I’ve been lurking around here for a while now, and thought it was about time I started a build thread of my own.
I’m in the process of fitting a 2WD 2005 Hilux dual cab body to a 99 GU Patrol chassis. It will be running a twin turbo Toyota 2JZ-GTE engine through a Toyota Dyna 5 speed gearbox fitted with an early 90s Hilux gear drive transfer case.
I’ve been running this engine and gearbox in my old 99 Hilux for about 8 years now and it has proven to be a fantastic setup.
The engine is completely stock apart from a 3” exhaust and a cheapo intercooler which is roughly twice the size of the factory one. On the dyno, this produced 199Kw (267Hp) at the wheels which equates to around 270Kw (362Hp) at the flywheel, and being basically factory standard, it’s as reliable as an old diesel Land Cruiser!
Chassis modifications will be fairly extensive involving lengthening to suit the Hilux body, new mounts, new cross members for the gearbox, centre bearing, and spare wheel, a new fuel tank, fuel and brake lines, steering shaft modifications, suspension upgrades, etc.
I will be fitting a Superior Engineering lift kit which will be about 3” although the body will sit a little higher on the chassis than it would on the Hilux chassis to get everything to fit so it will look reasonably high.
As the Patrol wheelbase was a little shorter than the Hilux I had to lengthen the chassis accordingly. I’ve made it slightly longer than the Hilux so I could position the front axle about 25mm or so further forward of where it would be on a Hilux to accommodate some larger tyres. Unfortunately the width of the Patrol diffs/axle housings is considerably wider than the Hilux though so even with some Monster Rides flares, wheel sizing is fairly critical to keep the tyres under the guards.
I intended on running some 285/75R17 (equivalent to 34”) tyres but as an American size, have proven difficult to obtain so far. There should be plenty of clearance for some 35s however the legal maximum I can run on the Patrol chassis is 34” and as all of this has to be engineered and certified, I’d rather save the hassles with the transport guys and the boys in blue.
People keep asking me why I’m doing this mod rather than just buying a 4WD Hilux in the first place and there are a few reasons for it:
- I wanted to keep the engine/gearbox from the old Hilux. As the engine is older than the new Hilux, it doesn’t comply with the emissions standards for the newer vehicle so can’t be engineered. As the “Patrolux” will be registered as a modified 99 GU Patrol, the engine complies with the emissions for the chassis. Besides this, the front diff is on the wrong side for my transfer case.
- The Hilux IFS suspension is far more difficult and expensive to modify for greater flex and larger tyres.
- The Patrol has a good variety of standard diff ratios and the diffs are considerably stronger than the Hilux diffs are.
- I estimate that by the time I’m finished, it will owe me little more than half what a modified Hilux would (not allowing for my own time and labour of course) and it will be exactly what I want.
And the biggest reason of all……… Because I can!!!
I’ll be doing all of the work myself and obviously there will be heaps of custom made stuff required so I’ll post pictures up from time to time as I progress.
Hope you enjoy my build up!
The Patrol before being dismantled.
Patrol Chassis and the 2WD Hilux which the cab will come from.
Removing the Hilux cab.
Side by side the flatter profile of the Hilux chassis is obvious. this is the reason the cab had to sit a little higher on the Patrol chassis. Equivalent to a 1.5" body lift I'd say.
Here the lengthened sections in the chassis rails can be seen.
The cab is lowered onto the chassis for the first of many times.
Here the cab is bolted onto the new mounts. I've fitted a 17" Patrol wheel with a +10 offset and a 33" tyre to check on the clearance between the tyre and guards.
The Patrol rear cross member is removed and a new one is fitted to mount the spare wheel.