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Dual Cab Cummins Build

18K views 199 replies 17 participants last post by  nigel3780 
#1 ·
Last year I started another company withthe sole aim to use it to acquire a 4wd that could fit the missus and our new son and take us on some adventure.
I have been borrowing a mates new hilux to go hunting etc, I was thinking of buying a hilux but there is no room in the back seat.
Then I thought I would like a chopped y62 or 200 but didnt want to remortgage the house.
I decided to buy a y61 and either chop it myself or buy one already done.
I searched for about 8 months till I found one I liked and wasnt stupid expensive.
Its a 2007 CRD with leather, sunroof etc.
 

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#95 ·
My little brother hit a roo in his elgrand and wrote it off. Turns out the steering wheel is the same as the patrol so I swapped my worn leather one for his which is in perfect condition. Also swapped the buttons.
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#96 ·
Sorted out pressure plate issue, was sent wrong one, new one on the way.
Hopefully this weekend is sump and oil pickup mod and install clutch etc.
 
#97 ·
Started the oil pickup yesterday, this was the first edition.
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But the main hit it on the way down.
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So back to the workshop this morning for version 2.0.
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This one will work. Now to weld it up and start cutting the sump.
 
#99 ·
Clutch is in, motor bolted to chssus, body is sitting almost where it needs to be, just have to massage the firewall a bit more.
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#101 ·
I will never have any more to do with them, I can't believe they are still in business.
Still waiting on some bits and pieces, been 9 months now.
 
#102 ·
Body is where it belongs. Took a bit of mucking around, though. The engine mounts supplied in kit make the engine angle toward the lh side of the car, which in turn makes the rear of the gearbox too far to the rh side. Had to modify the supplied engine mount tomove engine 18mm forward on that side.
This gave more firewall clearance too.
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Its been a while since I done any welding at home but the mig still works.
 
#105 ·
I finally recieved the flange adapter, oil feed and drain for the turbo from AECO. No gaskets if course.

This diy "kit" just makes it harder Im sure.
 
#112 ·
Bonnet and flares painted today.
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Still not sure what Im doing with rear wheel arch and flare situation. Might sort that out after everything else is fitted up.
 
#113 ·
Getting ready to make the intercooler fit.
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Cut the vertical lock support to make room.

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Will start making mounts tomorrow along with new vertical lock bracket.
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#118 ·
Cut the holes for airbox, snorkel and intercooler.
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#119 ·
Have to machine exhaust manifold to suit the t3 flange.
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