Outer Limits 4x4 Board

The storey starts 26 July 2010 we had viewed this beast 3 weeks before and the then GF said buy it or I leave you hahaha 3 weeks later we hauled and I mean hualed it out of the underground garage it was stored i.

I'm (were) from Malaysia (my future wife and me) - most people call me GECKO so does David Metcalfe (my nice neighbour he just calls the police hahaha serious) due to the large GECKO tatto I have on my arm. We have acquired a C304 (4 wheel model only) and in the process of restoring it.

As we pulled it out of the storage park with my BJ75 on 26/07/2010. It was not running but would tick over.




The mighty Toyota Troopy BJ75 struggled to pull it it appears the brakes were frozen on.

Onto the tow truck and down to a friends performance tuning shop hahaha.



Once they removed the spiders and cobwebs from the tank and put new fuel in it it started.

Then they changes all the fluids.

But they could not fix the brakes so I made decision to do the DISC conversion first before the rust treatment.

I drove it around at nite for 2-3 weeks testing it out - without brakes and only using the gears and handbrake. I learnt what was good and bad in the truck and what needed fixing. Now I have a 40+ item list to attend to.

Then last Saturday I took it to the hospital (escorted by the BJ75) which was entertaining saw this on the way out. Oh yeah I burnt off a 22R powered LC II on the way up a hill it could not pass until the downhill part hahha.


This is it after being washed and driven for a few weeks. Mr Grumpy my neighbour hates it and all 4x4's the other neighbours in the street think its neat including the ("SIR") who I took his kids for a run in it now he wants to book a jungle trip with me.


The interesting one is my car illiterate neighbour she I quote "that engine sounds so sweet" its nicer than my Honda. Then where is that big beautiful 4x4 on Sunday she asked.



Then the serious stuff removing all 4 wheels and portals - yeah yeah thats me working on the Jalopy.


Me working on the last wheel. The mekanik did 1 hub and left me to to the other 3. Not bad for my first ever working on a Vovlo and no manual either.


7 hours later a A stack of portals


Once that was done it was over to the BJ75 and pulled the WARN 8274 out of it it has water in it :( and the new axle to be fitted and a new knuckle this week and new leaf spring bushes and it also has a brake problem.

We are going to put on in this round of fixes:
1. LC II Front Discs front and Pajero rear as these is are parts which is readily available.
2. Install the WARN 12,000lb winch for REAR recoveries
3. Fix the taillights with LED lights
4. Fix the indicators
5. Fit new headlight wiring and H4 halogen bulbs and new reflectors
6. New radiator hoses and break hoses.
7. Battery Rack for 2 solar batteries and 2 120amp batteries and a 150AMP Alternator.

Once we
So thats my intro. I will post up stories as I slowly restore it.
The rest of the truck is STOCK.

I have previously been in (and out) a C304 during the RFC2007 when we got flooded and I was in the BJ75 in the same small convoy of 6 of us. I know what it can do - awesome. I cannot wait to take mine offroad here.

I also own a:
Toyota LC II - 13B/14B-T crossed monster very jungle ready
Toyota LC II 1KZ auto handbag jungle car
Toyota BJ75 - jungle ready
ISUZU pickup and
TOYOTA VIGO pickup.

My favourite is the BJ75.

22 September 2010 Update

Subject: Intro from Malaysia - WR7002 - C304

geckoadventure wrote:Pictures of the project.

Latest status is POTRALs with DISCS being assembled and fitted this coming week.

Rewiring of HEADLIGHTS, REAR lights and INdicators being done this week along with new fuse boxes.

Rear 12,000 WARN WInch being installed sometime this week also but not wired up thats my job later.

Maybe it might be ready to roll out of the workshop this week then it will be driven for a week before going to get the RUSTed front removed and replaced.

Fixed the passenger door lock up on saturday *_* stripped and cleaned and refitted.

The portals being fitted with DISCS and BEARINGS


The finished product.

7 November 2010

Well after waiting almost 5-6 weeks brakes are done and more mods done.

Came out of workshop with new disc brakes working but not well so new master pump seal kit and strip and rebuild the vacuum pump and hoses and wow they work very well long soft travel.

Its now boasting Landcruiser II Front Calliper and new rotors and Pajero rear discs. but its not stopping well.

Took it to a workshop and they stripped the master cylinder fitted a new seal kit and stripped the 10 tonne Hino vaccum cylinder and repaired it and wow they told me it had brakes again. Not bad for a MYANMA mekanik who got instructions from the cantonese mekaink I told in broken english who only speaks Cantonese and I used bahasa and english and cantonese to explain what was wrong to him hahaha.

New air filter box fitted and vacuum lockers are to be swapped this week for air as cannot buy the rubber seals here :(

Does anyone know where I can get the locker diaphram rubbers from UK or europe please?

Its Almost ready for a trip to the jungle.


The new look with 6 stud FORD rims :(







Front Wheels now offset an additional 60mm with the FORD rims :(






Offset from the hub to the edge of the tire is now widened the track 60mm each side.




The brakes in the Volvo are now AWESOME is all I can say long soft Travel and powerful extremely impressive for its weight and considering it's a truck.


First offroad trip a shakedown run last Sunday


Spent all Sunday afternoon changing the two engine fan belts don't ask its a prick of a job as the alternator has been changed previously then we noticed the belts etc do not line up the alternator is 3-4mm out :( . THis needs to be fixed in the coming weeks.

Then we changed the radiator hoses as they had RUST in them. Then we tested out that mighty PTO winch yup it worked also.

By 5.00pm we are ready to go to the jungle Ulu Slim some 90k away.

By the time we headed into the jungle its gettting dark. Stupid us but we really wanted to test it out.

At the first steel bridge we take the creek and yes we got stuck as the Volvo stalled as it was missing under 2000rpm as I crossed the river.



Then we were stuck no way back and no way forwards and by ourselves duh!!!!!!!!!!!!!!! and then we realise only 2WD is working and we have no front drive :(




Cleaned out a rock or two from behind and then we reversed out and then drove over the creek at a faster speed hahaha. Up the hill and it was very slippery wet and muddy we decided to turn for home.

Then we only had high beam and a missing truck under 2000rpm.

Back home at 4000rpm down the highway with only high beam.


Home at 9.30pm after driving flat out at 4000 rpm at 80k for the 90k home hahaha.


The perspex windows need to be replaced before it can go out at nite again its too hard to see out the front windows.

Monday Arvo Dropped the Volvo back to the workshop at Lunchtime to find out why the front axle not engaging and picked up the Landcruiserr II and drove it back to work the first time I had driven the Landcruiser in 5 days. They also to remove the radiator and flush it .

On the way to work.

1. WHats that long green thing in front - oh year a bonnet.
2. WHy do the brakes feel so heavy (and GREEN is a delight to drive) to push
3. Why does the steering wheel feel so vertical and FAT?
4. WHy does it not stop as good as the Volvo
5. Oh shit almost hit that car the brakes need too much pressure to work hahaha
6. Steering feels heavy even with power steering
7. Hey its got window wipers why do I need them
8. The Volvo sits better on the road - ooops whats wrong with me hahaha.
9. Damn where is that music coming from - oh really its got a stereo.
10. Wow its cool in here that airconditioning stuff really is cool.
11. Why do the front windows not open forwards and let air in?

More wallet adventures coming

11 April 2011

new tempered glass in the front window and the perspex ones tossed away wahooo now I can see driving at night. now need new wiper motors are they volvo or LR items can someone tell me?

rear doors had new latches fitted so the doors no longer open by themselves.

Now I have to fix the PTO it's automatic clutch is slipping under load.

next is either diesel conversion or high ratio diffs or the bus factory for rust removal not sure which depends which one I can afford first

27 June 2011

Volvo Update

• Rear facing WARN M12000 winch installed and removed so the winch motor can be repaired.
  PTO Fixed and running
  200liter (50 GALLON) fuel tank installed.

Well after much mucking around and people loosing sketches and plans of the Volvo (read lots of wasted weekends visiting workshops) I have finally found commitment to get the cabin restored and then the rear cabin. The shop is run by an australian.

3 weeks time it goes into a workshop 2 have the front of the truck repaired or replaced - replaced is what I want

Options to be done are twin headlights and get the front read for an intercooler. Radio console to be installed - hydrualic steering to be installed

The truck is now a daily driver after the carby rebuild and here is it in recent action with 2,200kg of drinks in it at a charity event for work.



Next weekend it ventures into the jungle for a charity trip and will have 500 rubber plant sapling in the rear roughly 500kg of weight for a 52kilometer trip one way and a 80+kilometer trip back out.

However it broken down last nite looks like coil failure so I have to go retrieve it today.

After the cabin rebuild they are going to make a ALLOY rear cabin with rollcage etc in it and a few other options to turn it into a camper/rollout kitchen/utility jungle truck as it has a date with the RAINFOREST challenge 2011 in December and its not going to miss it and it will have a 13B-T engine installed also. Currently we a re building up my spare 13B-T engine which has been sitting on the shop floor for 3 years. A new head has been found all we need now is a fuel pump and then we will rebuild the whole engine from scratch and yes find a TURBO as the other one was donated to the scrap heap.

Since everything is technical here is the trip report of the Volvo's first real and only jungle trip before the restore started. It did several others on some workout trips thru rugged oil palm plantations but no pics from them.

Volvo is loaded up - wait a minute a Volvo for a offroad trip - YUP my 31 year old Vovo C304 Military truck on its first jungle trip. Great 3 days away from the rat race of Kuala Lumpur. Wait for Tappa my winchwench for the weekend and he arrives 5pm late due to the traffic then we Head to Karak 70k away to pickup 500 rubber saplings for my CSR project for the blind village 52k deep into the jungle of Kelantan. God its going to take us hours. worse I now have a heart condition which means I could drop dead at any minute. It will cure with rest and proper sleep meantime in resting by not being at work.

Paul in DAFFY with Annuar is some 2-3 hours behind us playing catchup as the Volvo only cruises happily at 71k. Karak 70k away and 90 minutes later at the nursery and 475 rubber saplings are loaded in and we wheel around and head back to the Bentong exit and head North with the sun fading fast. We stop at Bentong for last minute supplies MILO and water and tea bags and dinner (for me its breakfast and lunch also) then back on the road this time Tappa is driving and we test out the newly adjusted 100watt headlights and new spotlights - PERFECT we can see. After 11 months of fixing the Volvo up to a reliable state I hope it will be ok.

loaded up and ready to rock where is TAPPA?


Tappa with cancer stick and loading the rubber plants.




We cruise on alone then the world lights up behind us - damn DAFFY (hot hilux SURF) has caught us man he musta been flying. Shortly after the noisy under the engine suddenly goes BANG and then the engine is quieter the noisy BELT has come off DAFFY informs us. I drift in and out of sleep as much as one can in a vehicle which makes 747 Jumbo Jet sounds quiet yeah ! Then 40k from Gua Musang the there is a downshift a jerk then the Volvo slows - NO DRIVE ses Tappa - #@#@ I say. A check reveals yup no gears at all - clutch no the truck is stuck in neutral and we decide DAFFY once again has to tow a GeckoAdventure truck - this time DAFFY cannot pull the Volvo without being in LOW range - so its a 35k an hour tow into Gua Musang where they drop me at the workshop it's now 1.30am and I inform them they must continue on the charity trip and take the rubber saplings and Tappa with them and I will catch them up later in the day. If I not there tomorrow nite then I'm not coming.

Satellite phone is our communication tool as we both have one. I sleep in the back of the Volvo awesome just rollout the US military matress out with a sleeping bag and SLEEP in seconds no putting a TARP up - love it. The workshop comes alive 9.00am and they muck around for hours finally they disconnect the HI/LO lever and the Volvo springs to life shifting manually at the gearbox. I cruise off for food and they fit two new Belts and its 1.00pm. A quick test drive with the mekanik grinning like a chesire cat its good to go refuel wow only 49 liters for 281k good stuff. I get a sat fone call from Paul they finished the charity work and heading down so they will wait for me at the big "Y" intersection (thats 70-80k away) . I finish fueling and tell them 90 minutes I will be there. Later interrogation revealed the Kg Rekom Orang Asli crew made the track so good there was not one obstacle on the trip in and no one got out of their trucks no one got stuck - simply awesome job to clear 10k of track with only hand tools my hats of to them. I was also dissappointed not to get there so I will be taking more goodies up on my next trip.

The Volvo enters the jungle and I cruise in high range stopping at a logging point

The Volvo resting at log collection point.




and Gua Cha which I find now disgustingly dirty since the logging trucks started using it as a resting point. Malaysian's take your rubbish HOME.

Gua Cha










and then when everything in the back moves after a huge hole bounces the Volvo all over the road. Then it's the Sungai Perias log bridge and I'm encountering lorri hantu's the progress is slow in the Volvo most hills taken in 1st and slow but the Volvo is very easy to drive. 4.50pm I arrive at the "Y" and collect Paul and Tappa and Annuar. We cruise off with the other 8 vehicles in the convoy just in front somewhere.

The Broken Miss Bitchy convoy








We find them well 3 of them Miss Bitchy's one a STORM has tossed it's FAN then the radiator mounts break off. A repair is being effected with wire and we wait to escort them. They are stunned a Volvo wow and then it starts raining damn that's not in the plan that's going to ruin a few peoples day's. Then the Vovlo is leading a small convoy of 5 and we reach the watefall turnoff and chat to the village people first and greetings exchanged and some gifts.

At the village and turnoff and yes thats rain clouds in the background.


Into Low range and up the hill 400-500 meters to climb (up to 680 meters) in 3k with 2-3 seriously steep ascents awaiting. The Volvo does it albiet slowly no issue with grip its ponderous 2,700kg ensuring all sneakers stay on terra firma.

It's steep and the track easy then we hear on the radio the convoy is stuck at a climb - I know which one too hahaha then gridlock on the track. Chaos 4 vehicles stuck on the slope. One winching up and almost at the top, the other winching of it and a Ferozza stuck against the bank. The last another Pajero unable to move as it slides backwards each time they move it. We guide this one out the way. Then I bully past the sticken Ferozza and park behind the Landcruiser II being winched up. 60 minutes later its out of the way and they have two at the top of the first climb. Then I push the Volvo up the slope from dead stop several times up and up 4,000revs or less first gear and lockers engaged front and rear slowly I make it. Daffy is next and it demolishes the hill the XT's providing awesome grip and the 1KZ the power.

The traffic jam



The second landcruiser ahread of me I pull up beside it and park unable to pass the winch cable.

Volvo victorius at the top of the slope 3 more to go.


Yup its a long way down that slippery slope.


Then the problem 1/2 of them want to stay and 1/2 want to leave they have our tarp so Paul goes back down to collect it and back up. Then the Volvo winches down the Landcruiser 80 Series and then the second Landcruiser II and my PTO jams winding the cable back in #@#@#@##@ Damn. We learn later that standing on the cable is not enough it needs to be held by a vehicle to wind it in tight else it flips off the spool. The spool is fixed later to put a cage on it 180feet of cable ruined. By this time its dark and it's raining again upwards we climb in the dark 800 meters to CAMP and the track is a SLIPPERY mess the Volvo sits on 3,800-4,000 revs first gear low lockers engaged engine screaming and slowly crawling up catching DAFFY the track is destroyed someone has bulldozed it what a mess. Then we see lights (wah lights who from) and a camp and we are at the waterfall. The camp is a MUDDY mess and we see the reason an excavator. We pitch camp right in the sea of mud opposite the wonderful Lata (waterfall) Pendat.

Dinner is cooked for me as I relax with a cold beer. 3-4am I am woken by a huge rainstorm pounding our camp and water flows freely under our beds. Morning reveals all the damage to this little paradise is immense a complete bank destroyed and the track which leads to the crashed C47 Dakota all gone and the HUGE bambo plants all ripped out in the name of a temporary shelter. We are camped in 3-4 inches of mud. They are putting a building up for 150 school kids for a research camp for 5 days - unbelieveable damage for a 5 day camp.

The magnicicient first 30 meters of Lata Pendat the rest climbs another 70+ meters up the hill.


Anyway we relax even if the Volvo is leaking oil from the front axles and the whole day is spent sitting at the waterfall or in the shade of camp talking crap and putting up ideas for the customisation of the rear of the Volvo and relaxing and eating. My heart is loving the rest they will not even let me cook or unpack the truck.

27 July 2011

Yahoo and Boohoo - this weekend is the big day for the Volvo its off tot he hospital for the rust removal from the front of the cabin and a few other mods.

1. Rust removal
2. Creation of a cage for VHF radio and stereo
3. Air conditioning installation
4. Rollcage external
5. Recaro Seats will be removed and replaced
6. possibly redo the cabin interior in CANVAS not paint.
7. Hydraulic steering
8. Relocation of the vaccum brake kit from the rear cabin to underneath.
9. upgrade lighting - http://WWW.RIGIDINDUSTRIES.COM" onclick="window.open(this.href);return false; lights coming etc.
10. LED lights for interior
11. airtight it from the engine bay heat

once finished stage 2 - pics as we progress.

1. rebuild of the reaar cabin
2. build one in ALLOY with
3. Drop sides
4. front half will have rollout drawers for the rollout kitchen and spares.
5. raise roof 12-18"
6. install solar charger
7. add two 200amp batteries for winch.
8. add new 12,000 front facing winch as a spare.
9. add two 145 liter fuel tanks and remove the recently installed 200 liter tank.
10. roll out awning to roll out either side for a 20'*30' tarp.
and a few more goddies including LED lights

so two - 3 months off the road coming up.

Sunday Nite at the workshop and the rust is revealed







3 months I cannot wait.

6 August 2011

There is a lot of RUST from the floor to the front window only where it was stored the rain poured in on this part only . The floor was starting to collapse so it had to be repaired now before it fell while I was driving it as the cabin cross member on the chassis had also rusted away :( oops.

Also someone stuck sponge in the inside of the doors I assume for sound proofing and it appears to be attracting moisture and hence rust.

20 August 2011

Progress report

Its all apart : ( took them the first two weeks

The rear cab removed
The front top of the cabin removed
The front bottom of the cabin removed.

They have pressure hosed eveything and the engine and gearbox out today to have the engine replaced with a 15B Hino Diesel which we will add a turbo and intercooler separately.

Anyone done a 15B conversion here? I know in West Malaysia they do a 14B-T conversion and H55F gearbox - at present I planning to keep the existing gearbox and hope it can handle the torque from the diesel if not I replace it with a H55F also. THis is the specs of the 15B-T which is what the end result will be.
15B-FT

Since 1995 this engine has powered the mighty MegaCruiser.
* displacement: 4104 cc 4CYL
* injection: turbo direct
* horsepower: 155 (114kw) at 3200 rpm
* torque: 288 ft-lbs (382N.m) at 1800 rpm
* valves: 16 ohv
* bore and stroke 108 and 112mm respectively



Shocks being measured up so I can order a very nice set of shocks from amadaextreme.com if they can make one big enough .

Chassis is now being stripped and we are going to sandblast and paint it the final colour

I am looking at painting it this colour

http://www.tamiya.com/english/products/list/spray.htm and colour number TS-46 Light Sand

which is of course one of the usa desert storm colours as close a match as I can get. Can anyone else give me a colour code so I can give it to the painter

I can paint my truck military colours but not malaysian army colours

Today I go to collect the 18,500Lb electric which I have put a deposit on it runs 24Volt so the Volvo is going to be converted to 24Volts which will not be an issue as the 15B engine is probably going to be 24volts anyway.

I also ended up today with a 14B-T no 15B's available.

Pics.

Drivers side repair almost completed


Front view almost all completed


Passenger side almost all completed


The PTO levers used to be here not sure where they going next but not here the 14B-T will melt the hoses.


The roof surprised me full of little holes :(


Police grills are going they are rust magnets


The sexy naked chassis



Next set of pics the cabin will be painted and back on the chassis with the 14B-T underneath I hope.

31 August 2011

Progress report

Its all apart : ( took them the first two weeks

The rear cab removed
The front top of the cabin removed
The front bottom of the cabin removed.

They have pressure hosed eveything and the engine and gearbox out today to have the engine replaced with a 15B Hino Diesel which we will add a turbo and intercooler separately.

Anyone done a 15B conversion here? I know in West Malaysia they do a 14B-T conversion and H55F gearbox - at present I planning to keep the existing gearbox and hope it can handle the torque from the diesel if not I replace it with a H55F also. THis is the specs of the 15B-T which is what the end result will be.
15B-FT

Since 1995 this engine has powered the mighty MegaCruiser.
* displacement: 4104 cc 4CYL
* injection: turbo direct
* horsepower: 155 (114kw) at 3200 rpm
* torque: 288 ft-lbs (382N.m) at 1800 rpm
* valves: 16 ohv
* bore and stroke 108 and 112mm respectively

Shocks being measured up so I can order a very nice set of shocks from amadaextreme.com if they can make one big enough .

Chassis is now being stripped and we are going to sandblast and paint it the final colour

I am looking at painting it this colour

http://www.tamiya.com/english/products/list/spray.htm and colour number TS-46 Light Sand

which is of course one of the usa desert storm colours as close a match as I can get. Can anyone else give me a colour code so I can give it to the painter

I can paint my truck military colours but not malaysian army colours

Today I go to collect the 18,500Lb electric which I have put a deposit on it runs 24Volt so the Volvo is going to be converted to 24Volts which will not be an issue as the 15B engine is probably going to be 24volts anyway.

18 September 2011

I saw the Volvo yesterday

Cabin fully completed and sat back on the Chassis.

Chassis and cabin wired brushed and no more rust found

14B-T engine dropped off for installation to replace the B30A engine . 14B-T is 3660CC 4 cyl turbo diesel from Toyota (Hino/Diahatsu). its 5" shorter than the B30A and a lot heavier - does anyone know the B30A weight the 14B-T is approx 375KG.

All "holes" and been welded up.

Air cond vents installed and air cond grill installed

New Dash is now to be constructed with PTO levers and all winch controls located on the old area above the radiator cover. New radiator cover also made to keep the hot air out.

Rear cabin is not going back on and to be replaced by an all ALLOY tray to save weight we estimate 300-400kg saved.

Seat positions checked and sorted.

Radio and stereo and GPS console to be installed

External ROllcage design and size agreed.

Intellitronix DASH to be installed. - Sacrilige - yes im tossing the original DASH its fot 3 sets of instruments in it so we going to function and simplicity - unless someone knows a better dash I can use?

http://www.intellitronix.net/intellitronix_010.htm

Power steering to be installed soon - unfortunately from a FORD

Mercedes brake booster installed under the steering wheel and all other brake stuff tossed.

Two electric winches layed out and ready to install on 8 MM plate and will hang upside down from the chassis just behind the PTO.

Fuel tank (150L or 37Gallons being designed) for left side underneath basically I have 22"*12"*42" to fit a tank in (or 55cm*30*107) minus a bit of anglin will give me 150-170 liters) - 3 Batteries to be installed on right side. Air intake to be sneaked out the right side by the rear drivers window with possibly a Toyota Air Box etc fitted.

Pictures later when I get them of the camera later today.

The truck looks so good I just wanna drive it now and its only a shell I just cannot believe the transformation.

20 September 2011

It's back to being a DUNE buggy

The engine and gearbox ready to be lowered into place again for the 14B-T Engine mounts to be welded in place. Sump needs to be cut a little to accommodate the front drive shaft. See the PTO on the REAR right (farest wheel) above which will sit the two electric winches.



The buggy from the rear with the WInch plate ready to mount the rear facing WARN M12,000 and the T-MAX 18,500 for forward operations. THe REAR pintel hood has been removed/relocated and will be lifted to give more ground clearance for dropping into rivers etc.



Maybe another month and it will be finished.

Awesome read.

i forgot to add the second part of the Volvo's jungle journey

Our mud camp at 665 Meters.










Soon it's Monday no one wants to go home but it's time to head back to the rat race we have breakfast and slowly pack up camp and try and fix the PTO - ooops we make it worse and now the PTO cable is jammed. We depart knowing this place will NEVER NEVER be the same again and is ruined for 10+ years we will have to find another secret location to camp at.

The apprentice cooks - basic cooking roti chennai and curry beef and baked beans and other simple meals hahaha.


That impressive Volvo



Down the big hills and it's all drying out so the track is easy. We reach the exit to the track and yup it starts raining so we stop and talk to to the villagers who are upset with what happened to their waterfall and their tribal land - I sense a legal battle looming as they have landrights over it.


Ok so it's pouring when we depart the village and driving the Volvo becomes hairy only twice do we really run out of control downhill one caught on video the other only the start of the sliding chaos still I managed to keep the Volvo straight even with no power steering. Soon the Volvo is completely covered in mud and the rain abates and we have a very narrow miss with a wildy out of control Lorri Hantu flashes past our front on a corner all 10 wheels locked up as it slides downhill and stopped with both front wheels on the edge of the bank. Stunned we carry on even more careful. Then an awesome sound the straining of a DIESEL engine and we see it a lorri hantu with two massive logs on it and one little balancing log. It takes us 5 minutes to pass it as it is just so wide. Once back down at Sungai Perias log bridge we relax only 20k of easy road to go. haha never say that we encounter a tree down but its actually 4 and it takes us 45+ minutes to clear it with two chainsaws going flat out and the winch to pull the logs off the road then we encounter a flooded road and we are out 3 hours later. Time for a comulsory car wash before entering Gua Musang and then a well earned meal its 7.30pm when we sit down for dinner. 281K to go home at 60-70k its 4-5 hours driving. Ps The Volvo consumed some 80 liters for fuel for the 180 round offroad trip basically 45liters per 100k hahaha totally worth it. 2.30am we roll into my driveway and unpack the Volvo completely then its sleep time. The next trip to the Village will be in October 2011.s


The Volvo went to the shop next morning the jammed PTO cable was cut out and the PTO got a cage to stop the 11mm steel cable flicking out ever again. The axles seals both sides replaced and its ready for the next trip and I'm taking a set of axle seals for the next trip just in case. The grand total 791Kilometers travelled by the Volvo almost incident free maybe next time - maybe.


Roll on the next trip.


Video clips

can be seen under youtube "geckoadventure volvo"

[youtube]Hlx5MSdvCog[/youtube]

http://www.youtube.com/watch?v=Hlx5MSdvCog

http://www.youtube.com/watch?v=xHClFBd0Ypk

Danger Toyota advertisement
http://www.youtube.com/watch?v=mWwa9Pf5hv0

Volvo at nite.
http://www.youtube.com/watch?v=PRzHIfuzwUM

Volvo first drive.
http://www.youtube.com/watch?v=RZYkbnlBNuc

http://www.youtube.com/watch?v=IFM4_6jiETQ

2 months later i wake up my heart is cured I can no longer feel the irregular heart beat the cardio visit the day after confirms my diagnosis. They put me on a running machine to check 15 minutes. after 9 minutes they call the cardio in to watch do his heart beat just goes up each 3 minutes we increase no blips nothing erratic - sir you must be very fit.

I go back to being a adventurer and white water rescue guide the next weekend but I slow my lifestyle down no late nights and lots of sleep.

9 November 2011

CURRENT STATUS battery box for the 24 volt batteries made and the 12v volt battery box is there but not so visible. That's a 12v 48KG battery sitting in the tray to show it all fits - will be covered this week also (to stop the frigging thieves taking them) and a fuel tank being made for the left hand side more progress to report in 2 weeks as Brett has been away at 4x4 Rain Forest Challenge Sri Lanka so all work stopped on it.

Engine now in place on new engine mounts.



Long discussion on ROLL CAGE etc and positioning of SOLAR battery and they 12V battery box.

New hinges made for engine cover so it no longer slides out and fills the cabin with hot air.

Power steering filler mounted in a easy to get to place

Intercooler purchased and ready to mount (very nice unit will take pic when in place) to fit behind the passenger cabin seat and has own fan etc built in.

Custom 3 core radiator to come from the USA as the local builder decided to build us something we did not want and offerred us a $100rm ($30usd) discount and was told to stick the poorly made radiator back in his car and leave - fool lost out on 3 as we needed the same one for 2 other trucks hahaha fool.

Fuel tank to be build this week on left hand side some 170-200+ liters (40-50US Gallons) and construction of the roll cage will commence and the bar for the harness seat belts to be made and fitted also.

12volt Alternator to also be fitted next week.

21 December 2011

Long time since update

Brett the builder has been in Sri Lanka at the SRI LANKA RFC 2011 and then we both at Malaysian RFC 2011 so there is 20+ days gone

Here is latest progress fuel tank built 180 Liters approx (45 US Gallons) with 5 liter internal tank. Steel frame to be built around it also.





Battery box is complete no pic :(

Roll cage is now being started.

PIcs after XMAS as I have my WEDDING Chinese TEA Saturday so no time to visit the Volvo in the workshop.

I am trying to get it ready for an 4x4 EVENT in 23-24 February where it will be BOSS recovery truck

Nice stuff cicak ,looking forward to the rear body work !

Cicak(bahasa) =Lizard(english)=GECKO to most people

28 December 2011

thanks for that info - yes its a similar setup not much room on the shaft end for any change and the idler and the drive gear is the same issue. So looks like only option is DIFF ratio and TIRE size.

The builder rung me today after I asked him if he could locate the radiator behind the CABIN.

YEs is his answer and he likes it as then no MUD can ever clog up the RADIATOR and it will be located beside the INTERCOOLER also and we can put a BIGGER radiator in now also.

A scoop now to be put on the roof pulling air down behind the CABIN and all protected by the ROLL CAGE

This is what gave me the idea - thanks KAMAZ. Theirs intake is out the side



He is too busy to work on the VOlvo he has a BIG trailer order and he is currently fixing up his 4x4 LandRover rally car (making it V6 3.0 TURBO NISSAN powered) for an event in FEBRUARY which I am playing RESCUE for (I wanted the VOlvo finished but ALAS it will now not be ready.

1 February 2012

Latest update

Workshop done nothing to my truck for 2 months except move it to a new location in the workshop.

Work will commence next weeek.

I have given the deadline date 15 April 2012 as it is needed for a trip on the 27th and I need a weekend to test it all out (and hoping no issues) .

So next set of pics may be the unveiling of the finished product.

8 February 2012

Went down to the workshop saturday to discuss whats left to do and the issues with this. ANy feedback on the ruining of the oriignal POLICE look is welcomed.
1. External "roofrack" sorted out (roof rack here as external rolll cages not allowed. I'm going to loose 6" behind the CABIN (this is a CAB/TRAY vehicle as delivered to the Malaysian Police).
2. The Radiator is being mounted on the LEFT Rear of the CABIN scoop from roof to pull air down. Radiator from USA to be imported. This when mounted will give me 4'10" of MUD before the MUD touches the RADIATOR
3. Intercooler to be mounted on the RIGHT side same height same reason and the AIR cond condensor also.
4. REAR canopy to be made of ALLOY over steel frame. front 1/2 of the rear will be a raised PLATFORM of approx 19" to allow 4 military boxes per side to be slipped in. Left side will have a slide out DRAWER for the COOKERS. The rest on the same side will have drop down panel for kitchen PREP. exactly same as I have in my TOYOTA TROOPy now so we know this design works.
5. The side panel for this side will be lift UP (from below the fuel TANK) to provide shelter to cook under and gas struts to hold up
The other 1/2 of the left side will be DROP SIDE and lift up and out for shade etc
6. The RIGHT side will be drop sides and lift up doors with gas struts.
7. The area between cab and chassis on right will hold recovery STRAPS and recovery kit and possibly the highlift JACK.
8. The rear will be swing down twin SPARES and drop rear and lift up and or off door for kayaks etc to stick out of.
9. The front where the Radiator used to be will be 40 liter water TANK (and pump to kitchen area) and a 12V SOlar battery and will be blocked. The built in fan from the intercooler will provide the air movement under the gearbox etc.
10. SOlar PANEL on the roof.
11. Inside cabin sound proofed and im looking at GREEN canvas over 6mm marine ply to finish it with nice fastenings (quick release). STereo and VHF radio and GPS etc and of course AIR COND.
12. 5MM alloy 5 bar checker plate for the rear floor. SInce I have over 200lb of winches (3 winches) sitting over rear axle saving weight is cruicial 8)
13. LED lights all 12V.

14. Paint job will not be military look due to ever driving it through southern Thialand I may become a target for the militants
Basically I can pack everything under the platform in 8 military boxes head off to the jungle and it will look empty in the rear

It's going to end up looking like a DAKAR truck reminiscent of the VOlvo 1983 entry


due to be finished 15 April 2012.

16 March 2012

Not much to report as we are waiting for the new pipe bender from the USA to turn up. There is 4 vehicles waiting for work and they all need the pipe bender.

The handbrake location modified as the 13B-T turbo clipped it.



The old roof of the rear cabin was in bad condition especially since it was only 6 years old.



The positioning of the military boxes for the new lifted platform we can see its going to work. 3 boxes long each side.



The rear rack over the rear wheelsm is to hang the two 18,000 and 12,000 winches underneath.



I will draw up a rough plan eventually so people can see what I have in mind.

23 April 2012


No progress to report im afraid.

The workshop still busy pushing out Army TRAILER orders not one thing has been done since November :(

and I have been very SICK :( for past 4 weeks - I got a dose of LEPTOSPIROSIS or SYNDROME

http://en.wikipedia.org/wiki/Leptospirosis

It nearly killed me and I am very lucky to be alive after 10 days in hospital and 3 in ICU and then 2.5 weeks off work and now 1-2 months complete rest (trust me im totally exhausted at 3pm each day) before I can start exercising.

This disease is killing quite a few people here and in my case I had RENAL failure and severe HEART issues. THe only reason i'm still here is the CARDIO told me you have a very very strong heart.

I am visting the truck in 2 weekends time as by then they are starting the rollcage.

WE are changing the colour scheme due to the issues in southern THAILAND so im going from military colours so something rather loud so if I ever drive through (and it highly likely) then no mistakes.

Updates soon as progress is made.

New date is to be ready for 15 Sepetember event.

11 JUne 2013

Work has started on the rear FRame see the arrow



The kitchen area layed out with 4 boxes. The farest away box will be a slide out draw for the cookers.




The cockpit with the air cond unit under the passenger front



The pilot seat with the mockup dash sitting in it. It will all be lifted about 50mm and the left side about 100mm during the rear dash makeup.




Over the weekend - Saturday I arrived at the workshop 11.00am and left 4.30pm
We discussed over 5 hours so much stuff

1. I sat in the pilots seat and we put a seat in and sorted out the DASH position and what it will look like - next time I go up a blank new DASH will be made which will allow any control to be reached while wearing the harnessss seatbelts. sinx im 6' 2" it has to be correct for me and the SHORT friends who will drive it. as it is a small very cockpit and we are not changign thelayout at all.

2. We discussed at length the new pipe bending machine (the quality of the bends is unbelievable not one crease) and the location of all components of the "ROOF RACK" the KAYAKS have to fit somewhere and the design completely including position of LED LIGHTS hanging off it. After watching a MAN DIESEL in the BRESLAU and a few VOLVOS (all cabovers) I changed the location of the LED light rack to on top of the roof as all VOLVO''s go a long way into the water/MUD on entry - oops (usually up to the bottom of the window). The whole roof rack will be tacked together in 2-3 weeks ready for my viewing.

3. The LED lights will allow FLOW of air over the roof to the RADIATOR scoop and INtercooler SCOOP.

4. The positioning of recovery kit was decided and including the highlift JACK and shovels etc

5. I cut and fitted the rear cabin panel then we looked at it and BRett said I can make it easier and nicer we use the new alloy composit material - he showed me and im hooked 3mm thick and LIGHT as and easy to work and even easier to clean and it will lighten up the CABIN - same for REAR CABIN also. The outside of the rear cabin will also be same material means I do not have to paint it - colours we are thinking of are GREEN or RED or bright PINK .

6. All electrics apart from the WINCHES and the STARTER and alternator will be 12Volts a 12V alternator to be fitted soon - I will now proceed to order all the parts slowly there is a list of about 30 items to be purchased - List later im still flabergasted after I starting writing it out

7. The rear cabin will be totally ALLOY protected by the "ROOF RACK" - man it will be light I estimate under 100kg. It will also be prepainted as it comes in COLOURED allow so all I have to do is pick the colour I like (BRIGHT YELLOW) and thats the final lCOAT . Then the cabin has to be paited to match only. Saves me about 2-3,000 in painting the rear inside and out.

8. 1 Month has been allocated to do the wiring alone.

9. Position of everything inside the cabin worked out Wiring BOX will be on the roof and flip down and a full length console for securing stuff. Air conditioning controller already installed.

10. Radio and VHF will be on the roof.

11. KILL switch for everything will be in reach of both PASSENGER and PILOT.

12. Rear floor will be wait for it a PLASTIC FLOOR - LIGHT 10mm thick and everything proof - it comes from NZ and is for CHEMICAL cabinet making More on this one later.

13. We discussed painting and underseal and soundproofing. Once the cabin is finished it will be removed and sent to Kuala Lumpur once I find a place to underseal it here. Then take it back to IPOH (it may even be painted in Kuala Lumpur first also since we only have to colour match it to the rear external panels). Then the internal soundproofing can be installed and then the alloy finishing and the fitting of the dash and the overhead consoles and the wiring can be completed.

My health is now fine I appear to be getting over the after effects with the cronic fatigue fading away and not so common, a recent medical checkup gave me the all clear.

Hard to believe is 3 months and it took me that long to recover.

After this I went for my first kayak trip in 3 months and spent 2.5 hours paddling on flat water and pulled up fine.

No pics of the F5000 kit yet he has not bought it . I assume it will be bought in due course presumably after he has mounted the radiator.

I saw another setup done recently to a VOlvo - Hilux steering wheel, ISUZU cabover steering box and used the 2.5 1JZ power steering pump and they welded a bracket to the chassis and reversed the steering arm - I was so disgusted at the "sloppiness" I did not take a picture. The steering wheel etc did not match the look of the Volvo.

I hope to have a lot more progress in 3+ weeks.

This weekend visit sick realative and then go paddling sunday

Next weekend KL Marathon so helping the blind kids sunday morning - saturday at local 4x4 shop for lunch and a meeting and check on some spare parts stuff for the Volvo

Radiator due to arrive from USA on 30th week at sometime

Weekend after Cengal Besar 4x4 trip (malaysia's biggest and oldest tree (1330 years))

Then a day trip to a waterfall (8th July) then finally 14 July Weekend can go see the Volvo.

We also have to find out why all the oil has leaked out of both DIFFS all over the floor :( pretty bad considering the crown and pinins were both replaced and all sealed up. Brett is quite concerned and is going to see why.

20 July 2012

Got to visit the Volvo (C304 4x4) Saturday. It was in pieces again




Cabin one side of the shop. The new 12v battery box sitting in the front and another to be made beside it.




Through the rear panel into the cabin.



And the chassis on the other side

The Engines mounts redone so they can be unbolted.


The 12v Alternator is being mounted in reverse on a bracket so it faces back to the engine as there is no room for it to actually sit on the engine.






The new radiator built for a hot rod from Summit racing in the USA. If you think its big is 18" wide by 31" high



The final pic is the BUGGY look.



Another visit in 3 weeks when the exo cage is built.

3 Aug 2012

Update as at today I was told

• Alternator fitted and ready
  
  Cabin fitted back on to chassis

Nothing else done all week

Next week they have two workers doing the exo cage.

I will find out when I get picture sent next friday.

12 August 2012

Saturday's visit a bit of a surprise the roof rack has started. The first two hoops done.

Two weeeks the exo roofrack will be completed.









Took a customer for a 4x4 trip along with me the VOlvo just blew him away he had never seen one.

13 August 2012

A customer view of my world.


http://www.youtube.com/watch?v=qehtKIBk6X4

3 September 2012

Yay progress

The external cage/roofrack is taking shape.

The front view still not complete.


Side view


The rear tray floor frame is also taking shape.


The Radiator on the left and the intercooler hanging in place on the right will be the exhaust.

9 September 2012

Friday went up to see the Volvo

The dash layout with actual size of instruments and layout.

The layout and the dash and the steeering wheel

Trying out the position of the Dually LED light for the front side facing positioning.

The harness seatbelts holder between the two windows and they are anchored to the floor.

Side view the rollcage is now attached to the rear of the cabin in 3 spots per swde.

The position of the exhaust (almost in the spot) the radiator (fan to be added), the intercooler (to get its own fan) and air cond unit.

The rest of the next two weeks will be spent fitting everything around the rear of the cabin sealing it all up and isolating the radiator from eveything else, positioning the highlift jack etc inside, intercooler connected up with the correct size piping , radiator connected up etc and all the other recovery gear ready to then start the rear cabin.

The exhaust is to go out over the roof and yes it will have one of those cute little flaps which lifts up. Im so excited about this.

After XMAS is the next best finish date now.