NewHilux.net

Over 1000 posts here and still no build thread? Time to rectify that.

I purchased my 05 Single cab D4D SR Hilux back in February 2012 with 170k on the clock - my first ever ute, diesel or 4WD. The decision to go the Hilux was mostly as I am a strong Toyota man.


Within days of getting it, I was getting tired of getting a face full of dirt every time I turned on the air con so I stripped out most of the interior and gave it a good clean.




I also debadged the exterior, removed the buggered side steps and bonnet protector and gave the whole thing a strong cut and polish. It was now clean at least

I did a few offroad trips with some mates, mostly beach and mountain trails around Brisbane, but the ute was purchased to double as my personal vehicle and a work truck, so even though I initially gave it some 4WD mods (UHF, 32" all terrains, OME lift) it was quickly becoming apparent that the more I had to upgrade it for work meant the less able it was to go off road - more on that later.

The steel tray on the back was extremely heavy duty, but was far stronger than I needed. As such I decided to make up my own steel tray, but from a combination of lighter steel and aluminium for the base, as I would mostly be carrying only tools around.

Took a little while as I had never done such a huge welding project before and wanted to implement some subtle unique designs to the tray (hidden latches, recessed channels for support addons) etc but eventually ended up with it like follows (toolboxes not on yet)


I quickly found out I had stuffed up royal, in the painting. Despite cleaning down the steel with turps, wax n grease remover and then thoroughly priming it, the paint never seemed to adhere to the metal which meant every paint chip would just peel off huge flakes at a time

When considering costs of sandblasting and getting it powercoating, I realised painted steel simply wouldn't last with constant abuse, so I sourced a 2nd hand aluminium tray (like all our other work trucks use) and bolted that on. Not as pretty, but far more durable and worry-free.

Show this is how the Lux is sitting now. It has a 240v air compressor built in over the top and bottom of the rear tray so whilst I COULD take it offroad, with my boxes full of tools and the compressor SOMEWHAT exposed underneath (water doesn't bother it, but mud/sand would) I just don't want to risk it.

In fact today it's going in to get the worn ATs replaced with new HT tyres, so I'm moving away from offroad capability.

Now the mod list (won't include work specific stuff - all kinda boring)

Rear LED worklights
Front LED light bars
Fuel pre-filter
Provent Oil catchcan
3.9" Ratio rear Prado diff center. Got the front diff ready to go in but lazy
Bullbar
Profender shocks front/rear with heavy duty EFS springs - good combo for work loads and fairly comfy too!
Aftermarket headlights and prado style front grill
2012 SR5 Optitron dash cluster
Android based GPS/Stereo
Dual Diaphragm Brake booster from Hiluxy (AWESOME stopping power)
Braided brake lines, DBA rotors and HPX brake pads
Exedy H/Duty clutch
Baileys high flow Injectors
Home made idle up kit
2008 Aurion steering wheel
Woodgrain trim
Aldi seat covers
Home made front mount intercooler kit
Gturbo stage 2 Grunter Extreme turbo running 30 psi
SAAS boost guage
HKS supplied, installed and tuned by Just Autos on the Sunshine Coast
2.75" Exhaust



With just the HKS dyno tuned


Power bug had now bitten, so Injectors, Turbo and intercooler where all organised and installed with weeks, with the next tuning session achieving this


Very happy, but being let down by a slipping clutch and it seems when you double the factory power output the snorkel seems to become a restriction haha. Going to get an NPC clutch with a bigger flywheel installed and see what I can do about this snorkel, I really want to hit around 240HP at the wheels.

I was previously running a CHIP IT module. The power output was great (so it seemed at the time), but it ramped up the fuel pressure hugely, so much in fact the injectors sounded like they were hitting the bonnet!. Within a few months the whole module just died, constantly throwing up error codes and sending the car into limp mode. I bought it 2nd hand and chipit had already gone bust so it was an expensive paperweight.
Either way that led me to going with the HKS, and even just the original HKS tune before turbo/injectors/intercooler made more power but much more smoothly

I would like to thank the following though for their help

Matt from Just Autos, whilst I have occasionally cursed his name when checking my bank balance he is a true pioneer when it comes to Diesel performance, doesn't compromise tune safety just to get a power figure and simply all round top bloke. Will be getting him to install the NPC clutch in a few months as I know it will be done perfect!

Matt from Baileys Diesel - First went to him for injectors about 18 months ago and will now never look anywhere else for Diesel fuel system components. I must have driven the poor bastard mad with my constant questions lol
When Bailey's brought out there new high flow injectors I got one of the very first sets, and they work fantastic with the new turbo.

Gturbos - What can I say? You want an awesome turbo for your Hilux, then give them a call. I had no issues whatsoever installing his bolt on core (well... aside from my own stupidness when getting my original turbo out )

Looking the goods here StevenS, nice work. You may find the the snorkel is a restriction on the dyno because of the lack of air being forced into it as the air cannot reach that high. In real time on the road you may find that the air is being forced both by forward movement and being sucked in. Just something to think about.

Looking good mate, some good power gains there!

Pete'90 wrote:Looking the goods here StevenS, nice work. You may find the the snorkel is a restriction on the dyno because of the lack of air being forced into it as the air cannot reach that high. In real time on the road you may find that the air is being forced both by forward movement and being sucked in. Just something to think about.

Cheers mate
I removed the snorkel on the weekend and the ute drives a tad bit better - think Ill just remove it entirely it doesn't serve a purpose anymore

Have made the decision to leave the snorkel off and line up another guard from a wreckers.

Doing so however leaves with me with the mounting bracket holes in the A Pillar, so figured I'd do something about them today.







I also got rid of the pissy factory radio antenna considering I've now got one on the bullbar that gives heaps better reception!

did your heavy duty clutch cause vibrations at all? mainly felt in 4th gear around 65-80km?

jakepivac wrote:did your heavy duty clutch cause vibrations at all? mainly felt in 4th gear around 65-80km?

I've had vibrations in 4th gear just slightly below 60km/h for as long as I can remember. When I switched to the exedy h/duty, it was still there.

Nice job with the tidy up of the holes

Well done Steve

HKS tuners are starting to become the item for high power diesel tuning it seems

Tradewind wrote:HKS tuners are starting to become the item for high power diesel tuning it seems

The quality of the tuners has also come a long way, who knows where Hilux diesel performance would be without Just Autos

We are not slowing down we have some cool stuff going on soon

JUSTAUTOS wrote:We are not slowing down we have some cool stuff going on soon

Can't wait!

StevenS wrote:

jakepivac wrote:did your heavy duty clutch cause vibrations at all? mainly felt in 4th gear around 65-80km?

I've had vibrations in 4th gear just slightly below 60km/h for as long as I can remember. When I switched to the exedy h/duty, it was still there.

Oh yo no worries then mate. I've got an exceedy heavy-duty clutch in and about 2 months after it has developed ugly vibrations. Pretty sure its clutch so might try heavy duty pressure plate with standard clutch.
Anyway your truck sounds awesome, way to go mate!

Not to hijack, but my excedy clutch is shocking for vibrations.

StevenS wrote:

Tradewind wrote:HKS tuners are starting to become the item for high power diesel tuning it seems

The quality of the tuners has also come a long way, who knows where Hilux diesel performance would be without Just Autos

I find their work amazing and I am not that easily amazed lol

awesome build thread mate, good to see others chasing some good power out of these engines. I bet you are loving the way she drives now mate. The boys at Just Autos really know what they are doing. I just a front mount and some injectors and ill be set your front mount looks sweet mate. There would be a few fellas keen to get you to make a kit up for them i reckon