Outer Limits 4x4 Board

The truck passed its certification. Took some work, mainly around the brakes. In the end we had to mount a remote brake booster to get enough clamping pressure to the front calipers to pull it up fast enough (the rear wheels were initially locking up at 80 k/ph which was exciting to say the least ...

Hi Glen

We didn't mod the bar, but lifted the mount point with a spacer welded on top of the chassis rail, and braced back with some angle (as per the photo)

I suspect the side bars also provide some support to the bar.

http://i103.photobucket.com/albums/m138/codlin/Winch%20Bar%20Rebuild/IMG ...

Have it almost all back together now.....

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1334.jpg
http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1338.jpg
http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1339.jpg

still got to do ...

Colour and clear coats are now done. We put a chipcoat seal onto the rear wall to help stiffen it up and deaden the noise, then painted over that. The roof inside the cab has sound deading panels on it, with the same chipcoat seal sprayed over that, again to stiffen it and cut down the noise.
Makes ...

The cage & tray has come back from the powder coaters..... looks great.

The side bars are now about ready for pwder coating too.

Its taken a while, but with great help from some great mates the cab is ready for painting.....
With the tray removed and sent off for sand blasting and powder coating, we could then sand down the welds, panel beat the bigger dents, seam seal on some of the joins and then bog applied liberaly over ...

Hi Chris

Mine is a 3.5 manual, so ARB makes both front and rear lockers for.

I assume you must therefore have the Gen II 3.0 automatic if you say ARB doesn't have a locker for it. If so then thats right, the automatic 3.0 has a smaller diff (7.5") than the manual 3.0 (8") for which there is a ...

Tread plate all cut for the deck and side skirts, fitted and bolt holes drilled.

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1068.jpg

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1069.jpg

Next step remove the tray and cage, drop off to the ...

Thanks guys for the comments.

I have cut the treadplate deck templates out of customwood and fitted, so shld cut the alloy plate this week all going good.

Got the truck home now. All the tube and chassis work is done. Now the hard work for me.... sand, fill, paint !!

Will stick with the existing truck colour, blue, prob with a clear coat over it.
The bar/tray will be powder coated black. I have found this is a lot more durable long term.

Hi Glen

The cage bolts to mounts on the side of the chassis (abt where the swaybar mount was) and on top of the chassis at the rear, and then onto the side bar at the front. That way its easily removed to paint.

Those rock sliders have been there for over 4 years now....... and have seen a fair bit of action in that so no won't be changing them.....

Hi Turoa, yes Jade has done a great job !! I did think about the wheel base, and agree that it would have been good to lengthen now, but decided that didn't ...

Work to do....
mount XD9000 winch to rear cross member
tags to pipe to mount tread plate deck
cut tread plate to fit
Mount high lift jack to rear cage
mount & wire stop lights
mount rear flood lights (maybe LCD) for reversing
harness mounts in cab
mount new seats
sand & bog cab and then paint cab ...

The exo-cage is built, with the front bar coming down onto the side bar.

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1053.jpg

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1054.jpg

Had to remove the snorkel to fit the right hand side bar, so ...

Hi sam
No SAS it the moment.... Front locker gives me all the additional traction I need.

maybe when I get sick off replacing bent idler arms every warrant of fitness

I have both also, so my 2 cents worth...... I would go for the front locker for the following reasons.
your only running 31" tyres
You're not into hard core off roading
The lower gears impact your top speed (5th gear) in low range = impact touring.

I find it is the front locker, not the low gears ...

Hi Sam

Yes it is Brians workshop. I've had the truck about 4 years now, so yes you probably have seen it around the Hutt a few times, maybe in the Akas.

cheers

Charles

Rear crossmember's been shortend and replaced. The standard pajero Rear hitch for hook has been moved to the new xmember. We will also mount a warn 9000 below and behind the rear xmember.

http://i103.photobucket.com/albums/m138/codlin/Pajero%20Trayback/IMG_1043.jpg
http://i103.photobucket.com ...

Have been considering for a long time how to protect the body of my truck, internal roll bar ? external cage ?

http://i103.photobucket.com/albums/m138/codlin/127_2706d.jpg

Meanwhile the body keeps getting further beaten up. And I needed to replace the std rear bumper with a steel bar, damage to ...

I had a similar sound occuring after I had removed the trailing arms to replace the axles mount bushes.

I turned out I had put the rubber bushes on the chassis end of the trailing arms back the wrong way round (they are flat one side and curved the other) and they wore VERY fast, resulting in some ...

The terminal is only 2 wires.

PM me with your email and I can send you a pdf of the the Mitsi Differential Locker Rear manual. This will also give you a wiring diagram along with fault diagnosis.

Hi Glen

Location of the locker pump is dependant on whether your vehicle is LWB or SWB. With the LWB the pump is under the right hand side rear passenger seat in behind the small door. With a SWB the pump is mounted behind the left hand side paneling, below the side window. To access this you need ...

Winch is in now and mounted. Using the motor off my original XD9000 winch as the 8274's original motor was 24 volt and had been cooked when I bought it. Looking to replace this with a 6hp motor some time (when the Pentagons not watching the credit card)

http://i103.photobucket.com/albums/m138 ...

Thanks

Yes had originally looked at trying to move the winch back further (given the greater depth of the 8274 to a 9000, however that would have meant cutting into the body panel that goes across under the grill, in addition to interferance from the bonnet lock mechanism. In the end it was simpler ...

I have had a Warn 8274 on the shelf in the garage now for nearly 12 months now….. Finally made the time to get this fitted on to my truck.
Problem is that the ARB bars for Pajero’s are all for low mount winches, not the high mount’s.

This is the bar 4 years ago, before it went onto the truck ...

NJV6, I went through comparing the ratio's as you have and in the end decided that the 3.15 gears matched the best (compared to waiting for 2.85 to be manufactured).
Basically (in low box) you get a new 1st gear, and then 2nd gear matches the old 1st gear, 3rd gear matches the old 2nd gear and so on ...

Ado

Be aware that in the manual box the 3.15 gears do not just "swap in" replacing the existing gears, it does require machining of the transfer case where the shifter rail goes thorugh into the transmission, machining of the large gear to allow for a circlip, and also machining off the bottom of ...

If its not the idler arm shaft, then check the drag link bar (its the bar thats goes across the back of the sump between each tie rod) from for a bend at one end.

I had this problem and caused a similar (probably worse) effect on the steering wheel positioning.

In a similar vein..... damn idler ...

Hi Magicfev

I have just (6 mths ago) moved from Gen II 2.8 to a 2004 3.2 DiD.
Yes there is lots more room with the 3rd row seat packed away into teh floor, than the Gen II, however it does limit you in that you can't set up just one seat, so room available reduced.

There is room behind the seat ...