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Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". - Car Talk (5) - Nairaland

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Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 5:51pm On Jun 29, 2014
Bossforeva: any P using the new one on winter? Pix of the new wheels, might be good to share too,, weldone

You got it wrong, bruh. I mean use the OLD wheels in winter, thus protecting the new ones from the ravages of salt and grit.

I haven't pictured the new wheels, as they are subject to change. wink
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 5:56pm On Jun 29, 2014
Originalsly: Ok....same size rims?...then again are you going for the ruff n rugged off road look with high clearance and lady inaccessible ?!...in which you will definitely need to keep the roll bars and a bit oversized wheels to add to that look....and what about search lights?...to give the impression that you go bear/lion hunting?! Or are you going for the city slicker look...low profile road hugging ladies welcome look?

The new wheels are bigger. I'm going more for the Street look, so though going higher, I'm most likely going to retain IFS rather than go the SAS route.

Searchlights x 4 will go on a custom roof bar.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Originalsly: 8:04pm On Jun 29, 2014
Sounds cool!...you know your onions!!
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 10:10pm On Jul 01, 2014
Mini update!

I dropped into the bodyshop this arvo, to see how things were progressing. The base frame for the custom rear hydraulically-operated bed lid is pretty much done. Tomorrow it will have a couple of diagonal braces welded in, to give the sheet metal skin more support.

The Toyota door hinges turned out not man enough for the job. Besides being on the weak side, the opening angle was wrong, the deck lid would contact the rear of the bed when opened. A twin-trapezoid / pantograph design was called for, this would allow the lid to lift at the hinged end, and move rearwards when it was operated. This would prevent unwanted contact with the bed top rail.

I opted for Audi A4 Sedan B5 trunk hinges. Besides being immensely strong, they incorporate hydraulic rams, that will assist the main hydraulically-operated rams on the lid.

I also took the opportunity to mark the areas that I want welded over, and smoothed off. The deck lid will be test mounted tomorrow. Things are looking great.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 10:20pm On Jul 01, 2014
Some pictures. Note the areas marked in marker pen, and the instructions to the shop.







Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 10:30pm On Jul 01, 2014
More...





Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 10:47pm On Jul 02, 2014
Less to report today.

Though I have managed to track down a brand new heated rear screen for my truck, with the correct green tint. Oddly enough, this is from a mobile auto glass supplier and fitter.

Since I'm a bit sceptic, I took the liberty of picking up my original rear screen from the bodyshop, and left it at work. Since the new replacement is being delivered to me at work, it makes sense to compare both, to make sure the dimensions and profile are the same.

More progress pictures tomorrow.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 6:24am On Jul 03, 2014
Hee the truck is going dark green in the paint shop
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 7:08am On Jul 03, 2014
Bossforeva: Hee the truck is going dark green in the paint shop

You couldn't be more wrong. Too dull a colour. wink
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 9:07pm On Jul 03, 2014
Sometimes, you learn hard lessons. Cheap is seldom good, especially when it comes to knock-offs. I got bitten by the very thing I warn others about.

I'm talking Chinese knock-off! grin

I ordered a set of fender flares for my truck, all the way from East Asia. Well they looked good in the pictures. Unfortunately, they're replicas, made out of fibre glass. While this is not necessarily a bad thing, the set I got will take some fettling to get them anywhere close to fitting. They might as well be made for a Range Rover, they are that much out, especially the rears. They can be reworked, but will take time, and that's something I don't have much of.

They are also much thicker than the OEM Toyota items, and the fronts don't taper towards the bumper. The result is a very sudden step from fender to bumper. Arrrrgh! angry

I ended up purchasing used but OEM Toyota items. They are of course for the double cabin model, the fronts are the same as on my single cabin truck, the rears however are different. A small section of the flares are on the cabin, just behind the rear doors, i.e the rear flares come in two sections. Still, I'm happy to work with those. Being ABS plastic, they are much more flexible, and durable. Glass fibre is brittle. Fine, until it gets struck, then it shatters.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 9:14pm On Jul 03, 2014
These are the glass fibre Chinese copies. Note the front flares at the top of the pictures, where it would meet the bumper. Very chunky, and abrupt:



Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 9:24pm On Jul 03, 2014
And compare with OEM Toyota items. Again, the flares at the top are for the front, nice finished ends. Note the flares for the rear are split, with the smaller sections normally fitted to the wheel arches on the truck's cabin. These will be reworked to fit my single cabin truck:



Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 10:09pm On Jul 03, 2014
It wasn't all doom and gloom though - I've been on the hunt for a heated rear screen for my single cabin truck. As I stated earlier, UK-spec single cabin Hilux's were never available with heated rear screens, this being reserved for the top-spec double cabin, in VX trim.

I got one from the least likely of places, an automobile glass supplier to the aftermarket. It was delivered to me at work today.

The old glass was shot, all etched by the rear bed cap over the years. There was no way it was going back on my truck after paint.

The side windows have faint scratch marks. Not really noticeable, but I'm fussy. And as I intend to tint the glass 40% dark, I knew the scratches would become more prominent.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 3:17pm On Jul 04, 2014
Bed caps can seriously scar your cabin, as I found out. The worn down paint at the rear of my cabin came from years of fitting and removing the cap.

Grit caught between the cap and cabin, as well as between the cabin rear screen and cap screen rubber, really messed things up. The cap is currently sitting in my garage, alongside the rear roll bar.

In her cap days:






Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 4:31pm On Jul 04, 2014
Are u still gonna fix the caps after the restoration?
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 6:53pm On Jul 04, 2014
Bossforeva: Are u still gonna fix the caps after the restoration?

No.

Besides the "capped look", which I don't really like, and the scuffs it caused to the cabin and rear screen, it would not fit once the custom hydraulically-operated bed lid is in place.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 12:32am On Jul 06, 2014
Some of the unwanted holes have had steel welded in place. I had a couple of larger pieces of steel stamped out. These are to weld into the bed grooves, where the tie-down hooks are, on both sides of the bed. These measure at 8' x 5.5" respectively.

I'm getting two more strips cut out, to weld into the rain channels either side of the cabin roof.

Areas plated over so far:

Rear reflector holes.
Rear fog lamp hole.
Cabin roof beacon hole.
Driver's fender aerial hole.







Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 12:49am On Jul 06, 2014
I have been sorely tempted to retain the tow hitch, but after offering up the rear bumper, I've decided to ditch it.

The bed is just sitting on the frame, all the bolts are off. The ones at the rear were a swine to get off. In the end, I roasted them off with an oxy acetylene torch. The U-shaped frame section at the rear meant it was not possible to get access to these bolts with a 17mm socket, 1/2" extension and impact gun.

The fuel filler flap is in the way of the fender flare on the driver's side. I don't want the OEM Toyota ABS plastic fender flare cut round the flap. My options are to cut a section out of the fuel filler flap, or delete it altogether, relocating the fuel filler inside the bed, in the wheel well itself.

I'm going to sleep on this until Tuesday.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 12:28pm On Jul 06, 2014
Picture of old and new rear screens. Note the deep etching on the old, non-heated glass. Well past it's best. It'll certainly keep the cabin dry if fitted, but that's about all it's good for:

Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Shagati(m): 1:01pm On Jul 06, 2014
Siena: ....or delete it altogether, relocating the fuel filler inside the bed, in the wheel well itself....

Won't this option make refuelling cumbersome? Having to raise the automatic cover every time to access the bed?
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 1:52pm On Jul 06, 2014
Shagati:

Won't this option make refuelling cumbersome? Having to raise the automatic cover every time to access the bed?

Not really. My old Audi Coupe Quattro was the same, and that was with a manual trunk.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by majalisa(m): 6:30pm On Jul 06, 2014
Siena:

Not really. My old Audi Coupe Quattro was the same, and that was with a manual trunk.
nice thread for a challenging project..kip it up
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 8:16pm On Jul 06, 2014
majalisa: nice thread for a challenging project..kip it up

Thanks bruh.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Temas: 8:40pm On Jul 06, 2014
@Seina
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 7:39pm On Jul 07, 2014
I spent the day away from work, and the bodyshop, I had to have a stainless exhaust system made up for a friend's Old Skool Audi Cabriolet.

However, some progress has been made in my absence. I got a call letting me know my Audi A4 B5 Sedan trunk hinge system had been fitted, and could I come down to see if it was okay? The thing is, I was 73 miles away, in Basildon. So it would be a mad dash back to Hayes.

Still, I got back in good time. The hinges have been fitted, and the cantilever-like set up works just the way I thought it would. The hinges are currently secured to the sides of the bed by 10mm self-tappers. I'm going to drop down some bolts and nuts tomorrow. The idea is the nuts will be welded in as captives (on the outside, within the groove / hook area). Because once the hook area is plated over and smoothed, the won't be any access, should I wish to remove the lid.

Tomorrow, I'll pop into the bodyshop during my break, and show the fabricator exactly where I want the hydraulic ram retainers to be welded to the frame, and the tab for the catch. The rams on the hinges are not strong enough to hold the lid open. I'm also toying with the idea of having no lock on the new tailgate, (which has been temporarily fitted to ensure the plated-over hook recess on the bed sides matches the profile of the tailgate perfectly).

I also took the opportunity to have the roof rain channel steel plates cut out, and dropped off. These will be welded in place tomorrow.

Once the bed lid' frame's hydraulic ram tabs have been welded in place, along with the catch tab, I'm taking the frame back to my fabricator, who will then weld in the support trusses, followed by the skin itself. Then it's back to the bodyshop for finishing.

We're cooking on gas, well on track. Things are looking great.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Eyop: 7:42pm On Jul 07, 2014
Siena: I spent the day away from work, and the bodyshop, I had to have a stainless exhaust system made up for a friend's Old Skool Audi Cabriolet.

However, some progress has been made in my absence. I got a call letting me know my Audi A4 B5 Sedan trunk hinge system had been fitted, and could I come down to see if it was okay? The thing is, I was 73 miles away, in Basildon. So it would be a mad dash back to Hayes.

Still, I got back in good time. The hinges have been fitted, and the cantilever-like set up works just the way I thought it would. The hinges are currently secured to the sides of the bed by 10mm self-tappers. I'm going to drop down some bolts and nuts tomorrow. The idea is the nuts will be welded in as captives (on the outside, within the groove / hook area). Because once the hook area is plated over and smoothed, the won't be any access, should I wish to remove the lid.

Tomorrow, I'll pop into the bodyshop during my break, and show the fabricator exactly where I want the hydraulic ram retainers to be welded to the frame, and the tab for the catch. The rams on the hinges are not strong enough to hold the lid open. I'm also toying with the idea of having no lock on the new tailgate, (which has been temporarily fitted to ensure the plated-over hook recess on the bed sides matches the profile of the tailgate perfectly).

I also took the opportunity to have the roof rain channel steel plates cut out, and dropped off. These will be welded in place tomorrow.

Once the bed lid' frame's hydraulic ram tabs have been welded in place, along with the catch tab, I'm taking the frame back to my fabricator, who will then weld in the support trusses, followed by the skin itself. Then it's back to the bodyshop for finishing.

We're cooking on gas, well on track. Things are looking great.
Hello Siena please i need your attention on this thread because i don't want to derail this one. Thanks https://www.nairaland.com/1802722/direct-injection-vs-indirect-injection
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 8:15pm On Jul 07, 2014
Eyop:
Hello Siena please i need your attention on this thread because i don't want to derail this one. Thanks https://www.nairaland.com/1802722/direct-injection-vs-indirect-injection

No worries, I'll take a look shortly.
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 8:22pm On Jul 07, 2014
Some progress pictures - forgive the iPhone quality.

Close-up of the cantilever hinge set-up. It works perfectly - the lid moves upwards and rearwards, away from the bed, as it's lifted. Just the way I planned it:


[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg6_zps992255d7.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg4_zpsd87d5c6a.jpg.html"][/url]

Cut steel strips, to plate over the roof rain channels:

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg9_zps5b0dbbbc.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg8_zpsf41ceb14.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg7_zpse84c5b0b.jpg.html"][/url]

Cut steel plates, to weld over the hook recesses on both sides of the bed - these won't go on until the captive nuts for the hinge bolts are welded in place, and I'm happy with clearance:

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg11_zps75af5877.jpg.html"][/url]

Remember there will be a rubber seal all round the top of the bed rail, as the bed area MUST be water tight. I have decided not to go with a plastic bed liner - The floor and sides are going to be carpeted. The carpet won't be glued in place though, as I would want it removable for cleaning. The floor and side will have moulded expanding foam, but again, not glued to the bed. The carpet will then be bonded to the foam.

Bed hook recesses prepared for welding plates. I truly detest those recesses, and I can't wait to see them disappear for good:


[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg10_zps1f6f4456.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg3_zps5bab2400.jpg.html"][/url]

Pictures showing temporarily fitted bed lid frame, and new tailgate. The hinges actually allow the lid to lift at 90 degrees in relation to the bed! Obviously lift will be limited to a sensible height by the 2 active hydraulic ram's fully extended limits:

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg5_zps7d6b5684.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg2_zps04122148.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg1_zps0c7a8d51.jpg.html"][/url]
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 8:13pm On Jul 08, 2014
[color=More progress today!

The roof rain channels have been plated over with the steel I had cut to size. And one side of the bed has also been done. Tomorrow, the other bed side will be completed.

The bed lid has to have the automatic hydraulic ram bosses welded to the lid and the bed lid frame, then I can send it off to have the steel skin welded into place.

Saturday is my day off work, so I'm going to spend the day in the bodyshop, and lend a helping hand wherever I can.

Some pictures:


[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg4_zpsef553a09.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg1_zps47c2661a.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg3_zpsafdc5843.jpg.html"][/url]

[url="http://s768.photobucket.com/user/NaijaGuy/media/Project%20Toyota%20Hilux/imagejpg2_zps31fcb48c.jpg.html"][/url]
Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 11:31pm On Jul 08, 2014
No roll cage?

Also what's the swoopy job circled in pic below?

Re: Siena's MK5 Toyota Hilux Customisation Project - "Apple Candy". by Nobody: 6:56am On Jul 09, 2014
No armour for my truck bud. Armour's only worth having if the truck is built exclusively for wheeling. This truck is going to be more for leisure and light expedition. So a lifestyle vehicle.

The Coupè you've circled in the picture is a Jaguar XK8.

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