Adventure Driven Talk

Tech Questions and How-To Articles => Build Threads => Topic started by: Se7en62 on January 28, 2018, 11:26:57 AM

Title: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on January 28, 2018, 11:26:57 AM
[Follow along on Instagram @overland_pajero (https://www.instagram.com/overland_pajero/)]

I've had this Montero --> Pajero in my garage for about a month now so I figured I'd put together another build thread since things are starting to rock and roll.

After my wife and I spent some time in our XJ traveling around Texas and the Southwest, we realized we wanted something a little bigger. I did the typical search for an FJ80, but after I started reading about the Gen 2.5 Montero my search was over. I found this clean one in Palm Springs, CA for $2,500, so after a couple conversations with the owners I bought a one-way plane ticket and flew to pick it up.

(http://forum.expeditionportal.com/attachment.php?attachmentid=431475&d=1515906802)

After meeting the previous owners at the airport and exchanging funds for a title and bill of sale, I turned around and drove it the 1,100 miles back to Austin.

(http://forum.expeditionportal.com/attachment.php?attachmentid=431478&d=1515907938&thumb=1)

(http://forum.expeditionportal.com/attachment.php?attachmentid=431479&d=1515907958&thumb=1)

I stopped in Phoenix to meet up with another member and install a set of manual hubs. After we were through, I only had enough energy to drive about half-way to Tuscon. Which was perfect timing to fold the seats flat and get some good rest.

(http://forum.expeditionportal.com/attachment.php?attachmentid=431476&d=1515907866&thumb=1)


UPDATED: 03/12/19

BEGAN AS:

1999 Mitsubishi Gen 2.5 Montero 4x4 Winter Package w/ 196k ($2,500)
Gen 2.5 (NL) Body
Anchorage Gray Pearl (F4470) / Munich Silver (F1688)
Factory Rear Air Locker
Power Windows and Locks
Moonroof
Leather Seating for 7
Heated Front Seats
15" x 7" Factory Wheels

RECENT MAINTENANCE by PO:
[CHECK @ 174k] Timing Belt
[CHECK @ 174k] Timing Belt Tensioner
[CHECK @ 174k] Water Pump
[CHECK @ 174k] Rear Camshaft Seals
[CHECK @ 174k] Valve Stem Seals

NECESSARY MAINTENANCE @ 197k:

[CHECK] Duracell Platinum AGM Group 24 ($140) <-- Made by Deka/EastPenn.
[CHECK] Replace Rear Door Latch Assembly ($8)
[CHECK] Hart Slotted Zinc-coated Brakes Rotors and Ceramic Pads ($227)
[CHECK] (4) Timken Wheel Bearings & (2) Seals ($78)
[LABOR] R&R Front Brakes, CV Axles, and Bearings ($290)
[CHECK] A.D.D. Updated Crankshaft Bolt ($35)
[LABOR] R&R Crankshaft Pulley & Update Bolt ($30)
[CHECK] Replace CV's w/ Cardone Reman. Units ($81)
[CHECK] Flush Radiator and Coolant System w/ Blue Devil Radiator Flush ($7)
[CHECK] Drain & Fill Coolant System w/ 2.375 Gallons Green 50/50 Antifreeze ($30)
[CHECK] Drain & Fill Transmission w/ 8.9 Quarts Mitsubishi Diamond SP-III Transmission Fluid ($32) [4qt Drain & Fill]
[CHECK] Drain & Fill Transfer Case w/ 2.6 Quarts Lucas Synthetic 75w90 [API Class GL-4] ($54)
[CHECK] Drain & Fill Front Differential w/ 1.2 Quarts Red-Line or Lucas 85w90/80w90 [API Class GL-5] ($18)
[CHECK] Drain & Fill Rear Differential w/ 3.3 Quarts Red-Line or Lucas 85w90/80w90 [API Class GL-5] ($27)
[CHECK] Drain & Fill Engine with 4.8 Quarts Rotella T6 5w40 and new K&N Oil Filter ($65)
[CHECK] Lifetime 4x4 Alignment ($87)
[CHECK] 8-Piece Steering System w/ UCA's w/ Ball Joints, Lower Ball Joints, Inner & Outer Tie Rods - ($134)
[CHECK] R&R EGR Valve ($48)
[CHECK] EGR Control Solenoid ($30)
[CHECK] Build and Install "Big 3 Upgrade" w/ 1/0 Wire ($136)
[CHECK] Replacement Front Passenger Window Regulator ($44)
[CHECK] R&R 4x4 Vacuum Switch Solenoid ($27)
[CHECK] R&R Fuel Filter ($19)
[CHECK] R&R Air Filter, Clean MAF, Clean Throttle Body ($40)
[CHECK] Detail Interior and Condition Leather ($28)
[CHECK] Replace Floor Mats ($40)

NECESSARY MAINTENANCE @ 202k:
[CHECK] Drain & Fill Engine with 4.8 Quarts Rotella T6 5w40 and new K&N Oil Filter ($65)
[CHECK] Rotate & Balance Tire w/ Spare Rotation
[CHECK] R&R Aftermarket Radiator with Spectra Radiator and Gates Hoses (Temp.) ($144)
[CHECK] R&R OEM Thermostat ($25)

NECESSARY MAINTENANCE @ 207k:
[CHECK] Drain & Fill Engine with 4.8 Quarts Rotella T6 5w40 and new K&N Oil Filter ($65)
[CHECK] Rotate & Balance Tire w/ Spare Rotation
[CHECK] R&R Auxiliary Fan w/ Spal 12" Pusher Fan ($80)

PENDING MAINTENANCE:
[DELIVERED] Hella 77mm Horns ($15)
[DELIVERED] Flex Technologies 3.5mm, 6mm, 8mm, 10mm Silicone Vacuum Hose ($45)
[DELIVERED] NGK Plugs and Wires ($47)
[DELIVERED] Fel-Pro Valve Cover Gaskets ($25)
R&R Valve Cover Gaskets, Plugs, and Wires

EXTERIOR UPGRADES & MODIFICATIONS:
[CHECK] AVM Series 400 (443) Manual Locking Hubs ($142)
[CHECK] (5) General Grabber X3 33x10.5R15 ($1,300)
[CHECK] Remove Factory Running Boards
[CHECK] Remove Factory Roof Rack
[CHECK] Rebadge as "PAJERO" ($100)
[CHECK] De-badged Gen 2 Grill ($18)
[CHECK] ARB Winch Bumper ($855)
[CHECK] A.D.D. Old Man Emu Expedition Lift w/ Bilstein 5100's ($950)
[CHECK] A.D.D. Adjustable Panhard Bar ($180)
[CHECK] A.D.D. 3-Piece Skid Plate Combo (Front, Mid, and Trans)Front Skid Plate ($500)
[CHECK] LED Headlights ($35)
[CHECK] Fabricate Full-Length Roof Rack ($180)
[CHECK] Install (2) Pelican iM2700 Cases to Roof Rack ($FREE)
[CHECK] (8) Surco GM100 5-1/2" Gutter Mounts ($120)
[CHECK] Rhino Rack Foxwing Mounts for Rear Awning ($58)
[CHECK] Cascadia Vehicle Tents - Mt. Shasta Extended Pioneer w/ Annex + Summit Rails and Shoe Bags ($700)
[CHECK] Teton 20F Canvas Double Sleeping Bag ($180)
[CHECK] Teton Flannel Pillows ($24)
[CHECK] ARB 4.5' x 8.5' Rear Awning ($80)
Fabricate Side and/or Rear Ladder
Trail Gear 67" Rock Sliders
Fabricate Fender Side Bars
[CHECK] Tint ($82)
[CHECK] LED Reverse Lights ($20)
[CHECK] Wizzy Wheel ($22)
[CHECK] Replace Hood w/ Hood in Better Shape ($40)
[CHECK] Spare OEM Gen 2.5 Headlights ($40)
[CHECK] Spare OEM GEn 2.5 Taillights ($40)
[CHECK] 35w LED Cube Lights Combo Beam ($24)
[CHECK] 100w Lightforce Blitz 240 10" Halogen Off-Road Lights ($100)
[CHECK] Lightforce Combo Beam - Crystal Blue - Lens Covers ($60)
[CHECK] Lightforce Hi-Mounts for RMDL Lights ($30)
[CHECK] Cleanwaste Go-Anywhere Toilet ($65) w/ 15-pack Toilet in a Bag ($15)
[CHECK] ECCPP Billet 6061-T6 AL 1.25" Wheel Spacers ($70)

​INTERIOR UPGRADES & MODIFICATIONS:
Replace Front Seats Mounts w/ "Bouncy" Seats, but retain heated-seat function
[CHECK] Remove 2nd and 3rd Row Seats
[CHECK] SafariStraps 41"x28" ($85)
[CHECK] Powertye 16"x32" Net to be used as Attic ($15)
[CHECK] Replace All Interior Bulbs w/ LEDs ($35)
[IN PROGRESS] Build Drawer System ($135)
[CHECK] Dometic CFX95DZW Dual-Zone Fridge/Freezer w/ Wi-Fi ($600)
[CHECK] DFG Offroad Fridge Slide w/ Cutting Board for CFX95DZW ($440)
[CHECK] LED Courtesy Lights ($FREE)
[CHECK] LED Cargo/Map Lights ($40)
[CHECK] Build Cargo Compartment 12V/80A Power Supply ($162)
[CHECK] KPPOL 50w 6-port USB 2.0 Quick Charger ($16)

RECOVERY:
[CHECK] Smittybilt XRC9500 ($200)
[CHECK] UltRanger Winch Hook ($30)
[CHECK] Luso Overland Pintle Hitch Recovery Point ($75)
[CHECK] UltRanger 3" x 20' Tree Saver
[CHECK] UltRanger 10-Ton Snatch Block


NUTS & BOLTS:

[CHECK] Everything I've bought has been Grade 8.8 or higher, so... ($130)


I'll update this thread with new posts, but also keep this main post updated as well as a running log.

Anyway, here's some pictures from Last Saturday starting with a before and after. The PO had (3) different brands of tires on it, so they had to go ASAP.
(http://forum.expeditionportal.com/attachment.php?attachmentid=432759&d=1516647963&thumb=1)

Filling up and admiring the rubber. I can't wait to get this thing off-road now!
(http://forum.expeditionportal.com/attachment.php?attachmentid=432758&d=1516595290&thumb=1)

I just can't get enough of this face.
(http://forum.expeditionportal.com/attachment.php?attachmentid=432699&d=1516595413&thumb=1)

Today I'm installing new LED headlights. Suspension and small parts are being shipped. ARB bumper should be here this week sometime. Next weekend should be more eventful with installs.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on January 28, 2018, 11:30:05 AM
Is there a way I can scale the pictures to me smaller?
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on January 28, 2018, 11:46:48 AM
Any suggestions on part #'s for the inner and outer front CV axle boots? I've heard it's unadvisable to replace with aftermarket CV's and to just reboot them.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: PajEvo on January 28, 2018, 02:15:57 PM
Is there a way I can scale the pictures to me smaller?

Our software won't scale the pics unfortunately. You'd have to remote host and link back.

But I'm enjoying the tale so far. Sounds like you've got a comprehensive build going. We like those. :)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Sir_Monty on January 31, 2018, 02:41:53 PM
Nice gen2.5! Build is already going to be good. Good to see another Texas truck.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 02, 2018, 09:55:00 AM
Thank y'all! I'm pretty stoked to be working on this truck!

I finally tracked down the where the oil leak is coming from. I realized that if I'm parked on a flat surface or with the front-end facing down hill that the oil leak goes away. If it's positioned facing uphill though, it leaks more. This helped me realize that when the oil pools at the back of the valve cover it leaks down the back of the block, then down the lines and then drips from the backside of the transmission pan (engine oil only, not tranny fluid.)

Anyhow, I went ahead and ordered a new Fel-Pro valve cover gasket set. Then since I'll be under the intake plenum anyhow, I figured I'd do the plus and wires while I'm there. So, NGK Iridium plugs and NGK wires are on the way as well.

That said, I keep getting the EGR (p0400) code. I've removed it a couple times now and so far with a fresh tank of 93-octane it hasn't come back. If it does, i'm going to suspect the gasket around the EGR pipe at the driver's side upper-rear of the engine. That was removed and replaced when Bobby and I rerouted the wiring harness while I was in Mesa.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 02, 2018, 10:01:28 AM
Oh, the first shiny part to arrive was the ADD Adjustable Panhard Bar. This belongs on my mantle, not under my truck!

(http://forum.expeditionportal.com/attachment.php?attachmentid=433967&d=1517591085)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on February 02, 2018, 02:34:07 PM
Glad you like it!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 08, 2018, 12:02:02 PM
This past weekend, I was able to get a few things started and finished tonight. One was to just replace all the broken little tabs that hold the interior trim to the rear door. No pictures, but it's self-explanatory.

Next I installed the JDM Corner Lamps. These came with orange bulbs, but had a different connector. All I had to do was swap the connect from the OEM corner and go grab a couple of 1137's in Amber. I left the lower light disabled for now, because I like this look better.

(http://forum.expeditionportal.com/attachment.php?attachmentid=434392&d=1517891689&thumb=1)

Next up was to swap the wobbly "red-ball" transfer case selector for a Gen 2's "white-ball" selector. It was fairly straight-forward, but I overcomplicated it because I hate to do things twice if I can do it right the first time. In the interest of someone else doing the same task, I'm including a little write-up here.

First, follow this link and follow the instructions to remove the console, but when you get to Step 9, read my text below:
http://the2point5build.blogspot.com/2017/06/transfer-case-shifter-replacement.html (http://the2point5build.blogspot.com/2017/06/transfer-case-shifter-replacement.html)

Now you're at Step 9 and can't figure out how to get your Gen 2.5 transfer case forks to look like what's pictured, while also conforming to the fact that your transfer case has to be in 2H before reinstalling the new selector. Well, it won't happen because (A) That image is of a Montero Sport's transfer case gate and (B) The forks in that image are not in 2H either. So disregard that image.

All you need to know is whether or not your transfer case is in 2H, then use some bent-nose needle nose pliers to pull the return spring to the passenger side while you install the new selector. Below are images of what your forks look like in 2H, 4H, 4Hlc, and 4Llc.

Transfer Case Forks in 2H
(http://forum.expeditionportal.com/attachment.php?attachmentid=434393&d=1517892223&thumb=1)

Transfer Case Forks in 4H
(http://forum.expeditionportal.com/attachment.php?attachmentid=434394&d=1517892250&thumb=1)

Transfer Case Forks in 4Hlc (Notice how the 2WD/4WD fork is in it's 4-Locked position and is now aligned with the Hi/Lo fork. This alignment allows the selector key to pass over into the Hi/Lo fork when you shift to 4Llc.)
(http://forum.expeditionportal.com/attachment.php?attachmentid=434395&d=1517892288&thumb=1)

Transfer Case Forks in 4Llc (Notice now that the 2WD/4WD fork remains in the 4-Locked position, but now the Hi/Lo fork has moved rearward into 'Lo' for 4Llc.)
(http://forum.expeditionportal.com/attachment.php?attachmentid=434396&d=1517892382&thumb=1)

When you're making your adjustments, just make sure that you're transmission is in 'Neutral.' If the transfer case selector doesn't move smoothly, something isn't right. Once you're done, the selector should work perfectly. Now, go back to the link provided above and finish your reinstallation of your selector and console.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Sir_Monty on February 08, 2018, 08:52:09 PM
Thank you for sharing these pictures. This gives me a better understanding of how it works. And what to do if I move something out of place.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 10, 2018, 08:12:27 PM
Installed the A.D.D. Bilstein 5100's up front this evening. Tomorrow I have a lift reserved at 9am at the local DIY shop so I can get the rest of the suspension installed. My garage is enough to work on most projects, but I just prefer using a lift for suspension work.

(http://forum.expeditionportal.com/attachment.php?attachmentid=434910&d=1518318604&thumb=1)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 10, 2018, 08:14:36 PM
I also unboxed the ARB and it's laying in the garage now, but I thought I'd share it. Once the suspension goes on, I'll dive into installing this sweet puppy.

(http://forum.expeditionportal.com/attachment.php?attachmentid=434613&d=1518115969&thumb=1)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 12, 2018, 07:48:33 AM
Yesterday, I was able to get over to a local DIY shop and finish the suspension install. I have a garage, but I didn't feel like laying on concrete for 5 hours. this place is pretty cool in that they will rent you a lift with all the tools you need in a color-coded rolling cart for $30/hr. In all, it took me about 5 hours and I think it turned out pretty good. Now I just need to remove the rear sway bar and install the winch bumper. Once that's done I'll give it a couple days to settle before I consider trimming the UCA bump stop or adjusting the torsion bars.

(http://forum.expeditionportal.com/attachment.php?attachmentid=435023&d=1518446586&thumb=1)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on February 12, 2018, 10:14:29 AM
 Looks great dude! makes me want another blue one.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Sir_Monty on February 13, 2018, 09:08:39 PM
Very cool....also are you retro fitting a arb bumoer? Or is that really as gen2.5 arb bumper.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 18, 2018, 04:38:47 PM
Very cool....also are you retro fitting a arb bumoer? Or is that really as gen2.5 arb bumper.

It will require some retrofitting. Part # 3434040 is labeled as a 97-00 Pajero, so the outward dimensions are the same. However, the frame mounting brackets are off by 1". I plan to take it to a local fabricator to have the frame horns modified to fit the bumper's mounts.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 25, 2018, 10:14:05 PM
Another 4x4 enthusiast in a local group offered to help me out with modifying and mounting my ARB Winch Bumper (ARB Part#: 3434040). Now this bumper is the correct shape, but the mounts are a little different as they're designed to work with the 1997-2000 Pajero GLS. From what I've gathered the Pajero GLS has a slightly narrower frame "horns" at the very front of the frame. These "horns" are what the bumper would mount to, but in US-spec Montero's it seems that there are extra brackets that have been welded onto the frame horns by Mitsubishi which widen the horns by about 1/2".

This means the bracket's on the ARB Pajero Winch Bumper (3434040) are the correct width on the outside, but the width between the two inner brackets is too narrow so it has to be widened for the 3434040 to work with a Gen 2.5 Montero.

You can solve this problem in your own way, but what we decided to do was to cut the inner parts of each bracket and widen then with new material. It was fairly simple, but time consuming. It took us 12 hours (including lunch and a run to the hardware store for Grade 8 bolts) to completely finish. I will say that if you are using a Warn winch, then it will take you about 1-2 hours less time, since ARB's are built to use a Warn, though any winch can be used.

(https://uploads.tapatalk-cdn.com/20180226/d79a3a612455d7f6c2ddaf8089ba43fe.jpg)

(https://uploads.tapatalk-cdn.com/20180226/e4af563ddb8c9c0a4b41af1685645d15.jpg)

(https://uploads.tapatalk-cdn.com/20180226/e01f02916f64ed0b66cb3555133c6fab.jpg)

(https://uploads.tapatalk-cdn.com/20180226/0a86e22ce2dc1a1c280532e1485e80d6.jpg)

(https://uploads.tapatalk-cdn.com/20180226/a7e5f79f0e9c274b826bc10a0c948e9b.jpg)

(https://uploads.tapatalk-cdn.com/20180226/ff163b4d274102e8172c0d69dd4d1ad7.jpg)

(https://uploads.tapatalk-cdn.com/20180226/f0e1817a2eda40aac4c866c42d610971.jpg)

(https://uploads.tapatalk-cdn.com/20180226/307717f62167f535a3bd67510b3f6975.jpg)

(https://uploads.tapatalk-cdn.com/20180226/d90a131b35625f061d365e0d0af1cbde.jpg)

(https://uploads.tapatalk-cdn.com/20180226/41bb9b603d57eb76905130744ec30f78.jpg)

(https://uploads.tapatalk-cdn.com/20180226/780e7e725827199d73ee617c93500369.jpg)

(https://uploads.tapatalk-cdn.com/20180226/1d716de439250fe47008bc72e72adde2.jpg)

(https://uploads.tapatalk-cdn.com/20180226/0ae07f57b4bf9cdb855c2bec18f7da7a.jpg)

(https://uploads.tapatalk-cdn.com/20180226/0836a2154db24308a3748cb71700e19f.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Sir_Monty on February 26, 2018, 09:25:55 PM
Very cool thanks for sharing. Also did you have to order the bumper from a vender over sea. Or was there someone state side that was able to get it for you?
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 27, 2018, 04:04:49 PM
Very cool thanks for sharing. Also did you have to order the bumper from a vender over sea. Or was there someone state side that was able to get it for you?

Stateside: 4WP actually carries it.  8)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on February 27, 2018, 04:08:31 PM
I was having trouble getting one of the Rugged Ridge manual hubs to engage/disengage. I removed the hub, took it apart, cleaned it with silicone lube and then reassembled with white lithium grease. It's now about 90% easier to turn by hand than before with pliers.

Now, I'm sure the 4WD system and rear air locker work flawlessly. Next job is going to be to replace the fluid in the differentials, transfer case, and transmission and clean the tranny filter.

(https://uploads.tapatalk-cdn.com/20180227/35407da1124c9d86d56173ac0137418f.jpg)

(https://uploads.tapatalk-cdn.com/20180227/726cbae0b2206a78a0c61302e2c5e312.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on February 28, 2018, 07:21:00 AM
Well done, looking great dude!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 04, 2018, 08:30:07 PM
Knocked out the transmission drain and fill. I just removed the drain plug and drained 1-gallon of old transmission fluid out, then refilled through the dipstick with 4-quarts of fresh Mitsubishi Diamond SP-III fluid. It shifts smoother now, but in another 10k, I'll drop the pan and clean the filter for good measure.

After that, I wired the ARB's bumper lights up to the factory wiring harness for the foglights, since they aren't being used anymore. Then I rebadged it as a Pajero with some badges I bought online. I think it all came out pretty good. I am on the fence about the spare tire cover though. It may grow on me more...Thoughts?

(http://forum.expeditionportal.com/attachment.php?attachmentid=437615&d=1520220173&thumb=1)

(http://forum.expeditionportal.com/attachment.php?attachmentid=437616&d=1520220192&thumb=1)

(http://forum.expeditionportal.com/attachment.php?attachmentid=437617&d=1520220210&thumb=1)

I still need to wire up the side markers to run in unison with the running lights and turn signals. I'll do that after I find a connector that I can use to make a wiring harness. I think I might have some luck at the Wrench-a-Part if I pull some bumper lights out of an Eclipse.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 09, 2018, 07:30:48 AM
After several times reading through his thread, I decided I'd follow ImNoSaint's lead on replacing the dim factory reverse lights. I went the exact same route he did in his thread (here (http://"http://forum.expeditionportal.com/threads/168259-ImNoSaint-s-2-5-Thread/page3")) with the Nilight 18W LED Flood (http://"https://www.amazon.com/gp/product/B00J5AAX5S/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1") lights. Following his guide, it only took me about an hour and half to finish the install. Honestly, the most tedious part was tightening the hardware on the backside, since I have a tow hitch installed that blocks the inner most nuts.

For $19/pair, the result are reverse lights that light up my neighbors house across the street like a spotlight.

These tools, plus the angle grinder or die-grinder are all you need:
(http://forum.expeditionportal.com/attachment.php?attachmentid=438112&d=1520605408&thumb=1)

MORE DETAIL ON IMNOSAINT'S 2.5 THREAD (http://"https://www.amazon.com/gp/product/B00J5AAX5S/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1")

My finished product...
(http://forum.expeditionportal.com/attachment.php?attachmentid=438113&d=1520605500&thumb=1)

Today is also FINALLY PAJERO PLATE DAY! Which means I can get rid of my Montero's horrible (sorry folks) Cali plate and get it fitted with the plates of my native Texas homeland. It finally passed inspection after having to clear the EGR code and unplug the battery for a day to reset everything. The EGR did come back on afterward, so I'll still be diagnosing that soon. Has anyone ever run SeaFoam through the EGR's vacuum lines?
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on March 09, 2018, 08:45:55 PM
 Sometimes you can just clean the shit out of those EGR's and their passages and it works. Sometimes
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 12, 2018, 08:46:36 AM
Sometimes you can just clean the shit out of those EGR's and their passages and it works. Sometimes

I think I'm going to try before I R&R any part of it. I'll go through the vacuum lines one by one, blowing them out with compressed air and marking them with a silver sharpie. Then I'll clean and blow out the solenoid and EGR valve. If that doesn't change it, I'll replace them.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 15, 2018, 01:40:34 PM
Here's a couple of quick updates: I was able to get my new Texas Tags, which I'm really happy about. The next thing that I wanted to address preemptively was to flush the coolant system with the same solution I used on my Jeep. I just followed the directions on the bottle for a 6-hour deep cleaning.

(https://uploads.tapatalk-cdn.com/20180315/2b2b76d5f7f7c26329e711719bace490.jpg)

Not surprisingly, the solution found a leak. After a little advice from the Montero group on FB I just swapped out the line for a new section of 3/8" heater hose. I also ordered an Edelbrock inline fuel filter to install here to help catch any particulates in the cooling system after I finish the flush. I'll make another post once I throw that inline filter on.

(https://uploads.tapatalk-cdn.com/20180315/b2131d790a7b5c7a0b41e1a5c545287d.jpg)

After attempting the front brakes twice only to run into barriers (tools, skillset, etc.) I dropped it off at a local shop to let them knock out the Hart front brakes and Timken bearings. I'll update this post with a picture of the new rotor up front behind the wheel, because it looks pretty rad. The shop also threw installed my updated Mitubishi Crank Bolt as well.

(https://uploads.tapatalk-cdn.com/20180315/daf15a351bf155dffd4428f5d7b38069.jpg)

After I got it home, I wen ahead and finished replacing the rear brakes as well. That only took me about 20 minutes per side. These pads and rotors are from Hart Brakes (http://"http://hartbrakes.com/"). The rotors are their Black Slotted rotor and the pads are carbon-ceramic. The black color on the rotor is an anti-corrosion layer of zinc. These brakes performed really well during my brake-in session and didn't show any noticeable fade until about the 9th round of 60-15mph emergency braking. The brake pad material transferred well to the rotor and I could see the grayish dust collecting in the slots as well.

(https://uploads.tapatalk-cdn.com/20180315/13163123cff29ada67f49a846f23db9b.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 16, 2018, 07:48:26 AM
As she sits today. I still have quite a bit to do in terms of overland prep, but I'm nearing the end of the major maintenance. So far, I've put about 4k on it and really like it.

(https://uploads.tapatalk-cdn.com/20180316/50eac4a94594cc7efbb0c2c14908ccb9.jpg)

I am thinking it will get a K&N filter soon and if someone makes a phenolic manifold spacer then I'll do that, but performance wise it's going to remain stock. A swap to 4.90 gearing is likely though, but probably after our return to the CO BDR in July.

Next up will be to drain the brakes and replace with fresh fluid to stiffen up the pedal feel. I'll get to that tonight, as well as replacing the rear diff fluid and removing the tow hitch before we go hit the trails tomorrow.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: ChargerX3 on March 16, 2018, 08:00:00 AM
She is one good looking rig. Like the color combo and how you outfitted her.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 21, 2018, 02:27:39 PM
She is one good looking rig. Like the color combo and how you outfitted her.

Thanks! I really like the color too. i think I got really lucky as it's hard to be too picky with how rare as these things are.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 21, 2018, 02:30:34 PM
Last Friday, I replaced the diff and transfer case fluids. The transfer case received Lucas Synthetic 75w90 and the diffs each received Lucas Heavy-Duty 80w90. Both diffs and the transfer case were simple drain-and-fill's.

(https://uploads.tapatalk-cdn.com/20180320/b5a8e9c761cd53d161e856926937a195.jpg)

(https://uploads.tapatalk-cdn.com/20180320/88fd37b32f98f00e21feb134ae41356b.jpg)

I also removed the 3rd row seats. These are simple enough to remove and store for later use.

(https://uploads.tapatalk-cdn.com/20180320/c2942fcd513f5686b7cffab2b7172111.jpg)

First you just remove the single cover screw (Philips head).

(https://uploads.tapatalk-cdn.com/20180320/5c893eb206f8197f6f65045bf56bc41e.jpg)

Once you remove the inner cover, there will be (2) 12mm bolts holding the inner bracket.

(https://uploads.tapatalk-cdn.com/20180320/cefc64842e24e2478d1311bcd9afd047.jpg)

Next, flip down the 3rd row seats and you'll find a pair of (2) more Philips head screws. Remove them and then remove the outer cover.

(https://uploads.tapatalk-cdn.com/20180320/4e2fec79aca529d667b853cb31765d33.jpg)

Again, there will be (2) more 12mm bolts holding the outer bracket in place. Remove these and the seat will be free.

(https://uploads.tapatalk-cdn.com/20180320/077e3ce4de28c2c15a172179879d18a6.jpg)

(https://uploads.tapatalk-cdn.com/20180320/23200c46a4730c655e1453253eb318d9.jpg)

I also didn't like the way the bolts looked that came with the Luso Overland Pintle Hitch. They are a higher grade, but they developed surface rust very quickly. Rather than painting them, i just replaced them with the bolts that were used for the tow hitch since I was removing that as well. (Which I decided to do after I had tightened this back up. LOL.

(https://uploads.tapatalk-cdn.com/20180320/2641cdae1c9b1846575838c7d0d22b2a.jpg)

The last item I needed to address was improving the departure angle by removing the factory tow hitch. This was straight forward using (4) 17mm bolts on the bottom, as well as the (4) 17mm bolts holding the pintle hitch in place. The last bolt was a little tricky to access, so I pivoted the hitch out to a 45 angle on my floor jack which allowed me to grab the nut that was spinning on top of the frame. After that, I just wheeled it out and stored it for later use. - I will note that the trailer hitch connection, I just moved them up and mounted it to the frame.

(https://uploads.tapatalk-cdn.com/20180320/860b7acfbb42540dbf9b481f8509a56e.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 21, 2018, 02:32:37 PM
Sunday morning my wife and I bled the brakes and then hit the road. Here in Texas we have off-road parks due to the lack of public property, so we headed out to a location called Hidden Falls in Liberty Hill. This place is a about 2400 acres and features a gun range, dozens of trails with various difficulties, camping, and RV spaces. It's a pretty cool private facility and the cost is fairly low so a lot of folks from the Austin area frequent it. I've been out here before in in Jeeps, but this was the first time I'd taken the Pajj out.

(https://uploads.tapatalk-cdn.com/20180320/1cd25a5c9afd824e49a9bac4c134981c.jpg)

I realized right when we arrived that my 4H wasn't engaging, but later found that it was my driver's side manual hub that wasn't engaging the CV axle. Regardless, my 4HLc and 4LLc both engaged a psuedo-locked 3WD...maybe? Maybe 2WD locked? We went ahead and headed onto the main trail that connects all the others. I went straight to the back and hit a Level 3 which was just a deeply rutted up creek bed that ran up a steep hill. Then we turned onto another trail and head up to one of the obstacles there. No issues all day and then we drove home without issue.

VIDEO (https://youtu.be/9E8t9qCtoa4) <--CLICK HERE

(https://uploads.tapatalk-cdn.com/20180320/cf8ccb805bcf552e8171817d3bb8fc78.jpg)

(https://uploads.tapatalk-cdn.com/20180320/a62234b8092a07c74e98ec188d1f1d28.jpg)

(https://uploads.tapatalk-cdn.com/20180320/394abd15134b816b7a75dcf43c98e501.jpg)

I'm going to fix that hub Tuesday and then get back out to a different off-road ranch on Sunday to have another shakedown.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 21, 2018, 02:35:44 PM
I took another cue from anotehr thread here on ADD to add an inline fuel filter to the coolant system's return bypass line. The filter used is an Edelbrock unit with a sintered copper filter element. This is a cheap ($15) and practical precautionary upgrade for these old trucks. My coolant system is as clean as koolaid, but this should catch anything floating around in it.

(https://uploads.tapatalk-cdn.com/20180321/c78057c5b426f01620da5074400cb30f.jpg)

(https://uploads.tapatalk-cdn.com/20180321/035dfff42541d1239de0ada228ceb4e8.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 28, 2018, 10:20:24 AM
Fixed the hub on Saturday and detailed it. Then on Sunday, we went out to a private ranch near Boerne, TX to do some wheeling. We had a nice and diverse group of trucks: My Pajj, plus a black Lexus GX470 w/ Dobinsons (I think..) and 33's, a black Baja Tacoma with rear locker and 33's, a silver Tacoma with rear locker, and my buddy's well-built WJ with brand new Radflo shocks. We had a blast and everyone did the same lines, except at one point the WJ did a pretty gnarly line through a boulder field that no one else attempted. Regardless, the trip was awesome and the 'Rocket' did really well. It was about a 2-hour drive to the ranch, we did 5-hours of wheeling, and 2-hours home without an issue in about 82 weather.

VIDEO: LIFTING A WHEEL CLIMBING SOFT SOIL (https://www.youtube.com/watch?v=Pk2WdS9HPhY)

(https://uploads.tapatalk-cdn.com/20180329/cecae7b493d1fd0c1e75a6ca2553c14e.jpg)

(https://uploads.tapatalk-cdn.com/20180329/6000d53f3fdd1ccad202d6c519982aff.jpg)

(https://uploads.tapatalk-cdn.com/20180329/946e4415a2b9b4f64ce1cb8f327f6440.jpg)

(https://uploads.tapatalk-cdn.com/20180329/b50c951459f4fb717e8637ed56eae884.jpg)

(https://uploads.tapatalk-cdn.com/20180329/d133a65cfe76a21e463a4bb4e420d924.jpg)

(https://uploads.tapatalk-cdn.com/20180329/9a89ac857be1dd70de09e3ce6b075cf7.jpg)


Adventure Driven Design shipped by 3-Piece Skid Plate Combo last week, so we should be all plated up by mid-week next week. There was only one thing I could do...

(https://uploads.tapatalk-cdn.com/20180329/afc29f2f47c022137048e497e739313c.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on March 28, 2018, 04:41:26 PM
Thanks for sharing, i know it's extra work to post on multiple forums. We appreciate it.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 29, 2018, 10:28:04 AM
Thanks for sharing, i know it's extra work to post on multiple forums. We appreciate it.

No problem! I enjoy sharing your dedication to the marquee. It's also a lot of fun to educate people on the history and capability of these things, since there just aren't a whole lot in proper use. Maybe these threads will motivate a few more folks to pick up a Pajero/Montero (or four) and save another from the crusher.

Honestly, after getting my hands on this and learning about it I've become totally attached to it. The whole thing including the Dakar history, as well as ADD's contribution and commitment to create a domestic aftermarket where there hasn't been one for so long. Right when one is needed most...
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on March 29, 2018, 10:38:57 AM
Anyhow, I had time to take some pics while it was nice and shiny right before we pulled onto the ranch to go wheeling. I spent hours detailing it Saturday, primarily because I wanted to establish a baseline of cleanliness that I could maintain easier after each outing or road-trip. This is also a really good opportunity to inspect everything up close inside and out: door jams, door seals, latches, hinges, window trim, carpet, tie-downs, door trim, etc.

With lines like these, who would want to buy a Land Cruiser for 4-5x the price? This example is in excellent shape outside of having some paint fade from a sunny Southern California life. Now that i own it, it has gained a couple of Texas pinstripes from our Cedar Trees, but nothing that I can't live with as character marks or buff out eventually.

(https://uploads.tapatalk-cdn.com/20180329/ab03967555240617c9bde7ac32c0b1e8.jpg)

(https://uploads.tapatalk-cdn.com/20180329/8553af17645f9a185e44d1f2a97064e8.jpg)

(https://uploads.tapatalk-cdn.com/20180329/5a397e4b410276222f995b4ca78286a7.jpg)

(https://uploads.tapatalk-cdn.com/20180329/4303436c5dd7bbe2d82b9819fedb899a.jpg)

(https://uploads.tapatalk-cdn.com/20180329/6c4d30378899b1734f9478e67fd64c7d.jpg)

(https://uploads.tapatalk-cdn.com/20180329/82247bf31a84d56a7907872d5cd0282e.jpg)

(https://uploads.tapatalk-cdn.com/20180329/6ea75a89f0c2d7141cade14ced411490.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: MrGalantguy on March 29, 2018, 12:51:41 PM
Gorgeous Montero...cleans up very well!! 8)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 03, 2018, 08:56:36 AM
Gorgeous Montero...cleans up very well!! 8)

Thanks! I spent hours cleaning it, just to take it wheeling and get it filthy again. That said, it's nice as hell on the inside while it does work on the outside.  8)

Two of the three ADD Skid Plates arrived on Friday, but I don't want to install them until I can do all of them this weekend. So, I had nothing better to do on Saturday. After a few hours at the gun range with some buddy's of mine, I strapped down my gear and headed back to Hidden Falls. This place is only about 12 miles from Best of the West Gun Range, so I couldn't resist. I wasn't able to get many pictures since I was wheeling alone this time. However, I did run across a nice an accessible patch of Bluebonnet (State Flower of Texas) on my way home. These flowers are finicky and don't always bloom in the same fields, but this time of year our roadways are all lined in these vibrant blue flowers. They'll stick around through April so I'll try and find some larger fields to show y'all.

(https://uploads.tapatalk-cdn.com/20180403/f25db5c4ca678abb301f9d58e6a46735.jpg)

(https://uploads.tapatalk-cdn.com/20180403/7b119d7bb407312bf67dd21c3e7f9f6b.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: jaccox on April 09, 2018, 09:59:09 AM
Beautiful truck and pics man. I just got back from my maiden voyage on the X3's and I'm really happy with how they performed. They wrap around rocks like its nothing and the lugs on the sidewall will pick up a small animal if you're not careful. They aren't terribly loud for their aggressive tread pattern. And I slung them around switchbacks in the Appalachian Mtns for an entire week and never felt like I had too little of contact on the asphalt.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 12, 2018, 03:27:45 PM
Beautiful truck and pics man. I just got back from my maiden voyage on the X3's and I'm really happy with how they performed. They wrap around rocks like its nothing and the lugs on the sidewall will pick up a small animal if you're not careful. They aren't terribly loud for their aggressive tread pattern. And I slung them around switchbacks in the Appalachian Mtns for an entire week and never felt like I had too little of contact on the asphalt.

Nice! Yeah, I love mine. They've been doing really well on the highway up to 80mph or so and like you said, they aren't too loud at all. Definitely less noisy than my Destination MT's. These X3's are also wearing very nicely and look close to new when they're clean. In the sharp rocks, down to 20-25psi they really deform and grip amazingly well. July  and 3,000 miles, with 350 miles of trails is coming soon though and I don't expect these X3's to have a single problem across TX, NM, or CO.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 12, 2018, 03:32:35 PM
I've been a bit quiet, while my wife and I celebrated our 6th Anniversary over last weekend. L.I.V.I.N. :cool:

Two out of three skid plates have arrived. The last one, the mid-plate is shipping tomorrow, so those will all go in next weekend. I've also been working on sourcing some OEM CV axles, so I can rebuild them and swap them out for mine while I rebuild the set I have so I have a set of good spares. Aside from that, I've been researching batteries for weeks and have concluded that the ($$$) X2Power Group 31 AGM is going to be my next large purchase for this project. Following that I'll also get the electrical system sorted and to do that I started contemplating requirements with this to help visualize what I'm doing. - Now the system will NOT include (2) X2Power's at first, as I have a perfectly good flooded battery up front that's only a year old. The rest of this, I'm pretty close to pulling the trigger on (thanks to Amazon) so if anything seems out of place please let me know and you might possibly save me a headache and some money.

(https://image.ibb.co/mh9nu7/Electrical_Wiring.png)

As hinted at above: Another task I'm working on is upgrading from my ARB 37qt to a Snomaster 42qt. That upgrade should happen next week and I'm really excited about it.

Last but not least, is actually the next most important task at hand and that is the compiling of roof rack materials. I ordered a set of Surco GM100 5-1/2" Gutter Mounts today and will order another set tonight, for a total of (8) mounts. The rest will just be round tubing and light and accessory tabs and mounts, then we can fabricate it and get the RTT mounted. --- Oh! I also picked up brand new ARB 4.5" awning for the rear for $80 from my buddy so that's a bit of a bonus. Cheers!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 15, 2018, 03:11:02 PM
Gutter Mounts have been ordered...I found (2) sets on Amazon that were in "Used" condition for half-price, so I'll just refurb them if needed and replace the hardware with Grade 8 stuff. I should be able to get the rack pretty well designed this week.

In other news: We scored this nearly-brand-new Dometic CFX-95DZW Dual Zone Fridge/Freezer w/ Wi-Fi for $600! It was used at a local outdoor supplier's store as a demo for a couple months but that's brand new in my book. I had made some measurements prior to buying it and even though I figured it would be too big, I wanted to double check just to be sure. Turns out it fits PERFECTLY in the cargo area with the 2nd row seats still in place! - Now I'm selling my brand new (never used) ARB 37qt fridge (locals only.)

(https://image.ibb.co/g4bp7S/30739401_592075131154100_7323637177823264768_o.jpg)

(https://image.ibb.co/jEB0E7/30703730_592075171154096_316745922455273472_o.jpg)

(https://image.ibb.co/kX7wnS/30725719_592075214487425_1701639680165937152_o.jpg)

I have some pondering to do to figure out the layout for the rear drawer system and storage. I'm thinking the fridge will live on the left on a slide with a cutting board underneath on another slide. Then on the right, I'll build a pair of stacked drawers: One for recovery gear storage; One for dry-goods. Behind the lower drawer will live the auxiliary battery and on the right-side outer wall, the Renogy Wanderer PWM Solar Controller. - Then I'll do a box over the top of the fridge to store our pair of travel duffel bags. Then there will still be space on the sides for other smaller gear, like my Viair 88p Air Pump, tire repair, etc.

The backseats, I plan to remove and replace with a platform for my dog. She's a 100 lb Akbash that likes to stand while we drive, so she will get her own space and be separated from the cargo by a cargo net barrier. Since the back seat is set a bit higher on the rise in the floorboard, this should also create small storage spaces in the footwells of the rear seat area. I think this will be a good spot for tool rolls and other stuff I can access while parked or camped. - The fire extinguisher is likely to be mounted to the front seat, as well as my IFAK.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on April 15, 2018, 08:42:49 PM
What's an IFAK?

 Also post pics of your dog!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Davis_664 on April 15, 2018, 09:50:12 PM
What's an IFAK?


Individual First Aid Kit
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 16, 2018, 11:07:33 AM
What's an IFAK?

 Also post pics of your dog!

An IFAK is just an "Individual First Aid Kit," but it's typically more combat or heavy-trauma oriented. Mine is packed with sting/bite/cut treatment, chest seals for through-n-through gun shot wounds to the torso, and Quikclot for heavy blood loss. Then I have tourniquets stashed in a couple quick to access spots. All my IFAK is lacking is an Epipen. I also have an Xterra's first aid pouch that has a SAM splint, knife, various tapes, etc. to treat a twisted ankle or a broken bone.

As requested: Here's our 18-month old Beyza (similar to "Beyaz" which means white in Turkish.) She's an AKC Registered Turkish Akbash Dog and her grandparents are both from Turkey. These aren't real common in the US, especially in the role of a companion dog as they are normally reserved for the duties of a herd guardian. She's about 100 lbs, stands about 6' when she is on her back feet, but is as sweet as they come. These dogs are extremely intelligent and behave autonomously. In her mind, we are her herd and she must protect us, but without panicking the herd. Anytime we stop and she is off the leash, she will automatically set a perimeter of about 50-100m in every direction and watch it from whatever high-ground is available. Then every 15-30 minutes or so, she'll get up and patrol that perimeter...all day and all night. Since we camp in Mountain Lion and Coyote territory, we do lock her in the backseat at night (when we had the Jeep.)

(https://image.ibb.co/cqLXwn/IMG_20180416_110527.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on April 16, 2018, 12:45:00 PM
That's awesome, dogs are my favorite animals ever! Thanks for sharing.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on April 26, 2018, 06:52:52 AM
No real progress to update about, but there has been a good amount of mental elasticity lately. My ADD skid plates are all in and laying on the garage floor..They're so pretty that I don't want to install them. LOL. I just need to tap a couple mounting holes on my Pajero and re-thread them from the factory M8-1.25 to an M10-1.25 since they were a little stripped out. Then the skids should go on without issue. I was able to test fit them and they're a perfect fit and look really sick, so I'm stoked to get them on this weekend!  8)

I'm also waiting on new UCA's, ball joints, and tie rod ends to come in. Once those arrive, I'll do them at the same time I replace the CV axles. Then all the baseline maintenance will be done for a while.

(https://preview.ibb.co/kMNc1x/Capture.jpg)

Otherwise, I'm following ImNoSaint's lead on the use of a cargo net from Safari Straps. I ordered the same 41" x 28" net that he used as his cargo/pet divider and plan to go a similar route with a 'dog deck' in place of the 2nd row seats. My only alterations will be to the height of the floor (I think) and the added ability to unbolt/unlock the floor and fold it into a vertical position for when we need to install the 2nd row seats.

I'm working out the rear deck, fridge slide, drawers, and other specifics but I think this system should work really well for us. - It's just my wife and I and our dog.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: jaccox on April 26, 2018, 07:05:27 AM
FWIW I made my own safari net for like 1/8th the price of buying one. It took an afternoon and breaking some rust off on the sewing since I had not sewn in a while. It's not the prettiest and still could use a revision or two but here's a pic with it holding as many pillows comforter and blankets I could find to see if it would indeed hold.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 02, 2018, 02:45:05 PM
Everything has arrived, so hopefully I'll get the CV's, UCA's, TRE's, and LBJ's done this weekend. - The 'attic' net came in and turned out to work perfectly.

(https://preview.ibb.co/kHGMm7/31788976_599900237038256_8269254870343614464_n.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Sir_Monty on May 05, 2018, 07:26:09 AM
Very cool can't wait to see everything done. Also did you get TRE lockers for both front and back? Or just front since you have the OEM rear locker.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 07, 2018, 07:04:21 AM
Very cool can't wait to see everything done. Also did you get TRE lockers for both front and back? Or just front since you have the OEM rear locker.

Oh, sorry for the confusion. "TRE's" as in Tie Rod Ends. LOL. I do have the factory rear locker, but will likely go with either the ARB or TRE Air Locker. I'm kind of waiting around to see how other guy's TRE lockers and compressors hold up after wheeling them for a few months.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 10, 2018, 10:38:36 AM
Yesterday, I picked up the steel for this weekend's fabrication. My buddy and I are going to build a full-length roof rack measuring about 96"x50" and using (8) Surco GM100 5.5" Gutter Mounts. The dynamic-load requirements for this rack are to provide a stable platform for our CVT Mt. Shasta RTT, which weights about 170 lbs, a pair of loaded Pelican iM2700's around 20 lbs each, and some misc. items like recovery boards and lights; I'm guessing a total of about 265 lbs. The static-load when we're camping will increase to 600 lbs with my wife and I inside the tent with a backpack.

Below is the list of materials I bought (UPDATED w/ WHAT WE USED 5/12/18):

I'll revise this list with what was used, as I DO NOT expect this rack to end up weighing over 100 lbs. I had actually incorrectly ordered the first time, then kept some of that order as well as the new material for the revised design/order. I'm moving forward with a target weight of under 90 lbs*.

(https://preview.ibb.co/eYrWyy/32313397_604484966579783_1332911257426067456_o.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 14, 2018, 06:36:49 AM
We finished the fabrication of the roof rack Saturday. It's final measurements are 96" (L) x 50" (W) and based on a metals calculator it weighs around 98.5 lbs. There's dedicated space for my CVT Mt. Shasta Extended RTT which is 54" (L) x 48 (W), recovery boards, two Pelican iM2700 cases, and water storage. We also used some round tubing in the rear to use as awning mounts using some Rhino Rack parts. The side awning will be secured with a couple pieces of 3"x3"3/4" angle iron, cut into 1" strips. Now I need to take it down, prep it for paint, drill a couple holes to mount the Pelican's, and paint it. Then it'll be finished.

We used a couple 'templates' of 1x1 tack-welded to a pair of the mounts to check outside diameter of each gutter-mounted crossbar.
(https://preview.ibb.co/h7YL0d/32349640_606222589739354_4613703025263902720_o.jpg)

Then we mounted the side-bars and adjusted the height of the gutter-mounts 2 and 3.
(https://preview.ibb.co/d4oL0d/32452347_606222626406017_871745118317576192_o.jpg)

Once we knew everything was square, my buddy started tacked, then welded all the other crossbars and support structure.
(https://preview.ibb.co/n04FYy/32488100_606222673072679_3509177096184266752_o.jpg)

It fits perfectly, it's balanced, and wind-noise is minimal with only a steady low-hum from about 45mph and up that doesn't increase in noise with speed.
(https://preview.ibb.co/gF5B6J/32372892_606222746406005_5301412166497206272_o.jpg)
(https://preview.ibb.co/m0oW6J/32349605_606222713072675_2065419385752780800_o.jpg)
(https://preview.ibb.co/bLQdmJ/32677432_606222783072668_1613774162642337792_o.jpg)
(https://preview.ibb.co/bYXf0d/32468691_606222553072691_519564203841814528_o.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on May 14, 2018, 04:12:17 PM
Neato!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 17, 2018, 08:43:29 PM
Had a breif studder in the RPM earlier this week. After a breif conversation on the Montero group on FB I came home and inspected and cleaned my EGR valve. That didn't work, so I ordered a new one off Amazon for $45 and installed it today.  These are really easy to swap out and it's obvious when they are bad. In my case, the diaphragm was all torn up.

Here's the Part# I ordered from Amazon. It came with a new gasket too.
(https://preview.ibb.co/cOBWWT/aaa.jpg)

New (LEFT) and Old (RIGHT)
(https://preview.ibb.co/ntdBWT/aaa2.jpg)

New EGR Valve installed. - This literally take 5 minutes to accomplish.
(https://preview.ibb.co/dYPUJ8/aaa.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 19, 2018, 09:37:51 PM
I've been noticing that I have a consistent voltage drop between the 14V+ I see when driving, versus the 10.8-11.2V I see when I'm at a stop but still in gear. To remedy the issue, I've decided to upgrade my factory grounds and power wires in a kit referred to as "The Big 3."

I wasn't impressed with most of the store bought or pre-assembled "Big 3" kits. Instead I decided to build my own from parts readily available on Amazon. I went with 1/0 to give me plenty of room for upgrades on both the alternator and battery side. My current alternator is the factory 100A unit, but I plan to upgrade that in the future.


(https://preview.ibb.co/i3ju38/9da50374fba1b0f8d206fbac4fe52e38.jpg)

I'll be installing all this tomorrow and will make a follow-up post with more pictures. The only thing I'm still considering is adding a 350A breaker or ANL fuse near the battery to protect the 1/0 AWG wire from shorting in the event of an accident and causing a fire. I can always install that later, so we'll see. Maybe some of you have some valuable input or advise for me.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: concealer404 on May 21, 2018, 06:38:55 AM
Interested to see how the ground upgrades work out.  :)  My factory volt gauge has been all over the place, but the truck appears to not care, other than definitely dropping some voltage at lights in gear.  (Slight light dimming, fan speed decrease)  So far i've figured that if it was really in the "bad zone" i'd get the charge light.  But that may be hubris.  :P
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on May 21, 2018, 01:38:47 PM
Yeah report back on the ground upgrade
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 21, 2018, 02:45:41 PM
Interested to see how the ground upgrades work out.  :)  My factory volt gauge has been all over the place, but the truck appears to not care, other than definitely dropping some voltage at lights in gear.  (Slight light dimming, fan speed decrease)  So far I've figured that if it was really in the "bad zone" i'd get the charge light.  But that may be hubris.  :P

Everything you've stated is exactly what I'm dealing with and it's annoying me. LOL. I've completed the ground and power wire upgrade and while it didn't remedy the issue I still feel much more confident in the truck's overall long-term reliability. The issue of flickering lights is actually MORE noticeable now, which to me signals the alternator being the root cause of the problem. My logic is that the transmission of energy from the alternator is now intensified by the more efficient grounds and power cable, making the light flickering more noticeable than before. It's a win. - Now I just need to test and probably replace the alternator since it's a cheap Chinese unit the PO had installed.

Yeah report back on the ground upgrade

I'll create a post when I get home to go over the procedure I completed. It took me all day, but that's because I'm anal-retentive and fixed or mended everything else I saw along the way: sanded, primed, and painted the area below the battery including the tray where year's of leaking batteries caused some surface rust; replaced the factory wiring harness sheathing back to the firewall; removed and replaced the factory Ground wires at Engine/Frame, Frame/Chassis, Chassis/Battery, including cleaning each ground location to bare metal and spraying with either clear-coat or silicone sealant; and improving two additional grounds below the factory fuse box.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: concealer404 on May 21, 2018, 03:35:54 PM
Ah yeah that was the other one.  My brake light (i have a sinking fluid level sensor, so my light is almost always on) pulses with the turn signals.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 21, 2018, 09:11:27 PM
Alright, so here is my update to the "Big 3 Upgrade." All-in I recommend doing this upgrade, especially if you are planning to upgrade other electrical components or add a lot of electrical draw. Even if you don't have those plans, this is a simple enough (time consuming) procedure. You can buy the kits online, or you can build your own from scratch as I have for about $100, plus the cost of whatever tools you don't currently own.

I found this ground strap hanging from the driver's side exhaust manifold. It's suppose to be connected to the main engine ground, so I made sure to clean the copper up and reconnect it with the new grounding wires.

I also found that surface rust from battery acid corrosion, so I sanded it all down, then primed and painted it. The battery support also needed it, so that was done as well. "When in Rome..."
(https://preview.ibb.co/cGY80o/64c311e0e487aade89fe8db8e9455d85.jpg)

This is the main engine block ground after removing the factory wire.
(https://preview.ibb.co/fDFz6T/58d438669b4af8c6bab6b4bb2fc0a134.jpg)

This is the factory frame ground where the engine and chassis grounds meet. I cleaned the metal with my 20V Dewalt, (2) 10" extensions, and a copper wire bit.
(https://preview.ibb.co/gWMd0o/b4430d58c1608f77d1b0e7d0db7a950c.jpg)

My first idea on the chassis ground was to replicate the factory one, but this configuration didn't work due to fitment issues.
(https://preview.ibb.co/hs60D8/224118c8e574a55e6852e2af7ac875be.jpg)

Under the factory chassis ground at the bottom of the fuse box mount is another ground where I cleaned the points and reconnected.
(https://preview.ibb.co/m5BBLo/342c38022040f1ce188e7fb3b52b45e7.jpg)

Midway point...
(https://preview.ibb.co/dWdafo/9ea2677c2a71a2526e6c5a63cf9ae29d.jpg)

New engine block ground.
(https://preview.ibb.co/dmxU6T/9387393ca1ac7c86256af4935426882b.jpg)

New frame ground where the engine block and chassis grounds meet.
(https://preview.ibb.co/cd3Qfo/97f8e579318828edba5a0e1cb4bba9c6.jpg)

New chassis ground for frame (right) and battery (left).
(https://preview.ibb.co/gAfhRT/141cd63a4268045a0e6edb8beb12e00b.jpg)

Factory power output on alternator.
(https://preview.ibb.co/kxC1Lo/8d3232b07eb85a45b839ae30161dd83a.jpg)

New 1/0 AWG power wire from alternator heading to positive terminal of battery.
(https://preview.ibb.co/iGCJ0o/476feef2b3432e53f804ad7f430c2ff1.jpg)

Buttoned up and finished...
(https://preview.ibb.co/nErYY8/259f4a77823642b0c6e5bfc9a6cc8fc0.jpg)
(https://preview.ibb.co/kk10D8/f46b2338b8f268bbe8f37964007678ef.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on May 22, 2018, 07:45:11 AM
I'm so doing this, thanks for sharing.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: jaccox on May 22, 2018, 02:45:23 PM
Looks fantastic. Now you can save me the bear of having to do a proper writeup on this lol. Just be sure to get an ANL on that positive wire to prevent any weird electrical fires that may be possible.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 29, 2018, 08:59:31 PM
Haha! No problem guys.

Final prep on the rack is nearing a finish. My garage is a wrecked mess, but the epoxy floor makes for a quick clean up.

Anyhow, I hit it with the angle grinder, then wire wheel, then painted it with VHT Roll Bar and Chassis paint. I like that paint because it's self-priming and has a finish that just about matches the ARB bumper. Plus, the left-over paint I have I can touch up my ARB after trips.

I also replaced all of the hardware that came with the Surco mounts with M6 and M8 allen head bolts, washers, and nylon locking nuts. I also added a set of ROAM awning mounts, which I'll use to mount an ARB awning in the future. The rear awning mounts from Rhino haven't arrived yet, but they're on the way.

Mounting of the Pelican's includes (4) Grade 8 - 3/8-16x1-3/4" bolts, washers top and bottom, and nylon lock nuts. To strengthen the Pelican's mounting points, I added some 36" long 16ga 1" wide Aluminum strips that I cut down to (4) 14" pieces. Those will go inside the Pelican cases to provide more structure to the mount. they'll also serve to help re-waterproof the cases when I install them with some silicon.

(https://preview.ibb.co/gTeDky/33839838_613877455640534_3579274454263398400_o.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on May 31, 2018, 01:07:21 PM
Yesterday, I noticed that Sam's Club has the Duracell Platinum Group 27 AGM in-stock for $159. That's half the price of a comparable Northstar! I did some digging and it looks like these Duracell AGM batteries are made for Duracell by East Penn, which also makes Deka so I know they're high quality. Their specs are solid too with 93Ah and 900 CA.

I'm going to buy one of these on Saturday unless someone convinces me otherwise.

(https://preview.ibb.co/eXkbyT/b1a7ea11e19e2ac0889658b09df02f77.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 04, 2018, 07:50:56 AM
Alright, a couple updates: The EGR code is gone for now, not sure if it will return pr not but while I was swapping batteries the system was powered down for several hours so it may have done a hard-reset. Fingers crossed, because it's a nuisance.

The battery has been upgraded to the aforementioned Duracell Ultra Group 27M AGM Dual-post. It should run our fridge for a couple days at a time until I can get a Group 31 and mount it in the rear with solar. That's in the months to come.

(https://preview.ibb.co/mYW5so/5c780cb41eb7ab8987842fc562914253.jpg)

The other update us that the roof rack is finally finished. It was a lot of time and work, but worth it in the end. This rack will likely last me for years and years to come. The cases up front are hard-mounted to the rack and I also made rubber landing pads for the cross bars that the tent will rest on. These should reduce vibration and negate metal on metal contact.

(https://preview.ibb.co/ibspJT/8ab3ee706dd190e02a6394d46835ccf9.jpg)

(https://preview.ibb.co/dQ5WXo/10576def628df4ac0a7ca2a3a753dea2.jpg)

(https://preview.ibb.co/fBo758/697e4a8f4cfa391f3c852d0d6caef244.jpg)

(https://preview.ibb.co/heXBXo/7c488eb6489edf9a7d03095646d3d3af.jpg)

Now my CVT Mt. Shasta Extended Pioneer is ready to be mounted. I'm going to treat the rain fly with Aqua-Tite and replace the seam tape with Seam Sealer. I also ordered CVT's newer Summit-style tent mounting rails, so those will go on as well.

(https://preview.ibb.co/c5ridT/82edb9388bf05f5eb648df60809d7fae.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 08, 2018, 09:51:34 AM
We've cleaned the tent and it's just about ready to be mounted. I'm just waiting on the rain-fly to seal. We treated it with Aqua-Tite and it take 2-3 days to fully cure. Once that's done, the tent will be loaded from the rear. Then I can install the ARB 4.5' awning with the Rhino Rack mounts I bought. When we designed the roof rack, we actually made it specifically to fit these Rhino Rack mounts in the rear...Why? I don't know...angle iron would have been a lot cheaper. LOL.

Anyhow, our DFG Offroad fridge slide with cutting board has been made. I spoke to Carlos at DFG and he said he's just waiting on another part to arrive and then the slide will ship out. - In anticipation of that being delivered, I went ahead and ordered the materials I need to supply the fridge with constant power. I'm using some 4AWG welding wire from the same manufacturer I used for the "Big 3 Upgrade." It'll run through an 80A Bussman circuit-breaker, then back to a Blue Sea Systems 12-circuit fuse panel with BUS terminal. From there, I'm using a dongle of sorts to provide a 12V DC outlet to the fridge with a 15A inline fuse.

The passenger side window doesn't roll down, so I ordered a replacement regulator as well. That will be here next week and I'll knock it out next weekend.

This weekend I'll be replacing the PO's cheap Chinese alternator with a Denso Reman unit that came in yesterday. I'll get everything I can done with regards to the rear power station, but I also need to install new CV axles, UCA's, LBJ's, and TRE's this weekend as well. - It'll be a busy weekend in 100 heat with 50% humidity, but I can finally seethe light at the end of this 6 month tunnel. Quick, but labor intensive.

I'll post another update this weekend...
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 11, 2018, 03:10:39 PM
As I said before, I had a pulsation in the interior lights that was really consistent. After looking at my voltage readings a couple times and asking around, I found that my alternator was going out. I ordered the Denso Reman unit from Rock Auto and it was a quick 1 hour job that completely eliminated my pulsing lights and stabilized my voltage.

(https://preview.ibb.co/fJg2L8/70dc045f73b06e1e672afc80c9b739ed.jpg)

(https://preview.ibb.co/dcBPYT/1806d834cb11afaaf3b1c34bb4a6cf26.jpg)

(https://preview.ibb.co/fgQ7no/6432efcd82fa81d08cb3978a19e57605.jpg)

While I had the airbox off, I went ahead and replaced the 4WD solenoid that causes the front wheel lights to flash on the Super-Select display in the dash. This was a $20 fix that took me 5 minutes to do.

(https://preview.ibb.co/m484YT/9b9b3f3f50ad07818ce6f85aa3213685.jpg)

(https://preview.ibb.co/c3K07o/d3125ff6d32102146f2c5b5ae3bc7222.jpg)

(https://preview.ibb.co/bOCbf8/c7a1615f2708112ed47ccf841f2d0bf3.jpg)

Next I started working on my removing and replacing my CV axles. I realized I needed another tool, so I parked that job for this next week.

(https://preview.ibb.co/ixU07o/c64b9784c8e981c4520711c93cf39d61.jpg)

Next up on the rack was to get the tent tightened down and the rear awning mounted. I used a set of Rhino Rack Foxwing awning mounts. Why? Idk...I could have used angle iron like the sides, but sometimes these things just work out.

(https://preview.ibb.co/j5JSno/11099639aec4400d73081a342feaec12.jpg)

(https://preview.ibb.co/kwE07o/404b11d9b1dba8d764ae48dfeca8f66d.jpg)

I also started to put together my solution to provide steady power to the rear cargo area. I'll finish all of this today after work.

(https://preview.ibb.co/gzM2L8/08867c46580661c58252e2385e9e7130.jpg)

Finally, I needed to give it a test flight, so I drove it down the road to check for rattles or any ither issues. I used rubber strips and 3M tape on all metal on metal contact points between the tent and the rack so there was nothing to report.

As it sits right now, the exterior is just about finished for now...

(https://preview.ibb.co/i6udtT/5e2614285028de5ac8cf904479c6a708.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on June 11, 2018, 04:16:24 PM
 Nicely done dude!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Shovel on June 12, 2018, 08:11:29 AM
Looking great! 

It's nice to see these trucks repaired and maintained and improved, instead of just beat until they surrender. 
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 13, 2018, 07:18:25 AM
Thanks guys! I'm pretty stoked on the results so far. I still have some more work to do in the next 2 weeks, but it's coming along now.

Last night I ran my 4-AWG wires from the battery to an 80A breaker under the hood and then down along the frame rail to a grommet in front of the rear shock. That grommet leads into a small pocket under the back seat that's barely accessible through the bottle-jack door. Once Ifished them through the harness hole, I was able to then route them back out another hole and under the carpet to the driver's side rear wheel well. Then from tehre, I ran them up through the top of the plastic wheel well surround. - It took me a few hours to get it done right, but it's done.

(https://preview.ibb.co/h8OMjd/5cff54e6210a9dfd96f39d0a6e32df05.jpg)

(https://preview.ibb.co/ekmkAJ/dcaa4d45ce63c0b417dce428ca34f915.jpg)

(https://preview.ibb.co/jDTyVJ/880b588d5138ed2c349783114167e022.jpg)

(https://preview.ibb.co/jLL1jd/7dd933908259eb64c1aab6304ee68b9d.jpg)

(https://preview.ibb.co/cwyyVJ/c53da9f25a40dcbae5c717f6527b2e80.jpg)

(https://preview.ibb.co/nPyXqJ/0e245534a297f8ce883f36907d10aaff.jpg)

When I got home tonight, I just needed to mount the Blue Sea Systems fuse panel next to the speaker and hook everything up.

(https://preview.ibb.co/fVTMjd/b8b7009ae5eab3d0b028e153eede54a1.jpg)

For the time being, I'm just using the 12V DC plug extension as an outlet to connect the fridge. Once the fridge slide arrives next week, I'll figure out how to secure it so it won't come lose offroad. - I know an Anderson clip is likely the route I'll go.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: concealer404 on June 13, 2018, 10:37:19 AM
Thanks for documenting all this.  :)  I ordered all the stuff you did for the Big 3 yesterday, will add to the list of things to thrash out this weekend.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 14, 2018, 08:48:25 AM
Another evening in the driveway with positive results. After cleaning the throttle body, idle air control solenoid, MAF sensor, intake tube, filter box and replacing the air filter the Pajero idles like a new truck again.

**Word of caution to those cleaning the MAF, these trucks do use a Korman Vortex MAF, so if you use the MAF cleaner spray, make sure you are spraying from a ways away and without the tube. you'll also want to make sure it's COMPLETELY DRY before turning back on. I used my compressor to dry it from both sides and then let it sit for 20 minutes.**

(https://image.ibb.co/iKWfUd/Capture.jpg)

(https://preview.ibb.co/g8ZCaJ/35298611_622482384780041_9046293915379957760_o.jpg)

Removing IAC Valve

(https://preview.ibb.co/eSQkvJ/35297238_622482444780035_2736050521541443584_o.jpg)

Dirty IAC Valve...

(https://preview.ibb.co/imUCaJ/35206696_622482518113361_5303754242228486144_o.jpg)

Clean IAC Valve

(https://preview.ibb.co/dFtupd/35200377_622482591446687_4325164687072165888_o.jpg)

Clean Throttle Body (open and close the butterfly while spraying cleaner and wiped it down real good.) The lower opening is where the IAC Valve mounts and was completely black when I removed the IAC Valve. Make sure to clean it real good and remove as much carbon as you can so the cleaned IAC Valve doesn't have anything to cause it to stick.

(https://preview.ibb.co/nuAJFJ/35265641_622482671446679_4758080025956188160_o.jpg)

Reassembled...

(https://preview.ibb.co/mUUpNy/35199085_622482731446673_2294261234763038720_o.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: reversecaoboy on June 15, 2018, 09:42:21 AM
Good tips.

I've been meaning to do this for a while now. And give my airbox a good cleaning. It managed to get a bunch of mud down at the bottom.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 20, 2018, 11:08:15 AM
Alright, so this last weekend I attempted to replace the CV's, but it became a bigger chore than I felt comfortable doing myself. I was able to replace the upper and lower ball joints, but the CV's gave me some trouble. The passenger's side bolts between the CV and the half-shaft didn't want to budge. Honestly, I should have cracked them loose before taking the wheel and knuckle off. The driver's side was another pain since it separated form the inner CV cup and spindle. I tried a few different methods, including a slide hammer and it wouldn't budge.

My mechanic is really good, so I called him up and he said to just bring it over and he could knock them out this week. I should get it back today sometime.

(https://image.ibb.co/hrFK0J/Paj.jpg)

In the interim, my AVM Manual Locking hubs arrived on Saturday to replace my shitty Rigged Ridge units. Then my DFG Offroad fridge slide arrived today. I'm gonna give Carlos at DFG a shoutout here, because he's a stand-up guy and went above and beyond to get me hooked up. When I was looking for a fridge slide, I originally thought I'd build my own. After looking at the cost of locking drawer sliders and metal, I was easily close to $400 in parts once all was said and done. Could it have been done cheaper? Yeah...but I'm particular and don't like to spend the same money twice, or repeat the same job. I'd rather do it right the first time and be done and happy with it.

Anyhow, I searched high and low and even contacted MSA in Oz for their drop-down fridge slide ($1k.) They didn't return my inquiries, so I kept looking and that's when I found DFG Offroad (www.dfgoffroad.com). They're located in Florida and even though his website didn't list my particular interest I contacted him to ask. The very next day he had added this new model to his website and I placed my order online; He even gave me a discount for it being Memorial Day weekend!

It took him 2 weeks to build and ship it and it arrived today unscathed. This will allow us to knock out the interior platform, install the fridge, and the dog bed this week.

(https://image.ibb.co/bQhGfJ/DFG_and_AVM.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: reversecaoboy on June 20, 2018, 02:33:56 PM
Looks awesome.

I've been meaning to ask, how's the ride of the OME springs and ADD Billies unloaded?

I would really love to get the bilsteins but trying to minimize the amount of lift
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 21, 2018, 06:08:17 AM
Looks awesome.

I've been meaning to ask, how's the ride of the OME springs and ADD Billies unloaded?

I would really love to get the bilsteins but trying to minimize the amount of lift

My 1999 Montero rides smoother than my 2015 Silverado Crew. If you aren't planning on carrying extra weight (RTT, Fridge, etc.) go with the standard OME springs in the rear (I have a spare set if you're interested). If you need the extra capacity, get the Expedition Springs since they are designed to handle an extra 400 lbs of cargo, but unladen they do create a slightly rougher ride without being pre-loaded by said cargo weight. The whole system with the Bilsteins only lifts the truck by less than one-inch before you load anything.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 25, 2018, 10:06:08 AM
Being our last weekend before our big trip, we needed to get a couple big cargo management items checked off the list: Beyza's dog platform and the cargo foundation and fridge slide.

The fridge slide was a custom request for a slide with a cutting board for our Dometic CFX95DZW. Carlos at DFG Offroad Accessories made it happen. I highly recommend him. - One of the rivets came out and FedEx damaged the locking mechanism in transit. I sent a quick text and he shipped me replacements overnight. He's a stand-up guy and DFG offers fridge slides for most fridge brands and models. If you need something that's not on the website [like I did] just ask him and he'll build it.

(https://preview.ibb.co/eBn178/36224886_632964547065158_7564623463474790400_o.jpg)

(https://preview.ibb.co/mrFon8/36137131_632964623731817_3137010930081071104_o.jpg)

(https://preview.ibb.co/b2WiLT/36087902_632964697065143_4676203647053332480_o.jpg)

(https://preview.ibb.co/juykZo/36064664_632964370398509_6080570550260858880_o.jpg)

(https://preview.ibb.co/n8ouuo/35296724_632964760398470_7459728507996733440_o.jpg)

My wife and mother-in-law worked on Beyza's dog platform and after I pick up a couple bolts today, it will go in at the same time the fridge is mounted.

I also replaced the window regulator in the passengers side front door. It was quick painless and now the window works perfectly.

(https://preview.ibb.co/e1WTn8/36114311_632964430398503_8295420837608030208_o.jpg)

Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 26, 2018, 07:27:34 AM
Fridge is in and the slide works perfectly. It's a bit big, but I'm not complaining given the deal I got on the fridge. LOL. I can always build a trailer and remount it, or stick it in my truck bed. It's fine for now. - I won't be able to get the drawers and rear deck done before we leave on Friday, but I do plan to add a pair of stacked drawers on the left side and a deck across the top with a piano hinge above the fridge to allow entry from inside if we wanted.

(https://preview.ibb.co/cXZRaT/36052027_634060503622229_8995043694134427648_o.jpg)

(https://preview.ibb.co/iZbTpo/36175935_634060573622222_530066738910330880_o.jpg)

Here's the final few things that I'll knock out today and tomorrow:
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on June 26, 2018, 07:54:54 AM
Make sure you post up a long term on that fridge in a couple years.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 26, 2018, 08:52:56 AM
Make sure you post up a long term on that fridge in a couple years.

I will. Dometic has been doing mobile fridges forever, so I fully expect to keep this fridge until it dies in 15 or 20 years.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 27, 2018, 06:27:48 AM
Beyza (our Turkish #Akbash) is already enjoying her new doggy platform we built for her. Being a 100 lb dog, she wasn't going to be too stable offroad in the backseat so this is what we came up with. I cut the plywood to fit, then my wife used some foam padding, a layer of waterproofing material, and then a heavy canvas for the top. She stepled it around the bottom. It's bolted to the floor using the factory bolt holes that would normally mount the rear seats. Then I reused the rear seat mounts so that we could still hook the cargo net divider up to the floor to make it tight.

(https://preview.ibb.co/d3dd9o/36293286_635418416819771_6289658972798451712_o.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: MrGalantguy on June 27, 2018, 09:17:44 AM
Great build sir.

The itch to invest in a mobile fridge is getting stronger. ::)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 27, 2018, 11:46:24 AM
Great build sir.

The itch to invest in a mobile fridge is getting stronger. ::)

Thank you! I tell ya, just keep your eyes peeled on FB Marketplace and CL. I scored this one for less than half of what they retail for because a local outfitter didn't need it as a display demo anymore. They had only run it for 2 months as a display model on their showroom floor.
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on June 29, 2018, 10:28:54 AM
My Montero is as done as it's going to get for now. - There's a few more things I'd like to square away, but they'll have to wait because it's time to hit the road! Today, we're heading out on a 9-day 2,800mi (4,500km) overland loop that will include over 500 miles and 71,000' of gain/loss across Colorado's epic BDR including 4x4 tracks, forest roads, alpine lakes, and mountain passes. I'm stoked!

Towns, Trails and Passes along route:
Cortez, CO
Dolores River Canyon 4x4 Track (28 miles and 5 river crossings.)
Ground Hog Pass
Last Dollar Rd.
Alta Lakes
Ophir Pass
Clear Lake
Ophir Pass (Reverse)
Telluride, CO
Imogene Pass
Yankee Boy Basin
Governor Basin
Mt. Sneffels Trailhead
Ouray, CO
Corkscrew Pass
Hurricane Pass
California Pass
Engineer Pass
Alpine Loop [Northside]
Lake City, CO <-- Fireworks!
McDonough Reservoir
Pitkin, CO
Hancock Pass
Hancock Lake
Pomeroy Lake
Mount Antero
White Mountain
Buena Vista, CO - Sandy OHV Tracks
Turquoise Lake
Hagerman Pass
Sylvan Lake

(https://preview.ibb.co/ctQAsJ/36285924_635997280095218_8997353360042491904_o.jpg)

(https://preview.ibb.co/kSu1hJ/2018_BDR_PLUS.jpg)
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Crumb on June 29, 2018, 07:20:25 PM
 can't wait for the trip report!
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: Se7en62 on July 09, 2018, 08:16:57 AM
We just got back and I'm working on a full-length article, a short recap of the trip, and lots of photos going up on my Instagram @overland_pajero.

Our route was adjusted IRT to allow us the time to push further north into the Routt NF, nixing our track through the Dolores River Canyon. We'll save that for next time...We also had to nix the areas between Buena Vista and Weston Pass due to a new forest fire that started burning near the pass.

The only mechanical issue we encountered was a bad radiator cap that gave up the ghost on Ophir Pass at 11,500'. We made a new temporary seal for it using some rubber from a solar shower that we cut up, then picked up a new cap when we went through Gunnison the following day. Spec is 15 lbs and someone had installed a 13 lb cap, so no wonder. - The one I installed was an $8 Murray unit rated for 16 lbs and we didn't have an issue after that. Needless to say, I will be adding a spare radiator cap to our parts bin on future overland trips.

Towns, Trails, Passes, and National Forests that we explored:
Cortez, CO
Dolores, CO
San Juan NF
4x4 Trails to Groundhog Reservoir
Ground Hog Pass CAMP #1
Last Dollar Rd.
Alta Lakes
Ophir Pass
Clear Lake and the 585 Valley CAMP #2
Uncompaghre NF
Ouray, CO
Corkscrew Pass
Hurricane Pass
Alaska Basin to over 13,000'
California Pass
Engineer Pass
Alpine Loop [Northside] CAMP #3
Lake City, CO
Guadalupe NF
Los Pinos Pass
Gunnison NF
Gunnison, CO
Pitkin, CO
Hancock Pass CAMP #4
Buena Vista, CO
Leadville, CO
Turquoise Lake
Hagerman Pass CAMP #5
Ivanhoe Lake
White River NF
Sylvan Lake CAMP #6
4x4 Tracks Northeast of Sylvan Lake
Gypsum, CO
Old Mine Trail through Gypsum OHV area
Colorado River Valley
Medicine Bow-Routt NF CAMP #7
Arapaho NF
Title: Re: 1999 Pajero NL "ROCKET" - Overland Build
Post by: MudRaider on July 11, 2018, 08:13:23 AM
It's been great following this on here and the pics on IG. Thanks for the effort of documenting.
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 10:25:53 AM
I just realized that I haven't updated this thread in a while, so here it goes:

In July, my wife and I met up with some friends in Colorado to explore over 600 miles of backroads, alpine passes, and 4x4 trails over a 9 day stint, making 7 remote camps across the state.  We followed the same BDR we completed last year, but this year we took our time and explored more along the way.

The Montero was comfortable on the 2,200 miles of highway and handled the 600 miles off-road with ease. With all the extra weight on-board, it's factory lockers made easy work of the larger obstacles on Hancock Pass. - Not bad for a 19 year old truck I built from stock in 6 months!  Though, 4.90's have definitely been added to my short-list.

The trip itself went off without an issue aside from my radiator cap failing at 11,500' on Ophir Pass. The previous owner had used a cheap one and the gasket had just split. We cut up my solar shower to create a makeshift gasket to get us through the next 2 days and 150 miles of trail to Gunnison where an OEM unit was waiting.

Along the way we racked up over 70,000' of elevation gain/loss in 7 different national forests. We were even fortunate enough to spot three Moose, two Black Bear, two Porcupines, and dozens of Mule Deer and other critters.

All said and done, it was another epic overland trip across Colorado's stunning BDR. (Pics below are chronological...and OutdoorX4 is publishing my article titled "Montero Milestones" this month.)

(https://i.ibb.co/gWNKHrM/36905666-647531938941752-452864912218128384-o.jpg)

(https://i.ibb.co/mzJtz5S/36965643-647532065608406-2818067255680565248-o.jpg)

(https://i.ibb.co/8b01YJd/36887866-647532298941716-8910382041825017856-o.jpg)

(https://i.ibb.co/cLP4MmN/36875918-647532472275032-3193022096804413440-o.jpg)

(https://i.ibb.co/vqVykHg/36869698-647532932274986-5355160005714640896-o.jpg)

(https://i.ibb.co/7JBwRDg/36910726-647533212274958-3566622343897808896-o.jpg)

(https://i.ibb.co/XFD7t2z/36866937-647533325608280-5542172957775757312-o.jpg)

(https://i.ibb.co/tHycbb2/36856434-647533492274930-318552475894284288-o.jpg)

(https://i.ibb.co/GcTSNG9/36827640-647533582274921-7310558920802566144-o.jpg)

(https://i.ibb.co/3R3vq69/36846135-647533788941567-5056442861319356416-o.jpg)

(https://i.ibb.co/r6dFwCG/36875939-647534062274873-8248348077648248832-o.jpg)

(https://i.ibb.co/rHLYPXq/36971795-647534132274866-3798022335559106560-o.jpg)

(https://i.ibb.co/sFnyN6C/36887396-647538442274435-759988703476056064-o.jpg)

(https://i.ibb.co/k3xNZWC/36900022-647539735607639-5446686707980173312-o.jpg)

(https://i.ibb.co/QFBBhKg/36836049-647539918940954-3233843411605782528-o.jpg)

(https://i.ibb.co/5BYfxf9/36821179-647540832274196-7702338192501899264-o.jpg)

(https://i.ibb.co/mhw08XT/36852339-647541215607491-2478331661779992576-o.jpg)

(https://i.ibb.co/QnMx2dp/36865290-647593035602309-6896529807249506304-o.jpg)

(https://i.ibb.co/tbBFQ61/36823902-647593505602262-4272432367102066688-o.jpg)

(https://i.ibb.co/fQ37Tb6/36858997-647593668935579-4869456795753512960-o.jpg)

(https://i.ibb.co/P1vhmBP/36912392-647594035602209-6839742441151528960-o.jpg)

(https://i.ibb.co/mRYLBrK/36837006-647594212268858-299951779989159936-o.jpg)

(https://i.ibb.co/5134r7r/36823900-647594302268849-6274272377014583296-o.jpg)

(https://i.ibb.co/8B44GDG/36910874-647598405601772-7253063671079763968-o.jpg)

(https://i.ibb.co/KGGvh1Z/36935088-647603512267928-2031734644445020160-o.jpg)

(https://i.ibb.co/rv2cG0J/36825377-647603592267920-5880636309348810752-o.jpg)

(https://i.ibb.co/qpM2XZm/36901625-647604045601208-2532325709997670400-o.jpg)

(https://i.ibb.co/yVvbtVG/36965820-647604265601186-1298473797329879040-o.jpg)

(https://i.ibb.co/NCfgBzn/36927799-647604558934490-4315691818873257984-o.jpg)

(https://i.ibb.co/Jpq7GZG/36836427-647604678934478-6720771288706580480-o.jpg)

(https://i.ibb.co/QrbSCCv/36769251-647616792266600-9113257665319927808-o.jpg)

(https://i.ibb.co/9NbsCXY/36950637-647617005599912-4331392677414174720-o.jpg)

(https://i.ibb.co/n877nzJ/36827647-647617068933239-2095172599897128960-o.jpg)

(https://i.ibb.co/yVy3LYq/36901631-647617235599889-756563686100828160-o.jpg)

(https://i.ibb.co/4tTxYC8/36883296-647624018932544-478992113107730432-o.jpg)

(https://i.ibb.co/JpGjkJn/36854487-647624775599135-399862163927203840-o.jpg)

(https://i.ibb.co/4tyVPJB/36831837-647625308932415-5157834635312365568-o.jpg)

(https://i.ibb.co/hdjfsDR/36827637-647625655599047-430392294705725440-o.jpg)

(https://i.ibb.co/W0qz7dP/36832147-647656788929267-505389068008292352-o.jpg)

(https://i.ibb.co/3CgKYqq/36847969-647656935595919-6472870200197775360-o.jpg)

(https://i.ibb.co/gvbJJdk/36819781-647657645595848-4307199246894891008-o.jpg)

(https://i.ibb.co/JcVsR2W/36968997-647657918929154-6066368961723760640-o.jpg)

(https://i.ibb.co/YBkHKRr/36854490-647658242262455-8995164125017407488-o.jpg)

(https://i.ibb.co/6DhWwf0/36937012-647658365595776-7609296801299955712-o.jpg)

(https://i.ibb.co/GTJnqz9/36995161-647658652262414-5781730363642478592-o.jpg)

(https://i.ibb.co/hmjfyHg/36880770-647658802262399-2908527444552056832-o.jpg)

(https://i.ibb.co/FnB9f9H/36923527-647662092262070-5893017368623316992-o.jpg)

(https://i.ibb.co/3fFLQ6Q/36909150-647662985595314-1833588570216988672-o.jpg)

(https://i.ibb.co/3h5vbd2/36961343-647663175595295-1095400390590988288-o.jpg)

(https://i.ibb.co/zGLgJ89/36846650-647663822261897-3852018522670497792-o.jpg)

(https://i.ibb.co/9v7FqFL/36845530-647663885595224-5702719204667424768-o.jpg)

(https://i.ibb.co/QfwrYQ6/36878558-647664135595199-354253897621045248-o.jpg)

(https://i.ibb.co/HNpKpMw/36837012-647664175595195-6250949386042343424-o.jpg)

(https://i.ibb.co/Pm0JhV5/36840956-647666878928258-2483117634032238592-o.jpg)

(https://i.ibb.co/4VphMTN/36857573-647667048928241-2543072650180165632-o.jpg)

(https://i.ibb.co/tz79V1g/36838722-647667468928199-8304044968729640960-o.jpg)

(https://i.ibb.co/71fWQDb/36907599-647667608928185-5404765683982532608-o.jpg)

(https://i.ibb.co/SytC71Z/36862001-647668145594798-8598818276585242624-o.jpg)

(https://i.ibb.co/fXk8FYf/36939254-647668228928123-620434220912738304-o.jpg)

(https://i.ibb.co/P9fYYfb/36842249-647668308928115-8728527611774369792-o.jpg)

(https://i.ibb.co/DMXQs0Z/36963141-647668452261434-4424600146411520000-o.jpg)

(https://i.ibb.co/8gHnQLd/36904533-647668665594746-1631734882650554368-o.jpg)

(https://i.ibb.co/sy7kvbG/36904493-647668878928058-4301392721693638656-o.jpg)

(https://i.ibb.co/3cWbHHG/36867586-647669052261374-1023826856547188736-o.jpg)

(https://i.ibb.co/bmLzvj3/36852297-647669105594702-3423545550065106944-o.jpg)

(https://i.ibb.co/SVtCP48/36840317-647669185594694-673037060503764992-o.jpg)

(https://i.ibb.co/dpdsbyv/36898426-647669258928020-3505085834892148736-o.jpg)

(https://i.ibb.co/N3FHqrY/36930030-647669342261345-5234732356845174784-o.jpg)

(https://i.ibb.co/ZV8FjRd/36874308-647669412261338-6728779023301738496-o.jpg)

(https://i.ibb.co/ccXrgHF/36883424-647669505594662-1568266166642671616-o.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 11:32:50 AM
After we got home, I put another couple thousand miles on it and then the radiator let go. It was a cheap Spectre replacement and even though I know the brass-core OEM unit is superior my schedule and the radiators availability meant that it would be replaced with another Spectre radiator. I also replaced the upper and lower radiator hoses and installed a new OEM thermostat.

(https://i.ibb.co/PG4jXh7/20180728-112923.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 11:46:33 AM
Labor Day weekend was on the horizon, which would give the cooling system a good run-down. Here's our weekend exploring Padre Island National Seashore (aka PINS) in the Montero. Padre Island is the world's longest barrier island and stretches 113 miles from near Mexico to Corpus Christi, Texas, but in the 1960's the federal government dredged a cut to Port Mansfield at the 60-mile marker which split the island in two. Roundtrip, we drove 510 miles on tarmac and racked up 120 miles of 4WD in the sand over 2 days to find the clearest water and most secluded beaches in Texas. You just have to have a 4x4 to access any of them and the Montero got us down and back with ease. - We also hit 200,000 miles on our way home!


(https://i.ibb.co/cxXL9sG/40824737-703738783321067-7964980948800372736-o.jpg)

(https://i.ibb.co/RS9bpy4/41007369-703739529987659-5900133193129918464-o.jpg)

(https://i.ibb.co/Hx7dh6p/40920966-703739693320976-2870664331425480704-o.jpg)

(https://i.ibb.co/z79cM6y/40803356-703739649987647-2415094465984200704-o.jpg)

(https://i.ibb.co/2yc57Jb/40790547-703739619987650-5200494123101978624-o.jpg)

(https://i.ibb.co/6r44D1C/40694690-703739566654322-1335133731203055616-o.jpg)

(https://i.ibb.co/mChD0tq/40632817-703739503320995-8365629379505553408-o.jpg)

(https://i.ibb.co/Wx1xZYt/40622721-703739446654334-3569288290227978240-o.jpg)

(https://i.ibb.co/kDNkRys/40655323-703739399987672-6968595020559417344-o.jpg)

(https://i.ibb.co/Kr28fQK/40685413-703739296654349-7206085482004873216-o.jpg)

(https://i.ibb.co/L88sCbk/40772597-703739253321020-3123805065287041024-o.jpg)

(https://i.ibb.co/rxQHcDS/40684024-703739193321026-8864728321879965696-o.jpg)

(https://i.ibb.co/17Rg5Jm/40635170-703739149987697-7696144703632179200-o.jpg)

(https://i.ibb.co/sb2JtNT/40638906-703739059987706-6443966844117188608-o.jpg)

(https://i.ibb.co/VJd4zdx/40860507-703739023321043-326879562782736384-o.jpg)

(https://i.ibb.co/0q0kPYx/40747582-703738989987713-6659190966739533824-o.jpg)

(https://i.ibb.co/bvccMQq/40784180-703738949987717-1931238993903484928-o.jpg)

(https://i.ibb.co/5Fgn5vx/40685464-703738876654391-3198835807485952-o.jpg)

Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 12:00:03 PM
Next small project was to fix the ugly chrome trim after the factory black coating had come off. I had already peeled as much as I could off during the summer time while it was hot. I had a can of this rust-oleum undercoat spray and thought I'd give it a shot. Turns out it worked perfectly and has held up really well. I recommend you do this if you have peeling trim.

Note: I didn't have to both with the windshield trim because Safe-Lite came and replaced the windshield and all the trim and now it's all black too.

(https://i.ibb.co/Gd7R5JP/20181010-185021.jpg)

(https://i.ibb.co/T4fV3cM/20181011-182119.jpg)

(https://i.ibb.co/NnXQ7nT/20181011-205252.jpg)

(https://i.ibb.co/8xmCVQ3/20181011-182129.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 12:08:22 PM
I also got sick of seeing the oxidized hood. My solution was to use engine enamel, which required 2 cans to get a good coating. Though, I'd still like to mask it off again and hit it again for a more even look. This is temporary until I have the time to have it resprayed in the factory color and have the entire body buffed.

(https://i.ibb.co/0JXWKMx/20181011-184555.jpg)

(https://i.ibb.co/BTnQ0qB/20181011-211447.jpg)

I also ordered and installed these 1.25" spacers from Amazon. They are 6061 billet and have been on the truck for about 1,000 miles now without issue.

(https://i.ibb.co/qBV5ZB8/20181011-193304.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 12:16:51 PM
Nothing spectacular, but I had some time at my buddy's family ranch to clear some 4-wheeler trails out. I wish I would have got a picture of us driving over a 12" tree that had fell across the trail that we just wheeled over. Maybe we'll get back out there and put our chainsaws and winches to work to clear it out.

(https://i.ibb.co/4FW8KQ2/20181014-130613.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 03, 2018, 12:23:01 PM
Last weekend I installed a new CVT travel cover over our RTT. The 6 year old zipper on our last cover finally broke, which worked to my benefit because I like the grey color better anyhow.

(https://i.ibb.co/chjCtKX/20181122-102126.jpg)

This past weekend I finally had time to go meet a guy about a boat. This inflatable raft, when inflated will carry 700 lbs of people, gear, and a motor up to 4hp. It's a 9' Avon Redcrest from England. I figure this will serve us well when we camp near lakes and rivers, to explore the areas around us and reach more remote areas to explore on foot.

(https://i.ibb.co/fY4KQJV/47367122-759443261083952-8928865725641129984-o.jpg)

(https://i.ibb.co/7nYZ91W/47319300-759443301083948-6202030189577240576-o.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Shovel on December 03, 2018, 04:56:00 PM
Those window sills look good!   
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: Se7en62 on December 28, 2018, 08:51:35 AM
Took the Montero out and rod around the local off-road park to do a shakedown run with some friends. They're prepping for their 2019 trip up the AZ BDR in March, so they were testing a homemade trailer, honing some skills, and working some kinks out. - I think I'm on the way towards getting this custom rear bumper done pretty soon. I'm hoping to get rock sliders done in January and then the rear bumper done in March.

Oh, I am also putting my new camera to work in the new pics. I still need to find a better way to edit/host/upload them but I'm liking the setup: Sony a6500 w/ Sony SEL1018 10-18mm Lens

(https://i.ibb.co/t4nHvVt/LRM-EXPORT-17478971993478-20181216-192228341.jpg)

(https://i.ibb.co/bLc2g29/DSC087841.jpg)

(https://i.ibb.co/LgJfHzX/LRM-EXPORT-17207939247383-20181216-191757308.jpg)

(https://i.ibb.co/4NTyJpx/LRM-EXPORT-17246568450650-20181216-191835938.jpg)

(https://i.ibb.co/W3HpgHC/LRM-EXPORT-17465932335462-20181216-192215302.jpg)

(https://i.ibb.co/5MXvpcT/DSC088191.jpg)

(https://i.ibb.co/pXVgBrv/LRM-EXPORT-17297039754641-20181216-191926409.jpg)

(https://i.ibb.co/x3dmjLg/LRM-EXPORT-17491197387171-20181216-192240567.jpg)

(https://i.ibb.co/hVjr7B3/LRM-EXPORT-17517297043046-20181216-192306666.jpg)
Title: Re: Se7en62's '99 Montero NL Build & Adventures
Post by: MrGalantguy on January 04, 2019, 07:27:02 AM
Looks like a fun time. Like your cockpit setup 8)
Title: Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on January 21, 2019, 09:07:07 AM
New trip! - On Thursday, I'm heading up to Broken Bow Lake, Oklahoma to meet a group of friends. Then on Friday, Saturday, and Sunday we're exploring the Ouichita NF and Ozark NF on the hunt for snow, mud, and water-crossings. In preparation for this trip, I've added some auxiliary lights up front and extended my rear diff breather. The lights were $24 on Amazon and are 30w CREE combo spot/flood patterns, which is the perfect beam pattern for mounting at bumper height. They're wired to the factory fog light switch using factory wiring. Factory incandescent fogs drew 34w each, so these 30w LED's are more than safe.

(https://i.ibb.co/ChvGrqd/Auxiliary-Lights.jpg)

The diff breather is now ran all the way up behind the driver's tail-light and up into the D-Pillar.

I'm also cutting down one of my big camping tarps to make a deep-water-crossing tarp. I'm going to secure some Neodymium magnets inside the hem to secure it to the hood and bumper and block the grill from water egress on deeper crossings.

Anyway, here's our "route" though Friday - Sunday we're mostly winging it to explore with no intended destination.

(https://i.ibb.co/xHhs88S/Capture.jpg)
Title: Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on March 12, 2019, 12:14:37 PM
Quick and dirty: My 4 days in Arkansas was rad as hell! Arkansas is full of absolutely beautiful wilderness and the nicest folks I've met outside of Texas. We covered over 500 miles of backroads and 4x4 trail, including running up from our camp above Broken Bow Lake, Oklahoma and through the Ouichita and Ozark National Forests before wrapping up and airing up in Dover, AR.

I will admit that I got stuck for the first time, while crossing one of the many creeks we encountered. I took a bad line around a rock and ended up high-centered; Lockers on and all four tires spit rooster tails of freezing water into the air. - I ended up wading in knee deep water to run my winch line out to another truck in our group.

All-in, this trip was epic and I really can't wait to return during the Fall. Thanks for having us Oklahoma and Arkansas!

(https://i.ibb.co/98GcvWX/DSC9215.jpg)

(https://i.ibb.co/5Yqg4Ls/DSC9238.jpg)

(https://i.ibb.co/zNRsXDg/DSC9239.jpg)

(https://i.ibb.co/mJZC29R/DSC9244.jpg)

(https://i.ibb.co/C9xG3qV/DSC9258.jpg)

(https://i.ibb.co/mTXdksC/DSC9265.jpg)

(https://i.ibb.co/0t82vsN/DSC9295.jpg)

(https://i.ibb.co/7CGbN8X/DSC9300.jpg)

(https://i.ibb.co/JxpWKsL/DSC9307.jpg)

(https://i.ibb.co/KyQbyRH/DSC9316.jpg)

(https://i.ibb.co/YpSp0wy/DSC9322.jpg)

(https://i.ibb.co/bQQX5RK/DSC9345.jpg)

(https://i.ibb.co/dP96zSW/DSC9351.jpg)

(https://i.ibb.co/sQKVX8B/DSC9356.jpg)

(https://i.ibb.co/Jdh0NWV/DSC9371.jpg)

(https://i.ibb.co/myFH290/DSC9398.jpg)

(https://i.ibb.co/bvBsptD/DSC9423.jpg)

(https://i.ibb.co/sCFTbWm/DSC9430.jpg)

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(https://i.ibb.co/JHBFyZs/DSC9451.jpg)

(https://i.ibb.co/Syv9cHz/20190125-190724.jpg)

(https://i.ibb.co/Cw8G4BZ/20190125-204918.jpg)

(https://i.ibb.co/gF7gckK/20190126-101623.jpg)

(https://i.ibb.co/4Py3S5z/50876771-801892170172394-4392694973263249408-o.jpg)

(https://i.ibb.co/dMjjRzv/50936390-801891940172417-4123781904015032320-o.jpg)

(https://i.ibb.co/2WJbdFR/51037736-801891096839168-7453406913137475584-o.jpg)

(https://i.ibb.co/8xX5JtM/51148751-801892566839021-8136667885591330816-o.jpg)

(https://i.ibb.co/ZYgF2q7/51433359-801890893505855-1385155252499513344-o.jpg)

(https://i.ibb.co/HTF8k4D/51551238-801891770172434-1237337854154113024-o.jpg)

(https://i.ibb.co/B2svgGP/51611052-801892356839042-3096891275496914944-o.jpg)
Title: Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on March 12, 2019, 12:22:16 PM
About a week ago, I was digging around on FB Marketplace and came across a set of 10" 100w Lightforce Blitz 240's for $100. They had been used on a guy's trucks driving back and forth from Alaska to Texas, so the were a little rough. Nonetheless, I couldn't resist, so I picked them up. After a call to Lightforce USA in Oregon a pair of new covers ($60) and mounts ($30) were on the way. I disassembled them and cleaned their reflectors as best as I could. Now they are as good as new and ready to light our adventure across Arizona next week!

(https://i.ibb.co/MPqLjVZ/52920564-819737611721183-3728356703297601536-n.jpg)

Title: Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on March 12, 2019, 12:46:01 PM
We're heading to Arizona next week! We leave on Tuesday evening and will rendezvous with a group of friends from Texas and North Dakota in the Prescott area along a route setup by a buddy of mine. My wife and I's work schedules won't allow us to leave on the 15th with the group from Texas, so we'll be meeting them about half-way through their 879-mile route.

The guy form Arizona who will be meeting up with us is affiliated with the Arizona Backcountry Explorers, and he's posted a brief write-up here:
https://arizonaexplorers.blogspot.com/2019/03/7-days-on-epic-journey-across-arizona.html

(https://i.ibb.co/8jFPPR0/Capture.jpg)

In preparation for this trip and given current snow-fall and other bad weather throughout the Southwest, we've started some extra prep ahead of this trip. Primarily, just going around the truck insuring everything is good to go and adjusting what isn't. We've also bumped up our sleep system to include a 20F canvas double bag from Teton and a Mr. Buddy heater in the annex. Speaking of which, this will be the first time in 3 years that we've used the annex on a trip. The new CVT covers have enough material that we can no stow the annex under the cover and leave it all connected when it transit.

(https://i.ibb.co/R9b3BrG/53634253-826144451080499-350303416766955520-n.jpg)

You might also notice that my hood is no longer black! - I found an MMUSA Member about 70 miles away with a blue Gen 2.5 he was parting out. I scored the hood, OEM headlights and taillights, OEM fog light switch, a spare set of ignition coils, and a hand full of other odds and ends.

(https://i.ibb.co/ryD5F8M/53274690-826144761080468-5935858151277461504-n.jpg)
Title: Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
Post by: Se7en62 on January 13, 2020, 09:58:25 PM
Haven't done an update in some time, just due to travel and work and other projects we have going on. I'll update this thread soon, but in the meantime, check out our new short film we produced about this truck and two other Montero on an epic trip across Colorado.  8)

https://youtu.be/ml3Uwniuteo