2007 FG Project

Role1133

New member
Hello all! It's about time to introduce myself and my Fuso. I am going to start off by saying that I apologize for extensive story telling that is about to unfold here in order to catch up on what has happened in the past year and how close I am to resurrecting this Fuso from the frozen tundras of Northern Canada. Also, my knowledge of this process is ever growing and this is my first real build and my first Fuso so I'm sure to have a lot of questions along the way. I have been research very extensively for over 2 months on these forums, but the content is overwhelming to say the least so any input is greatly appreciated. So with out further ado here we go.

Last year I decided that it was time to move on from my 94 Dodge Cummins 2500 4x4 and custom camper (picture below) and start a new project. Ultimately I wanted to move into something that would provide me with a bit more space but still be a reliable 4x4 diesel, the Fuso checked those boxes. After doing some research and settling on an optimal year and then letting a few good options fall through the cracks, I pulled the trigger on a 2007 auction Fuso FG 140 unseen (in person) located in Edmonton, AB (auction photos below). What could possibly go wrong with that decision right!? Lesson #1 don't do that. For what its worth, I did purchase the truck for a remarkably low price which is the reason I have decided to stick with the project.

I booked A flight from California to Edmonton the next week and arrived at the auction company with high hopes only to find quite the opposite. Turns out my conversations with the auction company about the condition of the vehicle were a load of BS to say the least. The amount of problems that I could list off when I arrived probably could stretch the length of the wheelbase, but for the sake of saving myself the embarrassment of my impulse buy, I'll stick to the major issues. Immediately the most notable issue was that the truck was stuck in D Rate mode (limp mode) and would not go over 25 MPH. I decided to drive the 100 miles to the nearest Fuso dealership to sort out the major issues and take care of any recalls that are required to import into the US. After a thorough evaluation of the truck I was handed
*the list* as I have dubbed it, and it wasn't good. Lets just say I decided to fly home. It was decided that to even be able to drive the vehicle home, an overhaul of the rear brake assembly was needed and more importantly the high pressure fuel rails needed to be replaced, amongst a dozen other small repairs to make the 1500 mile journey back to California. upon further inspection the inside of the fuel tank was full of rust and obviously the fuel filter as well. I Decided to do a bit of research on the history of the truck itself and It turns out that the company that owned the truck let it sit for 2-3 years with out operation or maintenance. I quickly began to suspect that the fuel system was corroded and of course once the dealership finished the fuel rails they suggested replacing the injectors and fuel injection pump as it was still having pressure issues. After consulting with many fuel system specialists I decided that a 1500 mile drive home would tell me exactly what I needed to know about that fuel system. After all it drove 100 miles already and if the injectors and injection pump fail along the way then I'll just have to replace them anyway. So we treated the fuel tank, slapped a new fuel filter on, threw two extras in the cab, turned off D Rate mode, paid an exorbitant dealership bill and 2.5 months later off I drove.

To my surprise the easiest thing about that 1500 mile trip was the border crossing and the importing of the truck. Word of advice, if you have to import a vehicle; do it in the middle of the night. It Turns out overnight border agents are used to doing nothing all night and would rather stamp papers instead of ask questions! Also to my surprise the truck made it all the way home to California, in the dead of winter; with near racing slicks for the back tires, zero weight on the back, through one minor snow storm and all I had to do was replace a fuel filter once. I drove it straight, 48 hours at 55 mph (maximum speed the truck would go) stopping only once to take a 1 hour nap and replace the filter.

After another 3.5 months of relentless winter here in Tahoe and multiple failed attempts to get it running again. I Began searching for a qualified Diesel Mechanic, as I do not know a whole lot about high pressure fuel systems. I found a mechanic that used to work for Fuso in the SF Bay Area for about 5 years before relocating to Reno, a convent 30 minute drive away. When I showed up with the truck (on a trailer) I couldn't tell who was more excited, me for finding a qualified mechanic, or him for having the ability to work on a FG that has intentions on becoming an expedition vehicle. We decided that the Injectors and injection pump would indeed need some attention and after turning down the truck stop service centers recommendation to replace them both with new components. I decided to remove them and ship them to Bosch to have them rebuilt. It was determined that the fuel injection pump indeed needed to be rebuilt however the injectors just need to be cleaned up, saving me nearly half the cost of the quote for all new components. The truck has now been in the hands of the truck center for almost 4 months now as it has taken a while to weigh options and find the best path to take, also a slight mishap with Bosch has further slowed the process, as they sent a rebuilt fuel injection pump back that was not working properly. Now we wait for another rebuilt one to show up.

Again I apologize for such a long introduction to the project but it has been a long road getting to this point. Quite frankly I'm ready to move past the fuel system issues and get started on taking down some other items on *the list*. Here are some photos:


Auction Photos

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Previous truck

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fuel filter after 700 miles


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home


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Czechsix

Watching you from a ridge
Best of luck with your project, you've got your work cut out for you, but I hope it all turns out well in the end!
 

dlh62c

Explorer
Looks like a good find!

The duals will take you a lot of places. Without a load the ride will be harsh. Reducing air pressures to 35psi each in the rear will help. Try 70psi in the fronts.

Keep in mind these trucks are considered commercial, so check with your insurance carrier for coverage. For some reason insurance underwriters have trust issues when you tell them you purchased a commercial vehicle for personal use. Source insurance coverage for what the vehicle currently is, not for what you intend to turn it into.

Will this truck be registered in the state of California?

In 2020 registration of pre-2011 diesel trucks with a GVWR between 14,001lbs and 26,000lbs will become problematic in California.
 
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Role1133

New member
Looks like a good find!

The duals will take you a lot of places. Without a load the ride will be harsh. Reducing air pressures to 35psi each in the rear will help. Try 70psi in the fronts.

Keep in mind these trucks are considered commercial, so check with your insurance carrier for coverage. For some reason insurance underwriters have trust issues when you tell them you purchased a commercial vehicle for personal use. Source insurance coverage for what the vehicle currently is, not for what you intend to turn it into.

Will this truck be registered in the state of California?

In 2020 registration of pre-2011 diesel trucks with a GVWR between 14,001lbs and 26,000lbs will become problematic in California.
This compliance information is news to me, appreciate the heads up on this. I’m located on the California/Nevada border and the original plan has always been to try to register it in Nevada for simplicity’s sake once it is up and running. It’s a much easier road to navigate and will save a lot of money/hassle.

As for the insurance issues, I plan to do as you say for the first half of the build and insure it for what it currently is for now.

I’m sure I’ll have updates as the progress develops.
 

Role1133

New member
Finally had some free time this weekend so I spent some time learning how to use Sketchup to put my vision together for the habitat. By no means am I professional with Sketchup so forgive me. The dimensions that I used are 16'x7'6"x7' and this is obviously not set in stone. Important aspects for me in the camper is having a large "Garage" storage area for outdoor gear, a bed that is permanently set up, and a through cab. Advice, input, ideas welcome.


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