The old 1999 build thread

rascott

Observer
you are better at bodywork than i.
i would have just labeled it- place and date.
i look forward to seeing that suspension in action!
 

rascott

Observer
Hey! How are you? New Zuk yet?
still looking forward- i've been trying to keep tabs on your projects, for the inspiration.
suzitoo is slowly developing, on new axles. still lots to do, but hope to have her functional soon!
planning the next carnage run?
 

Toasty

Looking for that thing i just had in my hand...
still looking forward- i've been trying to keep tabs on your projects, for the inspiration.
suzitoo is slowly developing, on new axles. still lots to do, but hope to have her functional soon!
planning the next carnage run?
Yes! September 11-19th Southern end, same meet up location as last time Red Lake i believe? I'll confirm and text you the exact location.
 

Toasty

Looking for that thing i just had in my hand...
Reshaping the rear quarter, it's coming along.

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Not terrible.

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Installed Leo's 160 amp or whatever winching alternator. Stoked for this beast. I broke some motor mounts and that led to my PS line getting tugged on a little and leaking. Need to fix that.

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Brazed up the pump fitting to be a -8 JIC so I can just make a hydraulic hose because the '99 and '00 trucks have a unique pump and hose so there are no aftermarket ones I could find and OEM is even a gamble if it'll be correct.

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Installed a 1600cfm condenser fan and it is incredible. AC is super cold at a stop.

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Since I don't have ABS I made a bracket to hold the ARB Twin Air where the ABS would be.

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Lots more to do to get ready for the Sierra Nevada Challenge 2021!
 
@Toasty

Just read through your build from beginning to end, and I'm still busy picking my jaw up from the ground! Well done! and thanks for all the insights, knowledge and experience you share!
Compared to some of the more popular wheeling platforms (i.e Toyota, Jeep etc), the Montero (Pajero where I'm from, South Africa) is such a small community in comparison.
It's so good and helpful to see such passion and development you and your friends put into these machines. Makes me feel more confident choosing the Pajero out of all the other options I had, I'm loving my Gen 2.5 LWB 2.8 TDI so far, what a great rig!
Joined Expedition Portal specifically for these types of threads.

Basically I just wanted to say how impressed I am with you build, fabrication, R&D and work on these cars, well done, and I find the knowledge you have imparted invaluable. Much appreciated!(y)(y)(y)

How's the rig at the moment? Any new developments?
 

macdrew77

New member
Mr Toast you are a legend. You are one of the reasons I decided to buy a 97 Montero SR last year. Love having something different and love how capable it is out of the box. Thanks for all you do.
 

Toasty

Looking for that thing i just had in my hand...
Mr Toast you are a legend. You are one of the reasons I decided to buy a 97 Montero SR last year. Love having something different and love how capable it is out of the box. Thanks for all you do.

Glad you enjoy it!
 

Toasty

Looking for that thing i just had in my hand...
Replaced all 5 doors and fenders, pulled more dents pulled too! (I've since re-added some dents out wheeling already)



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Toasty

Looking for that thing i just had in my hand...
Working on cropping the fenders to clear 40's just in case, doing them proper this time. I started by drilling holes aligned with the stock mudflap holes spaced at each angle on the fender then folded them over and welded all the seams. Looks nice enough for a wheeler. Still have to do the other fender and hole saw for the snorkel.


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Toasty

Looking for that thing i just had in my hand...
Been slow on this, I guess I'm spread thin but also it's my daily driver so it almost never gets a break. Jorge started on the smoothing out of the rear corner, needs a little more finishing there but once the rockers are done I think I can start sanding the whole thing down.

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