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Oli's 120 D4D Manual

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  • #31
    Rear Door Table

    As per joey's guide I made and fitted a table to the rear door.





    For more details of the build see joey's post below
    http://www.pradopoint.com/showthread...ear-door-table
    HugoStiglitz
    Member
    Last edited by HugoStiglitz; 28-01-2016, 02:25 PM.

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    • #32
      Under Body Cleanup

      Well I spent today painting the underside of the prado, I used an underbody deadener and mat black rattle can.



      WORST JOB EVER, this totally sucked and I got as much on myself as I did on the car but it's done now. Sorry no progress shots as I was in no state to handle a camera or phone



      Before


      After


      Other parts


      HugoStiglitz
      Member
      Last edited by HugoStiglitz; 28-01-2016, 02:26 PM.

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      • #33
        Hot Water Heat exchanger

        So I have had the helton hot water heat exchanger for some time now and with the Christmas break I got started on installing it.
        First was to find a location to mount the unit. I had a look at aj120's install but decided to mount it on the guard behind the fuel filter. This is also close to the heater lines. Found some holes already in the guard to mount the brackets to.



        I removed a section of the top heater hose and connected up the exchanger with some straight hose. Even managed to use the original hose clips.



        Next was mounting the thermostatic mixing valve. This mixes hot from the exchanger with cold so u can't scald yourself if the flow stops for a while.
        It's mounted so I can get access to change the temp with the bonet open. (Pic is taken with the passenger side bull bar underside panel removed)



        Part 2 will come later on, I still have to find a waterproof pressure pump with ~10lpm flow.and find somewhere to mount it. Then the inlet and outlet fittings to be mounted somewhere
        HugoStiglitz
        Member
        Last edited by HugoStiglitz; 28-01-2016, 02:26 PM.

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        • #34
          Hot Water Part 2, Pump mounting

          Finally go round to do some more work on the hot water system.

          Pump: Jabsco 2.9 Pressure Pump. 11Ltr / min, 25 / 45psi to stop pump flutter.
          mounted it behind the other wing of the bull bar (Drivers side)
          made up a small plate to get a nice solid mount



          here u can see the pump from above


          location of the relay


          switch fitted and wired.


          will finish off the plumbing side next weekend.

          PLUMBING

          I spent a few days chasing down the perfect fittings. I had a very specific list of needs including
          Both Female & Male fittings with a valve.
          As close to 12mm as I can
          Quick Disconnecting
          Fittings to stay sealed under suction (as the water in side will be on the suction side of the pump)
          Must be brass or stainless
          Ends with a 12mm barb

          This ruled out all air fittings and after a few different stores I went into ENZED.
          They had 3/8" Brass hydraullic style quick disconnects.


          Perfect, these weren't cheap at $130 for the pair including barbs but I think they are the best looking solution

          Spend a little while to find the best place to mount them and started drilling and a couple of short hoses to connect to the pump and outlet of the mixer valve.



          They don't stand out like or look like crap and I shouldn't have any issues for quite some time
          HugoStiglitz
          Member
          Last edited by HugoStiglitz; 28-01-2016, 02:25 PM.

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          • #35
            Front Mud Guards (Aka Lowest Hanging Fruit)
            well it's been quite some time (12 months to the day) that i did someting of interest to the rig, here goes.

            as many of you will have experienced, the front mud guards cop a battering off-road. I have lost count of how many times i have Fixed or Removed and Re-fitted those suckers.

            My issue is my steel steps are mounted nice and high compared to the factory paper one's. this means however its quite a mission to get to the screw that holds the flap to the sill's.



            so i decided to make a change. I selected the flap with the most existing damage (last repaired with sikaflex and plastic strips) that way if i hated the look i could simply replace it with one from the wreckers.

            unfortunatly just removing them permenantly leaves a pretty ugly look



            I wanted to have the flap finish no lower than the bottom of the step. so the bottom of the step was my starting point. (easier to cut more off later on if needed)

            Measured and Marked with tape, the cutting begins (i started with a hacksaw but soon switched to my dremel)





            lower section removed



            i'm quite happy with the end result so i repeated the process for the other side


            now i'm just looking for some rubber that I can screw on to what's left to meet the 300mm requirement and pin it back with a small chain.
            HugoStiglitz
            Member
            Last edited by HugoStiglitz; 28-01-2016, 02:25 PM.

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            • #36
              Rear ARB Air Locker

              well an opportunatly came up that was very hard to resist (too hard infact) to pickup an Air Locker for the rear of my Vodka Cruiser.
              the center came from a Hilux with minimal use and included an air compressor & solenoid.

              For reference the Center that you need is an RD132 which is the same as the front of 80 & 105 cruisers and live axle hilux's as well as the rear of almost all hilux's. The compressor was the old style but serves the purpose fine.



              It was quite dirty so I gave it a good clean up before using it. I ordered all new bulk head fittings and 5mm air lines as well as seals and seal housing

              after some reading I decided that fitting a locker is a little above what i'm willing to tackle on my own so I got a local 4x4 specialist to do it for me.

              Pics of Compressor Mounting to Come

              I ordered an ARB style rocker switch from ebay for $9 compared to the $25 ARB wanted (Link Here)


              I am also going to follow 120D4D's guide on how to wire up the Rear Diff Lock dash light, why? because why not right!!

              All done and dash light working
              HugoStiglitz
              Member
              Last edited by HugoStiglitz; 28-01-2016, 02:25 PM.

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              • #37
                Problems with my Runva EWX 12000

                well its been around 18months since i picked up and fitted the winch so time for some feedback.
                As with many recovery items, they get quite infrequent use but when needed its often VERY NEEDED.

                so at around the 12 month mark i noticed that the free spool on my EWX12000 was starting to be a little tough to pull on. It got to the point of requiring 2 people to pull the rope from the drum. I called up my place of purchase (Overland 4WD in Maroochydore) and spoke to one of their senior fitters / tech's. He suggested that occasionally the torque of modern winches can cause the winch to twist. He suggested just undo each of the 4 mounting bolts about 1 turn, then nip them up again.

                I did this and all was good again...well until the next time i used the winch anyway. It became worse and worse until loosening and re-tightening would't fix it anymore. (18 months old at this stage)

                So i spoke with the Overland again and emailed Runva regarding the problem. They sent through instructions on how to check the brake inside the drum.
                but i figured if i'm taking the winch out i may as well give it to someone who knows what they are doing.

                Dropped off the winch to overland on Wednsday morning and they said they would have a look and contract runva regarding it. Being mid november i was just hoping it back for chrissy
                boy was i supprised when i got a phone call friday morning from Overland saying my winch was ready to pickup and was all fixed.

                The Diagnosis was water in the drum.....humm i thought. then i remembered back to the email conversation i had with Runva Australia prior to purchase.

                "We are able to give you tips on how to fully waterproof and seal your winch, in which yes it will be covered under warranty."
                was the line that stood out to me.
                "Once you have installed the winch, seal with silicone around all terminals, especially around the earth cable because that's where alot of stuff can get in the most"

                which I did. however water had still got in. Maybe i wasnt liberal enough with the silicone? Overland had commented that the water was very clean. Was it from too much pressure while cleaning?
                anyway, what's done is done but i was to be supprised once more. Overland had cleaned and linished rollers, re-greased and re-assembled. I picked it up and there was no charge to which I was most appreciative.

                Refitted the winch again, used a 1/2 tube of silicone on all 3 terminals. Hopefully i don't have any more issues but I do have those emails from runva in my back pocket just incase.


                All in all i must say Overland gave me great customer service and really looked after me.
                The winch has never missed a beat while under power (in or out) just the free spool.

                Would i buy again? at this stage I would have to say yes. If it happens again in another 18months? well it would depend on Runva's reaction.
                HugoStiglitz
                Member
                Last edited by HugoStiglitz; 28-01-2016, 02:24 PM.

                Comment


                • #38
                  Hello HugoS..,
                  I'm just in the process of starting to build up another Prado, this time a 2.8 GD 2016 Model due to be delivered in the next month or so. When I look at the Runva site, I notice an "latest model IP67" 11XP winch...have a squiz at the following link.

                  http://www.runvawinch.com.au/11xp-12...h-dyneema-rope

                  Perhaps Runva have now addressed the water ingress issues perhaps?

                  Thoughts/comments?

                  Thanks for the report.
                  SE Qld: GX 150GD Auto, (Feb'16 build): TJM T15 steel b bar, 9,500lb TORQ winch, TJM s steps, Rhino Pioneer Platform (42102B 1928X1236mm), front recovery points, Wynnum towbar, P3 brake controller, TNN Underbody guards, UHF, TREKtable & LED striplight, Custom Fridge & Drawers, Waeco CFX50, 9inch illuminator 160W LED spots, 40mm lifted Dobinson Suspension (Zordo's), ScanguageII, 30 Sec Wing Awning

                  Comment


                  • #39
                    Hey Brogers,

                    I do see they have their new IP67 which is great to see. i suppose only time would tell.
                    on a side note, having my time agian i would have gone with the EWX9500-Q as its not often you will need the 11 or 12,000lb rating (as you can double line pull when required) but every time you use the winch you will take advantage of the extra speed.

                    Comment


                    • #40
                      Just finished the hot water install and updated the posts. Pretty happy. It's a project that's dragged out for almost 18months since I bought the heat exchanger so it's nice to have it all finished.
                      HugoStiglitz
                      Member
                      Last edited by HugoStiglitz; 27-01-2016, 10:00 AM.

                      Comment


                      • #41
                        Extended Brake Lines

                        while I was at Enzed and I saw someone picking up a pair of brake lines. so I enquired if they make them or they come pre-made. they make them in store so I had them lookup the 120 Prado Chassis to diff lines and had them make up a pair 2" longer than standard.

                        easy, total cost was under $80 for the pair. (Not braided as the rest of the brake system is not so I wouldn't have noticed any improvement.)
                        the best price I could see online for a pre-made set was $200



                        I'm due for the 160,000k service soon so i'll get them to put the extended lines in then.

                        I plan to upgrade to some 3-4" shocks and flexi coils in the rear when the current gear starts to get tired.
                        HugoStiglitz
                        Member
                        Last edited by HugoStiglitz; 29-01-2016, 09:47 AM.

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                        • #42
                          Just thought I'd post a pic up of a few weekends ago out at glasshouse. Downhill so no weight on the rear

                          HugoStiglitz
                          Member
                          Last edited by HugoStiglitz; 29-01-2016, 09:46 AM.

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                          • #43
                            ARB UVP (Bash Plates)

                            So during December 2015 I was lucky enough to win a $500 ARB gift card through 4WD TV.
                            So after having a long think about all the goodies available I settled on a set of ARB Bash Plates.

                            First a pic of the old. they have taken quite a beating and are well deformed.


                            after removing the front plate I noticed that the front mount for the rear plate was quite bent.


                            Old vs New (yes the middle plate is backwards in the picture)


                            all done and dusted, they do mount quite easily and extend alot further back compared to the factory ones.

                            Comment


                            • #44
                              nice bash plate. my stockos taken a beating so time to find a replacement

                              Comment


                              • #45
                                Thanks ejukated,

                                I was surprised how much of a beating the stock ones can take.

                                Comment

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