Pajero Mk1 Tourer build-up

[cruisn06]

Mag spread:

[cruisn06]

Well where to start, I have decided to put the wagon on jack stands for a bit to redo a few things. well a lot of things. since its not a daily driver any more I have more time to perfect my setup and wiring. haha.

I got the garage cleaned out today and ready for the rework to begin:





I just need to pick up a 5" grinder and a welder and I shall be good to go for all future projects.

so far on the list of rework:
All wiring - complete strip and redo
front sway bar couplings need fixing
replace all bent steering parts
redo fuel tank lines
replace all rubber brake lines


that is the small list so far. its much bigger. lol

started by removing my bumpers:
rear came off easy enough, half the bolts snapped as they had rusted. so that will require a rethink.


Front bumper, not so luck, the nuts have busted there tack welds on the inside of the frame rail so I cant actually get it off without a grinder. but that will be sorted soon enough.



But I did get the headlights and grill surround stripped and both batteries removed.




I know a lot are wondering why so much lvoe for this wagon, or why keep working on it. I guess I get attached to wagons. lol. this girl has got me across the country an some very cool places. and since nothing is interchangable with any other model I would lose heaps of coin starting on a new rig. and if I were to sell it, I would be lucky to get 1500 for it, due to dents (character) and small flaws ( more character) and it qwerks when trying to start it ( more character then even I can handle)

so tune in for the reworking of the wagon, should be good. few mods will be added, stuff that was pointless will be lost.

[cruisn06]

Alrighty, where to begin, basically I have been sitting here staring at my wagon, looking at ways to shave weight, reuibld this and that out of ally, blah blah blah, basically it came down to a vast amount of work. but one way to drop weight quickly is to cut the body in half. haha.

I have been tossing this idea around for about a year now, I would gain room, lose weight, and it would look awesome, well I hope.

Here is a photochop of the plan, the cab was made a bit short, it will have about 150mm added behind the b pillar. like a small extra cab, which will allow me to fit a 1700x1700x1000mm canopy in size. with the spare tyres hanging of the canopy it will come in at the same length, but will allow me to raise my rear fuel tank for a slightly better departure angle.




I did get some new tools to sort out the swap, including and air compressor, 200 amp ac/dc tig welder, and paint gun kit.

Found the design of tray/canopy I want. now to find someone to build it.

[cruisn06]

Well, today was a good day, I have gotten the whole interior stripped. My storage system had no fail points that i found while removing it which is good, but it was heavy. so it had to go.



Then I reinstalled the front seat and set it all the way back to find where I should be cutting it at. where the green line is allows me 50mm behind the seat at its current setting which is more than enough.



Here is the line down the whole side of the wagon.

[cruisn06]

Well, the chop has begun... I am committed, no backing out now. LOL

Pretty straight forward to chop, pulled all the wiring out. and dropped my second fuel tank to make the cut.

We started at about 1pm and had the back of the body sitting on the ground by 5. It would of been quicker, but there is a video that goes with this and filming takes a while to setup ad get the shots right.

A good day. mixed it with beer and a bbq too, a lot of fun was had. Many thanks to those who showed up to help

With all the doors pulled off:




Starting to mark it out:


I used plumb lines to line the cuts up. a bit tricky on slightly curved surfaces. but I had my 1m ruler to help make sure it was all straight and square.. this was a measure 8 times deal. haha



Time to cut:
photos coming soon

After the cut!!!







Nice straight cuts:


The sills and roof support:




The frame with the body off, it was very clean. impressed for a 90 model. haha.

[cruisn06]

Alrighty, time for that update with the cut photos I was talking about.

















And BAM its off




I am heading back to Canada for 4 weeks for vaca so for now... she sleeps

[cruisn06]

Jeez, I left you guys hanging. basically, I moved out of my rental and into a mates place and purchased a 40' container to work out of. here is an update of where I am at. plus just picked up a spare parts pajero yesterday.


had a good weekend, got electrical put in and everything has a home, well most of it.










All righty gentlemen, that is it, setup. now I have to get involved in a wedding for the next week or 2 then back into it. but dont worry its not me getting married. haahaha

Started sanding the corners down. a few bits will need a thin layer of filler, but warpage is really hard to avoid welding 0.9mm steel. I am quite happy with the look so far.



its also hot as hell out here, pushing 40's so due to fire bans and what not there will be a bit of a lack of updates.  as you can see the can is not overly shaded. haha



Bought a parts pajero today. diesel 5 speed. shes a donor for both my pajeros. its a shame to take her off the road, but she will keep two girls rolling for years.

[cruisn06]

Got the window hole cut, plasma worked a treat. will have the interior sorted in 2 days of fab work on my next break, then shes off to the paint shop.

[TinusK]

Love your thread - very interesting read. Keep us posted!

[peterpot]

Well done, keep the pics going. very interesting!