats and much easier cleaning of them.

Seats Recovered.jpg
The light colour is so that i can see if someone has been leaving skidmarks on the seats when driving with me....

A closer view of the work done. I am very happy with the outcome seeing that tent canvas is not the easiest material to use to recover bucket seats.

Upclose.jpg
And a picture of the inside. Now I just have to level the seats and bolt them down accordingly..

to be mounted.jpg
At last I can now sit really comfortable in my SFA...

Post by **JohanM** » Wed Sep 08, 2010 1:31 pm

Jaco, those seats are from the 1989- 1994 Shape Corolla.

EK weet nog nie presies nie, maar dit gaan bietjie trickey wees om te mount omdat die rails verskil. Maar dit behoort nie te moeilik te wees nie

Sal fotos neem en 'n seperate thread begin daaroor.

Smurf · Post by **Smurf** » Thu Sep 09, 2010 6:12 pm

Daai is goeie werk wat jy daar gedoen het!

Post by **JohanM** » Thu Sep 09, 2010 7:16 pm

Dankie Pieter,

Ek is nog nie klaar nie, maar ek sukkel op die oomblik om genoeg tyd te vind om al die mods klaar te maak op die SFA....

Post by **JohanM** » Sat Oct 02, 2010 7:35 pm

Following my first long distance trip over the long weekend I decided that good was not good enough.

The Bucket seats were brilliant and I was only getting tired of sitting after doing 550kms in the driver seat, resulting in a well deserved rest. I have done in one day driving around Cape town and then driving back through the night a total of 1600km's and I was very happy with the outcome of the seats having driven 1400km's solo through the night, it was in fact easy due to being able to sit comfortable.

The roof consle worked well on the road with keeping things so to say organised. However I had long ago found the need for a decent floor console onto which you could mount things like cup holders ect and also put things like your phone while on the road....

So today it was once again time to make the floor console and upholster it in matching canvas. I also fitted the National Luna Split charging monitor in its place already. I have used an open ended rear as I have found that sometimes the lip prevents you from utilising the space fully between the two seats with either a soft cooler bag and a camera bag or other things needed at hand whilst travelling.

I am planning on adding 3x extra low power cigarette lighter plugs to the console to power the cell phone charger and some other low voltage devices in the cab during driving. Also I am busy looking at various ideas and designs for a real good but robust and easy to make/fit or get cup holder....

Here is it in its current shape.

Next up is the fitment of the National Luna Split charging system in the engine bay and the aux battery in the load box.

Maverick131 · Post by **Maverick131** » Mon Oct 25, 2010 12:36 pm

"While i was busy with the loadbin I added some extra dust proofing to the tailgate. I tested it with letting water into the bin, and nothing comes out the tailgate now."

Johan, how did you dust proof the loadbin. What dit you use/where can I buy it?

Post by **JohanM** » Mon Oct 25, 2010 9:37 pm

Jacus I used normal sealing strip that you buy in rolls. I also made up two steel plates that cover the tailgate latches where most of the dust comes in and fitted them in place permanently. You'll be able to see what I did at the afterparty on Saturday...

Hilux01 · Post by **Hilux01** » Mon Nov 08, 2010 4:21 pm

Johan,

Ek neem aan jy al op reis, dit lyk sommer baie smart. Se my bietjie, van watter materiaal het jy jou kombuis gemaak of lees ek dit mis?

Post by **JohanM** » Thu Nov 11, 2010 8:51 am

Hilux01 wrote:Johan,

Ek neem aan jy al op reis, dit lyk sommer baie smart. Se my bietjie, van watter materiaal het jy jou kombuis gemaak of lees ek dit mis?

Henk ek het die hele kombuis met 6 mm plywood gebou en 3mm 25x25mm aluminium gebruik om die kas sterk te maak en om alles mooi aan mekaar te hou. Die finishing is gewone shelving paper wat ek gebruik het en dan kry mens daai nuwe alum treadplate look alike shelf covering wat ek gebruik het om die agterkant af te finish.

Ook die hele eenheid het ek met 8.8 6mm & 8mm Boute aan mekaar gesit asook sikaflex221 gebruik om alles te seel waar die hout en alum ontmoet.

Verder is die unit so 5 lae geverf met gewone wit Velvaglo verf om hom lekker waterbestand te maak.

Hoop dit help so bietjie...

Traveler · Post by **Traveler** » Thu Nov 11, 2010 9:24 am

Ek hou van die keuse van die kleure wat jy gebruik het vir jou sitplekke se oortrek.

Post by **JohanM** » Thu Nov 11, 2010 10:31 am

Traveler wrote:Ek hou van die keuse van die kleure wat jy gebruik het vir jou sitplekke se oortrek.

Dankie Heinrich... Ek het gister campmor tent canvas waterproofing gekoop en gaan dit vanaand op die sitplekke aanwend asook op die centre console op die vloer. Ek wil net keer dat dit vinnig lelik word en ook waterbestand is....

Ps ek het nog genoeg materiaal oor en dink daaraan om die deurpanele ook so oor te doen en dan sommer door pockets ook op te sit, myne het dit nooit gehad nie...

Post by **JohanM** » Fri Nov 26, 2010 8:11 pm

So after a long while I managed to get the time to fit a set of Steibel trumpet horns instead of the standard little hooter. I also spent some time buidling a special box and bracket to fit the second battery in the loadbox and fitted the long awaited National Luna Split charging kit and also did some special fittings and sorted out the wiring in the front, and also moved the secondary fusebox to better location as where it was fitted it would have cause difficulties in routing the split charging wires from the battery to the solenoid.

So here is some pictures as I went along.

Here i stripped the front end off in order to access the void spaces in the front behind the closed section of the grill in order to fit the horns.

Here is the horns fitted one to each side and also did some rust prevention as i had to drill holes through the front member to locate them in such a way to clear the grill and bumper when fitted. I made up the harness and fitted it all at once and then routed the wires to the inside of the engine bay.

While i was busy doing some mods to the wiring, it was time to sort out all the wires for the engine, EFI & Auxiliary equipment. I also moved the relays up high to the to of the fire wall to prevent them from getting to much water when doing water crossings.

I also made spacer brackets that moved the auxillary fusebox and the solenoid from the NL system away from the inside of the fender to allow the standard & aux wiring harnesses to run behind these in order to avoid the engine bay looking to cluttered with wires.

After connecting the new hooters and testing the operation & loudness it was time to put the grill back on and secure it in place. I decided to use ordianry cable ties to strap the grill securely in place as the clips was broken from age, some missing and other places screws have been used. The reason why I opted for cable ties was that I could easily remove the grill should the need arise to and also to prevent it from ratteling over rough roads.

Here is the picture of the fusebox & NL solenoid fitted with the standard & Aux wires running behind these fitments.
Take note that here the Split charging system has not been wired and connected yet.

From here I made a the box for the second battery, made a switch box in the back that allows the fridge & side lights to be switched on and off using simple toggle switches.

I kept one switch as a spare should I need to add some more lights to the canopy or something else that needs to be switch operated.

OOOOMS · Post by **OOOOMS** » Fri Nov 26, 2010 8:22 pm

Baie netjies Johan, mooi om te sien daar is pride and passion in die projek

Post by **JohanM** » Fri Nov 26, 2010 8:25 pm

Dankie Mark, ek probeer dit maar so netjies hou as wat my skill toe laat om te werk....

Post by **Family_Dog** » Fri Nov 26, 2010 8:27 pm

Johan, you are creating a very nice end-product there!

Do those switches operate relays, and not the actual units directly? I think those switches are only rated at something like 2 or 3A, but for relays that is quite sufficient.

-F_D

Post by **JohanM** » Fri Nov 26, 2010 8:35 pm

Eric I have to practise on mine before getting my hands on Bulldog!!!

Those switces only operate the LED lights that is fitted to the side doors of the canopy and the engel fridge. These one's are rated at 5A IIRC which is enough for the engel fridge. I Also use the fridge switch to actually switch it on after flicking the toggle switch, however So far I have tested it , and no problems to date. Used the fridge all the time at the World record attempt and it is working like I want it to.

Also there is no other equipment that is being used off the second battery other than 18 LED's and the Engel. All wires are also really 3mm wire to ensure no loss of current.