NewHilux.net

Good question,

I'm not sure what the cost of a full SAS conversion would be so can't really answer it for you.

As I'm doing all of the work myself and I already had some of the gear (engine, gearbox, etc) that I'll be using for the build up, putting a price on what I'm doing is kind of difficult.

At a guess, a lot if you were to pay someone to do the compete job for you...

Bit of an update on how things are progressing.

I've now got the engine and gearbox out of my old Hilux and mounted in the new one. I had to remove the Patrol engine mounts from the chassis as they were too far back for the Toyota engine so I cut them out and made some new mounts. I also had to space the steering box out a bit to clear the new engine as it is fairly wide due to the twin turbo sequential control system. As can bee seen, it sits fairly tight in the engine bay.

I also fabricated a new gearbox cross member and will be using the standard Hilux gearbox mount and original Patrol cross member mounting location on the chassis.

Next job is to sort out the new fuel tank and the tail shaft centre bearing mount. Once this is done I can remove the engine and cab again and finish the welding on the chassis before cleaning it all up and painting it.
Then I'll get the cab back on and fit the new suspension.

I've also got some wheels and tyres on their way and have had a set of Monster Rides flares delivered!!!
Lots more to do yet though...

Love your work. This thread is great.

Slow progress over the past few weeks but I did manage to get time to machine and fit the steering box spacer and mount the fuel pump and surge tank.

My new wheels and tyres also arrived but I had to machine the wheels too as the hub bore was slightly too small to fit over the Patrol hubs despite me specifically asking what the size was before buying them.
Anyway, they only needed 0.8mm taken out which was no real issue.

Setting the cab further back on the chassis to position the front wheels slightly further forward than they would normally sit in the Hilux wheel arches has paid off as the new tyres clear the un-modified guards by about 5mm.
I'll still tap the pinch weld in though and I still have a 4" lift to go in as well so shouldn't ever have any rubbing issues.

Next job is to pull the engine out and lift the cab off again so I can finish welding the chassis and new cab mounts before giving it a coat of paint.


Wheels are Black Rhino 17" x 9" +12 offset.
Clearance is tight at about 5mm but this is still an unmodified guard

This build is awesome!!! I wanna see more!! i wanna see more!

Some good progress over the past week with the last of the welding done on the chassis before getting it soda blasted, primed, and painted and the inside of the chassis rails fish oiled. I've fitted the suspension kit which consists of a Superior Engineering "super flex" and drop box kit with a set of Tough Dog springs, shocks, and adjustable panhard bars.
The original brake lines were scrapped when teh chassis was lengthened so I've re made new brake lines and also fitted longer length flex hoses to allow for the lift.
Now the cab is finally mounted back on the chassis and it's starting to look like a Hilux at last!Looks the part with the new wheels and tyres fitted too.

Awesome! Keep the build pics coming

This is amazing

Awesome work

Loving your work mate, definitely will be a head turner once it's completed

Just out of interest is this able to be engineered?

TRDLuxxy wrote:Just out of interest is this able to be engineered?

I bloody well hope so otherwise all this work is for nothing!!!

Actually, yes. I put all of the paperwork into transport and got the "Approval in principle" before I bought either vehicle. I also spoke to the engineer who will be doing the inspection and report and he was happy with everything I showed him.

As it has to be registered as a modified chassis it will actually be registered as a 1999 GU Patrol not a 2005 Hilux.

Ok so it will be registered as an ICV then?

TRDLuxxy wrote:Ok so it will be registered as an ICV then?

As far as I am aware, it will simply be registered as a modified Patrol.

Oh ok, surprised it can pass even with hilux airbags? Not sure if that model patrol had airbags or not? How far out were the original body mounts from the patrol to the hilux body?

Certainly an awesome project and a better option than doing a sas thats for sure!

I know it seems like a massive amount of custom work, and there is quite a bit involved but apart from the extension, the chassis is relatively standard so I can't see any reason not to approve this type of conversion. Unlike a full SAS conversion which requires virtually every component to be extensively modified or custom made I am basically using the original suspension, steering, and brake system even though most of the suspension has been replaced with aftermarket replacements.

I think this model Patrol had airbags available as an option but they certainly weren't fitted as standard.
The location of the Patrol body mounts were close to the Hilux body however only being close, they might as well have been miles away so I removed all of the original mounts and fabricated new ones to suit the Hilux body.

Awesome build
So are you going to chuck the Patrol body on the old Hilux chassis

Richolux150 wrote:Awesome build
So are you going to chuck the Patrol body on the old Hilux chassis

Should do that and send it back to Nissan to show them how a real ifs should be. Not there half a***d attempt at one haha


Mate this thing is going to be awesome. Can't wait to see it done. Good to see someone doing something different

Thanks for the comments guys.
Haha, yeah that would have been funny, especially as the Hilux was only a 2WD! Should have done that before I sold the Patrol body. Would have made a good photo

Probably won't be much progress over the next couple of weeks. I have to order some fittings and machine some bits up for the A/C lines. All kind of boring stuff really but I have to get the A/C lines sorted before I fit the engine as the lines connect to a fitting in the fire wall which is reasonably inaccessible once the engine goes back in. Being an in line 6 cylinder rather than a V6, there's not much room to spare lengthways in the engine bay!

This thing is seriously awesome. I always thought it would probably be cheaper to just put a hilux body on a patrol chassis rather then doing a SAS.

I will be doing this in the next 6 months aswell, but will be putting an LS3 in it. No doubt i will be picking your brain when the time comes. Keep us all updated!!