My latest mitsu build-up...

[off-roader]

1996 Mitsubishi Montero SR
Purchased $1350.
http://pics.montypics.com/off-roader/2009-01-10/1231645036_dsc_7469.jpg

1st Upgrade: 2" Body Lift from 4crawler.com
2nd Upgrade: 35x12.5x15 BFG MT KM2 tires
3rd Upgrade: Safari Snorkle
4th Upgrade: Jeep TJ aftermarket front & rear bumpers modified to fit
5th Upgrade: BVG Roof Rack
6th Upgrade: Stay tuned... more to come shortly.

Current condition...
http://pics.montypics.com/off-roader/2009-03-15/1237172311_snv10033s.jpg

[kcowyo]

Very nice! Factory locker?

.

[off-roader]

Very nice! Factory locker?
.

Yes. 94-96 SR's all came with a factory locker.

[kcowyo]

You off-roader on the Wire too?

Are we under invasion? :elkgrin:


Welcome to ExPo - :beer:


- KC
.

[off-roader]

You off-roader on the Wire too?

Are we under invasion? :elkgrin:


Welcome to ExPo - :beer:


- KC
.

LOL, not invasion... integration! :victory:

[DavidG]

How close are the mounting points on the TJ bumpers to matching up with the Montero frame horns?

[off-roader]

How close are the mounting points on the TJ bumpers to matching up with the Montero frame horns?

FRONT BUMPER
Not really close. The front bumper mounts completely differently with the mounting bolts running front to back into the Jeep frame while the monty mounts left to right into the frame.

My fabricator modified the front frame horns to beef them up and make them so I didn't need to modify the bumper to mount it. Since I also have a 2" body lift, he raised the mounts higher so the bumper doesn't rub on too much off road.

Here's a pic of the mount on one side...
http://pics.montypics.com/off-roader/2009-03-17/1237354181_snv10041s.jpg

You can see the bumper is bolted to the frame from the front. There are a total of 8 Grade 8.8 (metric) / 5 (SAE) 1/2" diameter bolts & corresponding nuts/washers attaching it. There are also four 5/8" bolts mounting the modified mount adapter to the frame rail.

REAR BUMPER
The rear bumper on a TJ mounts more like a Montero (bolts running left to right into the frame rails) however the rails on a Jeep are much wider. Again, with the body lift he simply made an adapter (w/out having to re-inforce the rear frame rail ends) to adapt the wider bumper mounts to the narrower frame rails. There are 4 grade 5 bolts (2 on each side) attaching the bumper to each adapter and 2 more grade 8.8 (metric) bolts attaching the adapters to the frame rails.

He also cut off ~4" off the end of the frame rail. This 4" is used for nothing more than supports for some bumpers however with US models the supports aren't even used for that so they are truly not needed (so we cut them off).

Here's a pic of the right rear adapter (black) mounted to the frame rail and bumper (in Mitsu Sudan Beige which looks kinda gold in the flash) attached to that adapter.
http://pics.montypics.com/off-roader/2009-03-17/1237354158_snv10040s.jpg

[DavidG]

Thanks for the pics and info. It looks great with those bumpers. I can't believe how cool your low-buck rig build is! Are you happy with the 35's and 4.63's? What are your impressions of the KM2?

[Momrocks]

I luva cool build on the cheap! Most of the classic, historic expeditions I'm interested in were accomplished using tried and true mods...most were relativily affordable. It's too easy to get lured by fashion & flash and think it takes buckets of money to explore or camp. Well done, I anticipate the next installments.

[off-roader]

Thanks for the pics and info. It looks great with those bumpers. I can't believe how cool your low-buck rig build is! Are you happy with the 35's and 4.63's? What are your impressions of the KM2?

Thanks for the compliments. Yes I really like the bumpers although I will be modifying them to allow me to mount a hilift up front.

I like the 35's. With 15x8 rims (3.75" offset) they fit perfectly with almost no rubbing but I'll let you know more on that after my initial trail run this weekend. I'll probably have to trim the rear inner part of the plastic fender extensions.

I'll also let you know how good the KM2's are in the dirt. I won't know about the rocks though since I'm still waiting on rocker panel protection and won't be doing any crawling on this trip.

As for 4.63's, I do notice the loss in power and will be upgrading to 4.90's but to be honest it's not that bad if you don't expect your montero to perform like a sedan. I do wish 5.29' were available but I don't think anyone has found a source for those at this point. Hopefully they exist somewhere. I'll also be upgrading the xcase to the 3:1 gears from australia.


I luva cool build on the cheap! Most of the classic, historic expeditions I'm interested in were accomplished using tried and true mods...most were relativily affordable. It's too easy to get lured by fashion & flash and think it takes buckets of money to explore or camp. Well done, I anticipate the next installments.

Thanks. Yes this will not be a 'bling' mobile. I have never really been interested in those kinds of upgrades. It's part of my personality I guess.
Also you have to consider this is the 3rd Montero I've built up and I know at this point what's required to do the kind of wheeling I do.

[Justice R]

Good to see you over here Ray. Lots of good information here. I think I'll follow suit with a build thread for my 89..

[off-roader]

Good to see you over here Ray. Lots of good information here. I think I'll follow suit with a build thread for my 89..

Nice to see you here as well Justice. I was just going to comment that it's nice to see your build thread as well before I realized you replied to my build thread.
:cool:

[4Rescue]

Awesome looking truck mate, I'm loving the new Mitsu section. Were these Pajero/Monty versions (I don't know what gen body that is, 2nd? 3rd?) EVER offered with manuals, and were there air lockers still offered stock??? Again, nice truck, glad to see these great trucks coming out in the spotlight.

Cheers

Dave

[off-roader]

Awesome looking truck mate, I'm loving the new Mitsu section. Were these Pajero/Monty versions (I don't know what gen body that is, 2nd? 3rd?) EVER offered with manuals, and were there air lockers still offered stock??? Again, nice truck, glad to see these great trucks coming out in the spotlight.

Cheers

Dave

Thanks for the compliments Dave. The square bodied mitsu montero/dodge raiders are consider gen I's. They were available from 1985/6 to 1991. Here's a pic my 89 v6 2 door (Gen I).
http://pics.montypics.com/off-roader/2008-08-25/1219733268_070505_pismobeach.jpg

The Gen II Montero's (never sold as a Dodge model) were available from 1992-1996.

The 1992-1993 models were only available with the 3.0L engine & I don't believe they were ever offered with a std trim package that included a stock locker but I could be wrong. Justice and Phil could probably set the record straight on that.

From 1994-1996 the SR models all came with a 3.5L DOHC engine, & larger rear diff with the factory air locker. The 94-96 RS or LS models came with the 3.0L engine a smaller rear diff (not sure about the front). These were not offered with a locker in the US.

The Gen 2.5 Montero's look almost identical to the gen II but has a more flared/pronounced front and rear fenders. If you find with with a cold weather option, it should include a rear locker.

The Gen I v6, Gen II 3.5L models both support the ARB RD110 front locker. The Gen I v6 also has available an ARB rear locker (forget the p/n).
So with either rig, you can easily (for a price) get front and rear lockers.

The Gen II's are offered with manual tranny's but I don't recall if they're available in the US. Mostly because I'm not interested in a manual tranny off road. 1st and foremost the auto tranny's in these are extremely reliable and most get 200K+ w/out even starting to think about a rebuild.

Plus they're simply ton's easier to use off road (especially rock crawling) since we don't have extremely low gears available w/out major mods (4.9 difs & 3:1 xcase is about it) for the Gen II. If we did have those gears then a manual tranny would make more sense and be much easier to drive.

[off-roader]

Installed a navigation computer today. It's the same Acer One I use in my Gen I. It comes w/ an 8GB SSD drive and an 8GB SD card (Class 6). I upgraded the card to a 16GB version and I run both NatGeo Topo CA (hi res topo maps) and MS Streets & Trips.
http://pics.montypics.com/off-roader/2009-03-21/1237688115_snv10049cr.jpg
http://pics.montypics.com/off-roader/2009-03-21/1237688148_sn10050cr.jpghttp://inlinethumb35.webshots.com/12194/2309803150104986527S600x600Q85.jpg

So far, so good!!
:smiley_drive:

[wesel123]

http://pics.montypics.com/off-roader/2009-03-21/1237688148_sn10050cr.jpg[/img]

So far, so good!!
:smiley_drive:


What did you make the mount out of??? Look great!!!

[off-roader]

What did you make the mount out of??? Look great!!!

It's simply 1/16" aluminum plate. I cut & bent it to fit. You also have to trim a bit of the dash that's underneath the gauges. It can't be seen though even if remove the mount. I can remove my gauge cover and take a pic if you need me to.

http://inlinethumb55.webshots.com/3318/2449143270104986527S600x600Q85.jpg

Took it out on it's virgin off road trip. Bumpy off camber hills. No issues whatsoever with the mount off road. On road it sometimes has a tendency to bounce due to road vibrations/oscillations.

[off-roader]

As part of my plan to set this rig up so I can also use it in lieu of a tent, I'm also making up a pair of window screens for the rear windows.

Here are a couple of pics of the one I've made so far...
http://inlinethumb36.webshots.com/43811/2921644660104986527S600x600Q85.jpg
http://inlinethumb31.webshots.com/24990/2396421400104986527S600x600Q85.jpg

It's simply a 'sock' that fits snugly over the window section of the rear doors. The only 'open' area where bugs might get in is at the bottom and I'm holding that in place using magnets. and the screen material is pretty bunched up there so bugs won't be able to get in even if they tried.:smiley_drive:

[datrupr]

I like the screen. Any plans for something similar on the rear sliding windows? That would help create some nice airflow in the back for camping.

[off-roader]

I like the screen. Any plans for something similar on the rear sliding windows? That would help create some nice airflow in the back for camping.

I could do something similar. The current unit's lower edges have a strip of nylon webbing material (same stuff they use for duffle bag straps) with magnets sewn in.

For the rear windows I could do the same setup except around the entire perimeter. Plus I wouldn't have to have power on to open/close those windows.

[Harald Hansen]

I like the bug screen "socks"! I think i will make some of my own for the Disco.

[journey]

Can you repost the pictures?

[off-roader]

Can you repost the pictures?

Which ones?

Unfortunately Montypics.com had a storage 'mishap' when they did a server upgrade and they weren't backing up their servers :mad: so all those pics were lost. I'm sure I have them somewhere in my system though and can put them up although this time ill be using webshots instead.

[journey]

All the pictures in the first couple of posts are gone. I was hoping to see the before and after pictures from the first post. Thanks

[off-roader]

All the pictures in the first couple of posts are gone. I was hoping to see the before and after pictures from the first post. Thanks

Well, I'll try and dig up a good before pic when she was a stock 96SR with 235/75R15's later today when I get home and add it to this post.

Here's an intermediate pic still running stock bumpers but I added...
- a 2" Body Lift
- 35x12.5R15's BFG MT KM2's
- Snorkel
http://inlinethumb17.webshots.com/19664/2765830080104986527S600x600Q85.jpg

Here's a current 'after' pic as she now sits...
- Jeep TJ front & rear bumpers w/ adapters. I can literally remove them and sell them to a jeep owner and he could bolt them right up :Wow1:
- Roof rack (mostly for looks)
- Anti-rollover mojo sticker :cool:.
http://inlinethumb14.webshots.com/44109/2417699320104986527S600x600Q85.jpg
http://inlinethumb54.webshots.com/13301/2602169460104986527S600x600Q85.jpg

Up next in the build process...
- 2" coil spring spacers to even out the rear (install)
- rocker panel skids (build & install)
- 3/16"-1/4" skid plates for the engine and tranny / xcase (build & install)
- winch w/ synthetic line (mod the bumper & install)
- rear storage compartment w/ ARB fridge (build & install)
:D

[journey]

Hey thanks for getting those pictures up. You have a great looking ride.

[Dolomiti]

Another nice looking rig, Ray.

[off-roader]

Had some liposuction done to my rear end at lunch.

Tools used & fat removed...
http://inlinethumb60.webshots.com/43707/2215144160104986527S600x600Q85.jpg
Pics of the doctor at work carefully making the incision
http://inlinethumb56.webshots.com/42551/2014927630104986527S600x600Q85.jpg
http://inlinethumb17.webshots.com/44496/2167574670104986527S600x600Q85.jpg
The incision from the inside...
http://inlinethumb43.webshots.com/43882/2722628100104986527S600x600Q85.jpg

After he showed me the way to do it, I did the right side of the truck. No pics of me doing it though cause all that really matters are...

the results!
http://inlinethumb03.webshots.com/45378/2499632490104986527S600x600Q85.jpg
http://inlinethumb22.webshots.com/30613/2084576260104986527S600x600Q85.jpg

Ran out of time though. Will fill the resultant cavities with expanding foam tomorrow. :kewl:

[off-roader]

Update: Mounted my trusty 60" HiLift to the roof rack with a $1.50 worth of Yakima mounts... Have had it this way for almost a month and I haven't heard a peep out of it up there. The nice part is it's nice and secure and if it does happen to come off, it will fall into the rack basket.

You can see there's a piece of white bungie (small ~1/8" thick cord) holding the handle to the hilift body... actually works and it doesn't make a single sound up there even on the rough stuff!
http://inlinethumb29.webshots.com/44444/2097751290104986527S600x600Q85.jpg (http://rides.webshots.com/photo/2097751290104986527abHswC)

You can see a better view of the bungie cord.
http://inlinethumb17.webshots.com/45008/2868434530104986527S600x600Q85.jpg (http://rides.webshots.com/photo/2868434530104986527IitJlh)

Here's the forward mount wrapped around the rack and bolted through one of the hilift's holes...
http://inlinethumb09.webshots.com/43464/2994153250104986527S600x600Q85.jpg (http://rides.webshots.com/photo/2994153250104986527fAqQRB)

Here's the aft mount.
http://inlinethumb57.webshots.com/44664/2415882300104986527S600x600Q85.jpg (http://rides.webshots.com/photo/2415882300104986527PrOLZp)

[Sock Puppet]

Looks great! As a former'92 owner I'll keep an eye on your progress.

[off-roader]

Thanks. This is my 1st Gen II although I've owned 3 gen I's. The first I rolled off road, the 2nd a :sombrero:good friend has and is rebuilding, the 3rd I still have along with this SR.

[LaOutbackTrail]

Any updates to this fine looking rig?

[off-roader]

Any updates to this fine looking rig?

Thanks for the compliment. I'll be installing rock sliders and winch in the coming weeks. Will post pics as it happens.

[LaOutbackTrail]

So, Off-Roader, how do you feel about the driving stability with the lift and larger tires especially over the stock or near stock setup? I'm really considering these G2 Monteros to build. Out of the ordinary, good reliability, well set up from factory, all the right parts are available, and trucks look good!

Do you think an interior roll cage could be easily implemented? At least to behind the driver's seat, but it looks like going through the dash would be possible also..... Anyways, my main concern with these trucks is roll over safety, mainly at HWY speeds.

Ever pull a trailer with yours? Do you have an online source for all of your photos?

[off-roader]

So, Off-Roader, how do you feel about the driving stability with the lift and larger tires especially over the stock or near stock setup? I'm really considering these G2 Monteros to build. Out of the ordinary, good reliability, well set up from factory, all the right parts are available, and trucks look good!

Do you think an interior roll cage could be easily implemented? At least to behind the driver's seat, but it looks like going through the dash would be possible also..... Anyways, my main concern with these trucks is roll over safety, mainly at HWY speeds.

Ever pull a trailer with yours? Do you have an online source for all of your photos?

This is my 4th Montero so my opinion about them would be a bit biased.:Wow1::smiley_drive:
Out of the box, I'd say the Gen I and Gen II models are easily on par with similar year Toys (LC not 4runner) and definitely better out of the box than a similarly equipped Trooper.

The biggest problem for Mitsu's are the availability of aftermarket suppliers but for most upgrades, there are parts available. Front & rear lockers, rock sliders, front bumpers, etc.

There are 3 distinct generations that were sold in the US (I'm assuming you're in N. America).
Gen I: 84-91
Gen II: 92-00
Gen III: 01-06

Later models are still being built but are no longer imported here.

As for an internal roll cage, it can be implemented depending on your fabrication skills.

You can minimize highway rollovers by changing the way you drive... that is being a 'defensive driver' and keeping the speeds lower, compensating for longer braking times, and generally not driving it like it were a car.

In my gen I Montero's, I've removed the rear anti-sway bars and never had an issue with a possible roll-over because I drive the way I do.

No, I don't pull a trailer nor have I ever pulled one with any of the 4 I've owned. Obviously you should always endeavor to only pull as much as the rig is safely rated for but that said, I know many that have pulled trailers far heavier than what the Mitsu was rated for and done so for brief stints without problems.

Keep in mind like any vehicle, ensuring it's in tip top shape with fresh fluids and a properly working cooling system is paramount to 'pulling' success.

I have a some pics on Webshots of my current 2 rigs (where the pics on this thread come from) and you can probably see them by simply poking around their site. Unfortunately I don't have too many digital copies of my 2nd rig, and absolutely none of my first rig.

[LaOutbackTrail]

Thanks for the info!

Yeah, I am definitely looking at the Gen 2 truck. As far as driving, I drove my lifted Xterra like a granny and am ok with that. I now drive a first gen 4runner with the 22RE = slow. I understand the concept of driving slower in an SUV. :victory:

If I got one of these trucks it'd likely be built similar to yours or with 33s and OME lift. I'm thinking wider tires would go a long way in stability. Probably go with ARB bumper up front and leave the rear bumper as it is. They just seem to be the right truck, for me, and I like you assessment for it being on par with the Land Cruisers. Thats what I've been considering, but the poor fuel economy from the LCs are a big turn off and the Rover's reliability have left a bad taste in my mouth... not from personal experience, but the overwhelming reputation.

I'm wanting a larger vehicle for overland trips, but one that is still capable of class 3- 3.5 trails. Which will require locker, sliders, etc. of course.

I've got a 3 year old and we're planning another pretty soon, so I'd prefer a bit of safety, I think an interior cage would be add peace of mind. I'd like one for my 4Runner as well.

[off-roader]

Installed Hella 700FF driving lights over the weekend. At $79 for a pair and based on their venerable low cost cousins the Hella 500's, I felt the 700's would be reliable and provide just the amount of light required for my trips off road.

I mounted the lights on my bumper's upper mount tabs. Here you can just see the zip ties that hold the wires to the bumper on the driver side.
http://inlinethumb39.webshots.com/45862/2025587900104986527S600x600Q85.jpg

I figured one of the hardest parts would be to wire the switch into the inside of the rig.

Where I was supposed to drive a hole to get the wires in from the engine bay into the cabin was I was most concerned with since I hate drilling new holes into the firewall where you cannot undo them. Fortunately I found a pre-existing hole underneath to the left of the brake pedal. Good thing I found it prior to running a trail with a deep water crossing such as Fordyce, etc.!
http://inlinethumb33.webshots.com/46624/2372643160104986527S600x600Q85.jpg

The gray / off white stuff you can see around the entry to the cabin is putty I put there to minimize water intrusion.

Here's what is looks like underneath after I completed the application of that putty and put the carpet back where it belongs...
http://inlinethumb17.webshots.com/43856/2665246970104986527S600x600Q85.jpg

I mounted the round green switch in one of the available switch locations in the center console. This was accomplished with the help of a Dremel tool.
http://inlinethumb11.webshots.com/47498/2731138300104986527S600x600Q85.jpg

Per Grasscat's suggestion & prompting, I also added an extra 12V socket on the right there which I tested with my CB.

Below you can see the round relay mounted to the body via it's holder next to the radiator bracket and near the battery on the right are 2 new fuse holders/fuses (one is for the driving lights and one for the new 12v socket).
http://inlinethumb04.webshots.com/45891/2901268850104986527S600x600Q85.jpg

[Ford Prefect]

Wow, this is a great little thread. You have done a lot of really cool stuff to this truck. I did not know you could pick one up for such a good price too. Very cool.



I've got a 3 year old and we're planning another pretty soon, so I'd prefer a bit of safety, I think an interior cage would be add peace of mind. I'd like one for my 4Runner as well.

One thing for you to consider, (and if you already knew this, sorry for the refresher...)and I am not saying that a roll cage is a bad idea, but you need to be sure you realize it will change the way the vehicle handles. By that I mean... Your rig, if t were outfitted exactly like another rig, same model and everything, but yours has the interior cage... Your rig would roll over sooner than the other one. Any cage worth its salt is going to put a lot of extra weight up high, and if you want one meant to protect you at highway speeds then that would put even more metal up high, and further increase your COG.

just a thought for you to keep in mind when you are driving the thing. :)

[off-roader]

Thanks for the info!

Yeah, I am definitely looking at the Gen 2 truck...

Thats what I've been considering, but the poor fuel economy from the LCs are a big turn off and the Rover's reliability have left a bad taste in my mouth...

I'm wanting a larger vehicle for overland trips, but one that is still capable of class 3- 3.5 trails. Which will require locker, sliders, etc. of course.

I've got a 3 year old and we're planning another pretty soon, so I'd prefer a bit of safety, I think an interior cage would be add peace of mind. I'd like one for my 4Runner as well.

I like this specific model because it has a locking rear solid axle and for my wheeling needs this is preferable. However others prefer the comfort of an IFS/IRS design found in the newer 2001+ models. Mine also has a relatively powerful 3.5L dohc engine (214HP) and I know enough folks who have modified moderately & they're now capable of running nearly any difficult 4x4 trail (up to say Fordyce, Dusy Ersham, Rubicon, etc.).

What it's not is a rock buggy capable of doing the Hammers, etc.

As for the fuel economy, I'm getting 12-16mpg with my 35's. I'm sure that will drop some once I install my rock sliders and winch up front and even further still once I re-inforce or upgrade my skid plates.

As for the internal roll cage, it can be done but as has been mentioned it will raise your COG making your rig even more unstable and IMHO should only be done if you're regularly doing the +4 trails like The Dusy, etc. (scale of 1-5 excluding the new class of extreme trails used by rock buggies).

HTH.

[bobDog]

Check out the window and sightout screens on Svens new ride on http://www.xxxpedition.com He has em inside and they seem to work out great.:sombrero: Nice site to visit, lots of stuff including trips all over the world.

[off-roader]

Check out the window and sightout screens on Svens new ride on http://www.xxxpedition.com

Nice. I also considered simply using Velcro to secure them but decided I didn't want to modify the interior that way plus it does get pretty hot in the summer time and I'd hate to learn the hard way that they velcro adhesive wasn't able to handle the heat.

I'll probably stick with the magnet idea for now.

[off-roader]

More mod's on the way...
Things on the table currently include...
1) Installing the rockskids (AKA rocker panel armor)
2) Modifying my bumper and installing the Milemarker SEC-12000 winch.
3) Installing these (sorry in advance for the porn below).:Wow1::Wow1:
A buddy found a set at a local pick and pull. I refurbishing them today with my friend Mike's help.
http://inlinethumb40.webshots.com/46439/2247020130104986527S600x600Q85.jpg
http://inlinethumb61.webshots.com/27452/2951666300104986527S600x600Q85.jpg
http://inlinethumb52.webshots.com/40179/2638110220104986527S600x600Q85.jpg
http://inlinethumb18.webshots.com/44625/2028467580104986527S600x600Q85.jpg

[nwoods]

The Gen II Montero's (never sold as a Dodge model) were available from 1992-1996.

The 1992-1993 models were only available with the 3.0L engine & I don't believe they were ever offered with a std trim package that included a stock locker but I could be wrong.

The Gen II's are offered with manual tranny's but I don't recall if they're available in the US.

I don't know if my old Montero was unique, but it was a `92 LS with the 3.0L motor, 5 speed manual transmission, and factory rear locker. We loved it. This was back when we only visited Forest Service car camping sites and the occassional easy trail, but the Monty was always solid for us. We just simply outgrew it.

http://www.woodsfamily.cc/old/West/2004/mammoth/offroad/images/offroad-09.jpg

[off-roader]

I don't know if my old Montero was unique, but it was a `92 LS with the 3.0L motor, 5 speed manual transmission, and factory rear locker. We loved it. This was back when we only visited Forest Service car camping sites and the occassional easy trail, but the Monty was always solid for us. We just simply outgrew it.

Guess it wasn't unique. Does it have the large 9.5" diff or the smaller 8" diff?

As for outgrowing it... so you're now growing into that Jeep?!?:Wow1::sombrero:

[tdesanto]

The '92 had a 9" ring gear in the rear axle.

It breaks down like this for the rear axles:

83-86: 8" RG
87-95 9" RG
93-00 (if you had the 3.5L or the 2.8 TDI) 9.5" RG
2000-present 9.5" RG IRS suspension

The 9" ring gear is nothing to sneeze at. Even the Tacoma, Tundra, T100, and FJ Cruiser have an 8" RG.

[irsa76]

More mod's on the way...
Things on the table currently include...
1) Installing the rockskids (AKA rocker panel armor)
2) Modifying my bumper and installing the Milemarker SEC-12000 winch.
3) Installing these (sorry in advance for the porn below).:Wow1::Wow1:
A buddy found a set at a local pick and pull. I refurbishing them today with my friend Mike's help.
http://inlinethumb40.webshots.com/46439/2247020130104986527S600x600Q85.jpg
http://inlinethumb61.webshots.com/27452/2951666300104986527S600x600Q85.jpg
http://inlinethumb52.webshots.com/40179/2638110220104986527S600x600Q85.jpg
http://inlinethumb18.webshots.com/44625/2028467580104986527S600x600Q85.jpg

I might have missed something, doesn't your monty have superselect? If so why are you installing free wheeling hubs, AU spec Pajeros with superselect ran solid front hubs, no free wheeling hubs. Dad had the manual hubs on his '94 Turbo diesel base Pajero and had one grenade it's self.

[nwoods]

As for outgrowing it... so you're now growing into that Jeep?!?:Wow1::sombrero:

Too be honest, we don't fit in the Jeep either. We physically fit (unlike the Montero), but it does not adequately hold the "comfort gear" that my family likes to camp with. Full size Coleman stove, large sleeping pads, real pillows, relatively bulky sleeping bags, etc... Fitting four people, plus their gear for a camping trip is really not possible unless you use hiking gear, and we don't. I miss my LR3 every single day.

[off-roader]

I might have missed something, doesn't your monty have superselect? If so why are you installing free wheeling hubs, AU spec Pajeros with superselect ran solid front hubs, no free wheeling hubs. Dad had the manual hubs on his '94 Turbo diesel base Pajero and had one grenade it's self.

It has a central axle disconnect but that means the entire front driveline (axles, cv's, etc.) still turns even when in 2WD.

With the manual hubs, I can truly disconnect the front axles from the hubs allowing the wheels to turn without also turning the front axles thereby reducing the wear.

[off-roader]

It has a central axle disconnect but that means the entire front driveline (axles, cv's, etc.) still turns even when in 2WD.

With the manual hubs, I can truly disconnect the front axles from the hubs allowing the wheels to turn without also turning the front axles thereby reducing the wear.

Are you saying the Gen II Montero has less passenger area than a Jeep?:Wow1:

[montypower]

Your truck is looking great! :)

What type of truck were those hubs off of? Are they the same as the Toyota trucks?

What do you think about 33s vs 35s? Rubbing issues with body lift? Drive-ability? Performance?

[off-roader]

Your truck is looking great! :)

What type of truck were those hubs off of? Are they the same as the Toyota trucks?

What do you think about 33s vs 35s? Rubbing issues with body lift? Drive-ability? Performance?

Montypower, sorry about the late reply. Never saw your response until today.

The hubs are off early Mitsu 4x4 pickups. No they are not the same as the Aisin used on a Toyota truck. Some parts are interchangeable however.

I wanted the extra inch of clearance with the 35's and IMHO they simply look proper for this rig.

No real issues with rubbing once you either trim or remove the plastic rocker panel cover.

On road performance is of course reduced simply due to the gearing limitations. I'll eventually be swapping in a pair of 4.9x r&p's and will post up results then. Should bring the gearing back closer to running a pair of 33's instead of the stock 31's.

[tdesanto]

Too be honest, we don't fit in the Jeep either. We physically fit (unlike the Montero), but it does not adequately hold the "comfort gear" that my family likes to camp with. Full size Coleman stove, large sleeping pads, real pillows, relatively bulky sleeping bags, etc... Fitting four people, plus their gear for a camping trip is really not possible unless you use hiking gear, and we don't. I miss my LR3 every single day.


Are you saying the Gen II Montero has less passenger area than a Jeep?:Wow1:

Yeah, I didn't get that either. The new JK 4-door might have a slight amount more than the gen II Monteros, but definitely not more than a gen III.

[nwoods]

Sorry, I missed Off Roaders origional response. When I said "physically fit", I was referring to the passenger cabin, not cargo space. I'm abundantly sized, and my wife is also quite tall, thus my kids are all tall and lanky. We just dont fit in the seats comfortably. Add in gear and kid stuff, and we don't fit. There is absolutely more room in the Monteros cargo area than any Wrangler based Jeep platform :-)

[nwoods]

Sorry, I missed Off Roaders origional response. When I said "physically fit", I was referring to the passenger cabin, not cargo space. I'm abundantly sized, and my wife is also quite tall, thus my kids are all tall and lanky. We just dont fit in the seats comfortably. Add in gear and kid stuff, and we don't fit. There is absolutely more room in the Monteros cargo area than any Wrangler based Jeep platform :-)

The Woods Family Adventuremobile, a long time ago:
http://nwoods.smugmug.com/Family/camping/camp-26/936482457_MEWty-XL.jpg

[off-roader]

I'm abundantly sized, and my wife is also quite tall, thus my kids are all tall and lanky. We just dont fit in the seats comfortably.

Ah, ok. A friend of mine is well over 6' (6'8" or maybe taller) drove a 2nd gen Montero and he moved the driver seat back 2" by simply remounting it. But with 4 tall passengers, I can see that being a problem for sure.

[LaOutbackTrail]

Dumb question. Do these trucks have cup holders?????

[LaOutbackTrail]

Since Ray blatantly disregards posting pics of his truck...
http://lh3.ggpht.com/_VENBNvs8sok/Sta11YlXf3I/AAAAAAAAAFM/JN1IPrGRGl0/s720/RSP0443.jpg
http://lh3.ggpht.com/_VENBNvs8sok/Sta0nKtI9LI/AAAAAAAAADs/i8LFDtT701k/s720/RSP0397.jpg
http://lh5.ggpht.com/_VENBNvs8sok/Sta3hYj5SlI/AAAAAAAAAIw/nM_rRRutMqQ/s720/RSP0614.jpg

[LaOutbackTrail]

The perpetual lack of articulation these trucks have is amazing.
http://i171.photobucket.com/albums/u296/Blossom2468/20091009Mojave4x4Wire/7d840566.jpg

[speedtre]

Dumb question. Do these trucks have cup holders?????

Not a dumb question, cause I want to know where they are hiding on my new to me '99 Montero. I find it hard to believe an upscale SUV (which is what this full size Montero was when in '99) did NOT come with cup holders....but apparently that is the case...or I'm just retarded and can't find them, which is just as likely.... :D

[off-roader]

Since Ray blatantly disregards posting pics of his truck...
LOL, yup.:bike_rider:


The perpetual lack of articulation these trucks have is amazing.

It is IFS up front, & my torsion bars are torqued up so lack of articulation there is expected. Locker in back helps tremendously though. It does articulate nicely in back where it's a solid axle though. :-)
:victory:

[off-roader]

Not a dumb question, cause I want to know where they are hiding on my new to me '99 Montero. I find it hard to believe an upscale SUV (which is what this full size Montero was when in '99) did NOT come with cup holders....but apparently that is the case...or I'm just retarded and can't find them, which is just as likely.... :D

Yup you're retarded ;-).

In mine there are 2 in the center console under the cover. In the gen 2.5 (98-2000) I've been in (grasscat's) they are also in the center console but iirc they retract into the console. Yours may be different since his is a 98.

[speedtre]

Yup you're retarded ;-).

In mine there are 2 in the center console under the cover. In the gen 2.5 (98-2000) I've been in (grasscat's) they are also in the center console but iirc they retract into the console. Yours may be different since his is a 98.

LOL....I knew there was a good chance of that! I'm going to have another look at it, but I've been all over my center console, inside and out and not seen them...now where is that retard smiley face....this will have to do...:drool:

[off-roader]

LOL....I knew there was a good chance of that! I'm going to have another look at it, but I've been all over my center console, inside and out and not seen them...now where is that retard smiley face....this will have to do...:drool:
LOL, there's still a good chance you're right and they changed the console from 98 to 99.

[LaOutbackTrail]

You did go with a 35 12.50 15 tire, correct? I have been considering the options of doing this sort of build up. But, I've been warned by a couple of folks about the instability, too much on hwy flex, and load range of the 35x12.50x15s.... It didnt dawn on me until this morning that the 315 75 R16s would give me the height I would like, but also the load, less flexible side wall and likely better hwy handling behavior. But the price sucks.

So why did I post this here? I was wondering your real world experience with the 35 12.50 15s and your actual thoughts of them mounted on the Monty?

[off-roader]

You did go with a 35 12.50 15 tire, correct? I have been considering the options of doing this sort of build up. But, I've been warned by a couple of folks about the instability, too much on hwy flex, and load range of the 35x12.50x15s.... It didnt dawn on me until this morning that the 315 75 R16s would give me the height I would like, but also the load, less flexible side wall and likely better hwy handling behavior. But the price sucks.

So why did I post this here? I was wondering your real world experience with the 35 12.50 15s and your actual thoughts of them mounted on the Monty?

Love em other than the obvious noise of the MT's over say a basic truck tire or even an AT tire. I found I do have uneven wear causing 90% of the noise. I need to replace parts of the steering system for excessive play in them. This should cure most of the uneven wear and therefore most of the tire noise. Overall, the extra noise doesn't bother me really. Without the uneven wear, the noise is VERY acceptable.

In my experience when compared to most built 4x4's and even most stock pickups, the ride is comfortably plush.

Also, I'm not running the tire pressure at 32PSI as some 4x4 owners do. I'm closer to somewhere between 26-28psi (depending on what's in it). Being a 4 ply side wall tire, it's more than capable of handling a 2 ton load at that pressure and the tread wear is much more even. At 32 PSI, only the center tread area wears. HTH.

[LaOutbackTrail]

Would you consider putting a roof top tent on your montero? It seems as if my wife is sold and a trailer is not optional for my upcoming trip...

[off-roader]

Would you consider putting a roof top tent on your montero? It seems as if my wife is sold and a trailer is not optional for my upcoming trip...

Nope. too much drag. I'm happy w/ 15mpg and my 35's. It would probably drop to 12mpg with that on the roof.

[speedtre]

LOL, there's still a good chance you're right and they changed the console from 98 to 99.


Well the good news is I found the cup holder, the bad news in the side on the passenger is busted. :)

[LaOutbackTrail]

Nope. too much drag. I'm happy w/ 15mpg and my 35's. It would probably drop to 12mpg with that on the roof.

I would be less concerned about drag and more about the extreme top-heaviness of the RTT being up there. But, Drag is a good point. I'm hoping to find an Autohomeus type that is more aerodynamic anyways... if i can find one for decent price that is.

[off-roader]

I would be less concerned about drag and more about the extreme top-heaviness of the RTT being up there.

Also a very good point and more critical than drag for sure.

[off-roader]

Well, finally got around to updatting this thread with some old upgrades I did but never got on here.

I wanted to add secure storage in back. Folks have suggested building drawers or some kind of cabinet design but I've gone that route before and was not keen on the added weight it brings so this time I elected to have my design go on a bit of a diet...

Here's my setup...
http://i405.photobucket.com/albums/pp137/offroader_ii/DSC_4576.gif
For my needs I had just a few design criteria when my buddy (Michael aka Grasscat on here) and I designed & created a storage system for my 1996 Montero...

1) The solution had to be relatively light. As I've noted, I've built a few full blown drawer systems which I felt are simply too bulky and heavy for the benefit they provide. I wanted it to be lighter but also 'heavy-duty enough' a design to carry what I needed for a typical 3-7 day 4x4 trip on even the harshest rock crawling trips including an ARB Freezer fridge.
2) Platform would double as a bed.
3) I wanted to have full use of my middle row seating as required for family outings or airport runs LOL.
4) I decided to use simple sealed under bed plastic tubs.
5) And most importantly keep the design as simple as possible.

I first removed my 3rd row seats & folded the 2nd row seats forward (flat).
I then installed a platform cut to size across the entire rear half of the Montero. I used 2 sheets of 4'x4'x1/2" thick plywood for the platform. One of my idea's was to retain the ability to use the 2nd row seats since this is sometimes my daily driver. I also wanted to be able to store my ARB Freezer fridge securely on the platform hence the use of the U-Bolts in the animated gif above (they momentarily pop up out of the platform in the image above).

Here's a pic of the setup sans ARB fridge.
http://inlinethumb38.webshots.com/45157/2635157300104986527S600x600Q85.jpg (http://rides.webshots.com/photo/2635157300104986527RyEOxi)

Image Notes:
(A) 2 hinges to fold the platform up and back to allow use of 2nd row seats. I still need to trim 2 corners of the folding section at this hinge because I didn't take into account the curvature of the side of the Montero. Currently the platform will not fold back until I trim a 1x6" triangle off those corners.
(B) beefy 5/16" dia metal (U-Bolt) "handles" are used for strap points for my ARB Freezer Fridge. Worked great off road BTW!
(C) The platform itself is 1/2" plywood that's 73"x53" which is large enough for 2 of us to sleep on.
(D) This is the 1x2" hardwood cross bracing.
(E) Here you can see the 2x4's being used to support the sides of the platform. They're mounted to the OE mounting points for the 3rd row seats via 1/8" aluminum angle iron. I need to use larger more aggressive screws for attaching the 2x4 mounts to the aluminum angle iron. The small 1/8" dia. screws I used were simply not up to task. I'll use 1/4" fasteners this time.
(F) This is the 1/4 dia. carriage bolt
(G) Here you can see 4 of the 6 Rubbermaid tubs I elected to use. Dimensions are 16.7x13.3x5.3" (x4) and 29x18x6 (x2). I also added 1/2x3/8" door seal gasket foam to the perimeter of the covers to better seal the tubs.
(H) This is one of 4 turnbuckles
(I) Here's the 3" ID PVC pipe cut to size and placed at each of the turnbuckle mount points.
(J) Here's the 'J' bolt end attached to the built in strap points in the floor of the Montero.

That's about it! Very simple design yet extremely effective. Can be completed in a day or quicker with a buddy's help. Better yet, get your buddy to do the whole project for you. That's what I did. :o Well truth be known, I was simply swamped with work and I'm sure the GrassCat was just itching for a project. LOL! Thanks again GrassCat!!

Oh, before I forget, GrassCat did mention that this is a patent pending design. ;)

[LaOutbackTrail]

Anything new, Ray?

[off-roader]

Anything new, Ray?

Yup!

Installed 2" coil spring spacers from daystar (made for a toyota sequoia but fits a gen II Montero perfectly) and removed the anti-sway bars. :Wow1:

Link to that mod thread... http://www.expeditionportal.com/forum/threads/62133-Coil-Spring-Spacer-Install-amp-anti-sway-bar-removal-(96SR-Montero (http://www.expeditionportal.com/forum/threads/62133-Coil-Spring-Spacer-Install-amp-anti-sway-bar-removal-%2896SR-Montero))

[4D55 Performance]

Do these spacer fit the first gens as well?

[off-roader]

Do these spacer fit the first gens as well?
It's very likely since the gen I & gen II coil springs are almost the same in diameter. Assuming they are then it should also fit into the spacer. Will the spacer fit into the spring perches on the gen I? That I don't know. If the spring perch is like the gen II's then yes. I can check later this evening on my Gen I if it looks the same.:smiley_drive:

[off-roader]

Well, the winch is now mounted:sombrero:.
68394

Details on the mounting process here...
http://www.expeditionportal.com/forum/threads/65350-Non-winch-bumper-modified...-winch-mounted.?p=935429#post935429

[off-roader]

A few updates I've been meaning to post up...
June 26, 2010: Raised the fuel tank mounts +3" and mounted up a new fuel tank sans brush plate since I'll be fabbing up a new beefier skid plate in its place.
July 1, 2010: Timing Belt, Pulleys, Tensioner, Front Seal, etc. changed (preventative maintenance).
July 15, 2010: Installed Trail-Gear Rock Sliders.
July 23, 2010: Installed Baja Rack Jerry Can Holders on my non-Baja Rack (modified to fit).
November 13, 2010: Replaced faulty ignition switch.
November 17, 2010: Replaced faulty brake pedal switch.
May 22, 2011: Installed coil spring spacers & removed anti-sway bars.
August 10, 2011: Upgraded bumper with custom winch plate and installed MileMarker SEC12000 electric winch.
August 17, 2011: Installed custom ipad mounting plate for RAM ipad mount along with a Dual xgps150 ipad compatible bluetooth gps.

[scrubber3]

Digging the build... You have given me many ideas!

[LaOutbackTrail]

Hey Ray, I'd be interested to see some pics/info about raising the gas tank... :smiley_drive:

[off-roader]

Hey Ray, I'd be interested to see some pics/info about raising the gas tank... :smiley_drive:

Here you go... http://rides.webshots.com/album/578024022oLOdVJ

It took ALL DAY to do two tanks. My 96 SR's and a 98...

[LaOutbackTrail]

Awesome. Thanks.
Looking at installing a 1.5"-2" body lift this winter and doing this modification.

[off-roader]

Not sure if it can be done with just a 1.5" lift but I haven't verified that. May be safer to just do the 2" lift plus you'll also have more room to access the pump via the access panel should you need to.

[LaOutbackTrail]

You lifted fuel tank ~3" with 2"BL. I'd imagine I'd be able to lift the tank 2.5 inches with a 1.5"BL... but of course I haven't looked at it that hard. I'll likely keep the 33s but may up to 35s in about 30k miles. :smiley_drive:

[off-roader]

The reason it's 3" is because you mount the rear mounts on the 'top' of the rear crossmember. It can't be just be 2.5" because of the diameter of said crossmember.

[LaOutbackTrail]

Aha. My inference was from looking at the pics. Thanks. 2" is the same price as 1.5" anyways.:coffeedrink:

[off-roader]

Yeah I just looked underneath the back end on the gas fill tube side (remember, my fenders under there were cut shorter) to double-check the spacing and it appears there is ~1/2" (maybe 9/16-5/8") of space between the floor and the tank on my rig with a 2" BL. It may work with 1.5" but I don't know who's done one like that. Be my guess to try it out.

Keep in mind that 4crawler (whom I assume you're buying your lift from) probably won't buy back the lift kit once you've installed it since he can't sell it as new but you can always ask.:)

[LaOutbackTrail]

I'll likely go with the 2" just to be "safe". I'll tell my wife its the only one available. :elkgrin:

[LaOutbackTrail]

Ray, do you recall the specs on your wheels? Width and backspacing?

[off-roader]

I cant say how they fit a gen II with the stock bumpers so bear that in mind with all my comments below.

I've actually run 3 sets of wheels on this rig.

The recently purchased wheels are 15x10's with a -44mm offset. They rub a lot with 35x12.5's. I didn't realize how badly they rubbed when I first bought them but even after buying them, I will simply swap my 35's from these over to my old 15x8 rims (4" backspacking / neutral offset) then run a set of 33x10's on the new rims.

The 15x8's w/ a neutral offset (4" of backspacing) and 33x12.5's should fit with only the most minor rubbing if any at all.

With 35x12.5 BFG MT KM2's and my old enkei 15x8.5" rims and 3 3/8" of backspacing I got tire rubbing in the outer rear area of the front wheel well's plastic inner fender liner whenever the wheel was at almost full lock. Eventually the plastic areas of the inner fender that contacted the tire rubbed away so almost all the rubbing disappeared except under the tightest slow turns and when turning off road while the front tires articulated.

Also in the rear wheel wells your 35's will rub the plastic rocker panel covers. Mine eventually came off from the abuse although I will eventually trim the rear part back and re-install them.

[scrubber3]

Anything new Ray? I know you've done something...:elkgrin:

[off-roader]

I did add new 15x10" wheels. You can see them in my trip thread from my New Year's Hangover Avoidance trip to S. Cal.

I have done some maintenance work (replaced fan & fan clutch, etc.) but that's not a 'build' item.

Upgraded from the stock plastic snorkel grill to a metal one from Expedition exchange but that's not a big deal.

There are some upgrades that I'll be buying in Australia and some I already have but still need to install but I'll wait to finish them before I post any more details..

:Mechanic:

[LaOutbackTrail]

Mr. Ray,

Would you mind revisiting this write up? http://www.4x4wire.com/forums/showflat.php?Cat=&Number=1143789&page=0&view=collapsed&sb=5&o=2&fpart=1#Post1143828

What are your long term impressions with this kit?

Could you post the pics of the install?

Thanks!

[off-roader]

Mr. Ray,

Would you mind revisiting this write up? http://www.4x4wire.com/forums/showflat.php?Cat=&Number=1143789&page=0&view=collapsed&sb=5&o=2&fpart=1#Post1143828

What are your long term impressions with this kit?

Could you post the pics of the install?

Thanks!

Which kit? The snorkel or the bumper?

[LaOutbackTrail]

Sorry, the snorkel.

[off-roader]

Sorry, the snorkel.

The snorkel has been great. No issues whatsoever. Definitely worth it IMHO. I'll have to track down the install pics later once I'm back home from work.

[off-roader]

Swapped in Euro-spec tail lights so I now have reverse lights. With my aftermarket rear bumper swap, my new bumpers did not have a spot to mount the OE Mitsu reverse lights. They normally are mounted in the stock bumper.

You can read about the light install here... http://www.expeditionportal.com/forum/threads/81352-My-96SR-w-aftermarket-bumper-has-reverse-lights-now-Euro-Tail-Lamps-installed?p=1150562#post1150562

[off-roader]

Latest update...
(1) Master-Pull 3/8" winch line installed. :)
115287

(2) Method Double Standard rims and BFG AT 33's.
115288

[LaOutbackTrail]

Nice looking wheels, how about a shot of the whole truck?

[zukrider]

why 33's? you down sizing in whole, or just dropping for mileage?

[eurosonic]

Ooooh I like the wheels.

[off-roader]

Nice looking wheels, how about a shot of the whole truck?
Will do... Tomorrow when I get a chance. Was out and about all day.

why 33's? you down sizing in whole, or just dropping for mileage?
To increase mileage, reduce tire costs, & ease up stress on the entire drivetrain... Sort of in that order...

Ooooh I like the wheels.
Yeah I like them a lot. :)

[GrassCat]

why 33's? you down sizing in whole, or just dropping for mileage?

Street tires.

[off-roader]

Pic of full rig as promised (brightness adjusted to show the rims LOL)..115761
Rig looks smaller with these rims IMHO but they are street tires after all...

[LaOutbackTrail]

Looks pretty good. Post up more info on the wheels when you get a chance, please.

[off-roader]

15x8 Method Double Standard rims. Dont recall the back spacing/offset but theres only one 15x8 size available from them. http://www.methodracewheels.com
Price At America's Tire / Discount Tire was $140.00 ea when I purchased 5 rims and tires.

[LaOutbackTrail]

Have you noticed any difference in capability with the 33s?

[off-roader]

I haven't wheeled it with the 33's at all. Pretty much nothing more than street tires although the ride is a bunch smoother and quieter LOL.

[mapper]

Love the build and all the information you have offered in threads throughout this forum. Quick question; With you sleeping/cargo platform, which is awesome, what is the height of the space above and below the platform? and, to go with that, does your truck have a sunroof?

I'm looking at Monties but would be downsizing from an AWD Astro so I'm trying to see how functional I can make the space.

Thanks!

[off-roader]

Just a minor cosmetic update... Removed both the aftermarket roof rack as well as the OEM roof rack today. Looks nice this way... I may keep it and only put my rack on when its needed...

[LaOutbackTrail]

I've been considering taking my roof rack off when unneeded, but... the fact that i need two of my neighbors to help me install it kind of puts it in perspective.

[off-roader]

I've been considering taking my roof rack off when unneeded, but... the fact that i need two of my neighbors to help me install it kind of puts it in perspective.
The OE rack was light. The aftermarket one I had on it, not so much. The Wilderness Trails Rack I'm replacing her with? Yeah, it's heavy! To install it myself, I'll have to do it in sections... Front first, sides next, back next, bolt everything together, then bolt the floor on.

[LaOutbackTrail]

Yeah, I'd estimate the ARB steel rack to be about 100lbs... i can move it around the yard but it gets me a little winded....the truck is too tall to fit int he garage and there's no place on the ceiling to put it. One day, when I have a real shop to work in...

I agree your truck looks pretty clean without the roof rack.

[off-roader]

Thanks! I may leave it this way for daily use then just put a rack on for trips.

[mapper]

Off-roader, any chance you can give me a measurement of interior height below and above your rear platform? Thanks.

[off-roader]

I can once I get home. The bottom of the platform is at the height of the 2nd row seats folded flat/forward/down.

[mapper]

I can once I get home. The bottom of the platform is at the height of the 2nd row seats folded flat/forward/down.

Would appreciate it. Thanks. I don't own a monty yet so I don't have one to measure...just in the research phase.

[eurosonic]

Im waiting for the roof rack install/pics!

[off-roader]

Would appreciate it. Thanks. I don't own a monty yet so I don't have one to measure...just in the research phase.
Whups... to much stuff to do so I forgot to take the measurement for you.


Im waiting for the roof rack install/pics!
Will be installing it this weekend so I'll try and post something up then.

[off-roader]

At the highest spot in back there's 28" above & 14" below. Also, there's a 1 1/2" wide bar that spans the entire rear of the floor(for strength. This limits the maximum height of a single object you can store underneath to 12 1/2". For me its no problem. I simply put a 12" tall storage bin in back and another 3" of stuff on top of it.

HTH.

[mapper]

Sweet! Yes, that helps a lot. Thank you.:smiley_drive:

[off-roader]

New roof rack mounted. It's my old 4'x5' Garvin Wilderness Trails Rack refinished, extended, & floor bars upgraded to 80/20 extruded aluminum t-slot tubes.


Before: BVG rack mounted to Yakima Bars. OE Rack still in place.
151983


Rack removed, and OE mounting hole rivnuts sealed using epoxy & stainless steel 1/4-20 pan head allen bolts with stainless steel washers w/ a rubber grommet.
151984


Roof w/out the rack.
151985


All this in preparation for my upgraded Wilderness Trails Rack. I went from the original 5' length to 7' buy simply using 2 new side pieces I had a local shop weld up for me.


I then replaced the original 4' long floor (made from .75"x.75" square steel tubes) with 1"x1" extruded aluminum t-slot tubing. T-Slot tubes are available from a variety of sources. I bought mine from 80/20.
151986


The rack pre-assembled in the living room. I've already been told that it looks like a giant coffee table.
151987

After cleaning up the rack and repainting it, here's the finished result...
151988

[eurosonic]

i think we have the same racks pal.

Looks great man!:ylsmoke:

[grandpa]

That looks nice. Did you make the drip rail mounts?

[LaOutbackTrail]

That turn me over sticker is still distracting...... :p

[off-roader]

i think we have the same racks pal.

Looks great man!:ylsmoke:
Thanks. I can't recall from the San Mateo show. Was yours a Wilderness Trails rack?


That looks nice. Did you make the drip rail mounts?
No, the mounts are made by Garvin who is the Wilderness Trails rack manufacturer.


That turn me over sticker is still distracting...... :p
Good. I like that.:av-7: