Shizen's Gen3 camper build

[Monty85]

Hello Everyone !

I have had this 2001 Gen3 Limited since end of 2015. I bought it with the intention using it as normal driver and also camper on weekends/holidays. Idea is to keep mostly stock where possible and upgrade what’s necessary. I was tired and bored of camping in a campground with crowd and would like to use my Monty to get out more in the backcountry.

I have been reading few build threads on this forum and it’s awesome to see what people build to go overland. So far I have only had few weekend trips and one 10 days trip through cities/deserts in California/Nevada. Also work wise, it is mostly just the maintenance and repair with little add-ons. I thought I would post and share what I have done last year. Now hopefully I can get more work done and keep posting.

Cheers !





Whats done:

Engine maintenance:
all gasket and seals except headgasket.
Timing Belt
Waterpump
Pulleys/belts
sparkplugs and wires

Cooling:
Radiator flush
170F thermostat

Transmission/Diff:
all gear oil done.

Suspension/Tires:
Replaced all shocks with KYB Gas-ajust
Grabber AT 33"
Spare tire raise bracket

Camping platform:
plywood based bedding platform+interior mod

Lighting:
LED bar in front


Whats next: or say wish list

Roof rack
fix AC
Brakes and bearings (thinking to go with EBC green pads and Bosch or Centric discs)
Regear front and rear diff with 4.9 (picked up a set from 2002 Montero XLS)
ARB locker
Lift
Bumper + winch

 

[Monty85]

Bedding Platform

Making a platform using simple plywood.

Second row area also accessible with folding




Im 6'2'' and fit comfortably.



Removed a top memory foam layer from the mattress I did not like and sewed a cover for it





With the third row seat removed and space underneath, a lot can fit under the platform



Stapled the plywood edge with some strip of foam covered with left over fabric to protect interior panels and keep rattle noise away.

CURTAIN for privacy and darkening

picked up some cheap , dark fabric from walmart and cut them into shape of windows

Took the plastic interior panels out

Glued neodymium magnets on each peripherals of window inside the plastic panels.

Also sewed in magnets on the edge of the curtain for each windows so they would just stick ON when needed and when taken off, it looks stock.
I wanted to keep the clean look when the Monty is not a camper.

Testing magnets ... neobdynium on inside and regular cheap magnet on outsides. Holds really well.

 

[Monty85]

Tires and spare tire mounts:

Got a set of General Grabber AT 285/75/16.
Tire was about ~65lb and with wheels ~85lb

With 33'' tires, there is just enough space around fender to clear. No rubbing issues.
It also raised the vehicle.

When factory spare tire mount was used, this oversized tire was hitting the bumper while closing the trunk.
So had to relocate it few inches higher.

Used a square tube and few bolts and works great. Been using it this way for about year and half.

Good clearance between bumper and tire now.

 

[Inyo_man]

Nice looking rig!!

Enjoy!!

These are great vehicles...
I got mine with 29k on the clock and it just turned 197k recently.

Cheers

 

[Monty85]

Nice looking rig!!

Enjoy!!

These are great vehicles...
I got mine with 29k on the clock and it just turned 197k recently.

Cheers

Thanks Inyoman! Yeah i love it. Used to have gen2 before and always missed it. Wow 29 to 197k. Thats a lotta driving

Did ARB add lots of weight ? Does it sag the front end ?How heavy is that thing ?


Sent from my iPhone using Tapatalk Pro

 

[MTGunner]

Great build...but in my opinion I believe the best of this build is the young man, his skills and quality work. Monty85, I applaud you for a great build and your ingenuity. I love it when I see that youngsters are fabricating, engineering and working with their hands and minds. You should be proud! MTG

 

[IncorpoRatedX]

Well executed. I like what you've done to it.

 

[Monty85]

Thank you MTG, IncorpoRatedX for the kind comment ! Will try to bring you more interesting stuff.

 

[arb098]

Tires and spare tire mounts:

Got a set of General Grabber AT 285/75/16.
Tire was about ~65lb and with wheels ~85lb

With 33'' tires, there is just enough space around fender to clear. No rubbing issues.
It also raised the vehicle.

When factory spare tire mount was used, this oversized tire was hitting the bumper while closing the trunk.
So had to relocate it few inches higher.

Used a square tube and few bolts and works great. Been using it this way for about year and half.













Good clearance between bumper and tire now.

I really like what you did for the spare tire. I though about fabing up a plate to bolt onto the existing point to raise it up, but this looks like it might actually be a bit easier.

 

[Monty85]

Yeah its way easier and cheaper. Its just square tubing that I had left over. Drilled few holes and done. Top bolt needs a nut on inside. Bottom two does into factory mounting holes.
I also cut a rubber/paper gasket in shape of tube to protect the car paint from rust and scratches from happening.

 

[Monty85]

Roof rack build:

Been wanting to do this for long time and finally got some time to get this started.

Using few cheap material 3/4" Electrical conduit, started to build my rack.

Design is simple. Plan to use it mostly for throwing stuff up there while sleeping inside. Or if we happen to be in nice location, sleep up on roof and store stuff inside.

Only got platform done today. Next coming weekends will be the upper loop and mesh platform.

Finally, for the test, had my buddy walk across the rack while its suspended on 2x4 on sides, it didnt break

Update: 4/1/2018

After long break on my montero due to other priority projects and house moving, finally I got to work on to finish this rack in last couple of weekends. Also had my friend who is weld master to speed up the process.

After welding was done, spent lots of time cleaning the flux with wire wheel and sand blaster. Then finally finished it with Rustoleum truck bed liner. To mount it on roof rail, I used and welded in the Reeses Explorer round cross bar mount.

Very happy with the result. Now some day, I will probably rivet in some kind of wire mesh to make a platform.

 

[haolepinoy]

The roof rack looks great so far...just be careful welding all that galvanized steel (galvanizing poisoning). Beware the greenish-yellow ghosts.

Question regarding the Grabbers...what are the holes in the outer lugs for?

 

[Monty85]

Thanks haolepinoy

I try to hold my breath during welds usually. Also my friend gave me advise to grind off some layer before weld. I think it helps with both weld and fume.

About Grabber, which holes are you referring to ?

 

[haolepinoy]

About Grabber, which holes are you referring to ?

On your spare tire pictures...you can see what looks like small holes in the outer lugs on the treads. It may just be that they look like holes in the pictures, but are actually something else. Just curious.

 

[Monty85]

Ohh I believe those are for studs... I think General Grabber offers option of installing studs while purchasing if I remember correctly. Or you could also add one later yourself for icy surface.