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D40 Lab rat
May 5, 2015
8:35 am
mungyz
Guest

The Lab has started a new project :D

Started on this a wee while ago now but I need t post some pictures up somewhere other than facebook so I will go through the hundreds of pics & start loading them up on here cool

The short version of the project is:

2007 D40 Navara King cab cab unit
Full custom chassis using only the front suspension & the spare tyre/rear bumper mounts from a 2WD D40 Nav chassis
R51 Pathfinder rear suspension
20" wheels with R35 GTR sized tyres (rears are actual R35 GTR tyres)
Dobi lowering springs
All rubber mounts removed between chassis and body
(lowered ~10" compared to stock D40)
VK45DD converted to VK45DE leaving the stock 11:1 compression ratio pistons in there
Soon to have an Emtron ECU
Full custom 2.5" stainless steel exh
Full custom ally fuel tank ~125L capacity
Custom sports bar 2.5" stainless steel
Six speed manual gearbox adapted to the VK45DD/E
Z32 300ZX diff modified and mounted to R51 rear end (gives a limited slip diff that you can't buy for an R51 rear end)

Pictures to come….. beerchug

May 30, 2015
8:56 pm
mungyz
Guest

This was the donor Kingcab, we started with just the actual cab unit from this vehicle, she is an 08 with only low kms on the clock :D
http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/081220141098_zpsln6bttfa.jpg

I also purchased a 2010 Double cab to pillage a lot of parts from, the front suspension components came from that vehicle and were spliced to a full custom chassis to create this:
http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/310320151333_zps9omeqw4v.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/220420151371_zpsfbbhqwlo.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/300420151382_zpsz9xoa03m.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/150520151409_zpssxcdnbuc.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/200520151419_zpswnw97ky7.jpg

There are plenty more pics and I am being a little picky over what ones go public – I need to leave something for when she is completed laugh

August 1, 2015
7:09 pm
mungyz
Guest

So insert a bunch of dribble but then skip to the pictures:

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20150718_170807_zpsr6hvqwcw.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20150722_182428_zpswh0wvnyu.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20150726_163618_zps5rl9vhcv.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20150728_125245_zpsf9hy0fch.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20150801_131535_zps5bbu7tus.jpg

August 4, 2015
1:28 pm
lostsoul
Guest

I have to say, I am IMPRESSED.

Constantly amazed at how much you can get done so "relatively" quickly coupled with quality and ingenuity.

Excellent work sir, keep it up.

August 4, 2015
4:32 pm
mungyz
Guest

Thanks smile

Still a little way to go but all very simple from here.

All things going to plan she should be road legal early next mth – although things don't always go to plan………

August 28, 2015
7:01 pm
mungyz
Guest

Update for those watching:

She is at the certifiers getting what should be the final inspection.

If there are any issues then I will have to spend some time and sort it ALTHOUGH I'm quietly confident that I have it all sorted – famous last words machinegun

So IF there are no problems it's very possible I could be on the road early Sept

Might be time for a BBQ at The Lab if things work out coolbeerchug

September 13, 2015
8:11 pm
mungyz
Guest

So just two things to fix:
More clearance for front bump stops – will just fit lower profile stops.

Less bump steer at full droop on font suspension – have got modified shorter shocks to fit.

Once those two things are done we are good to go! cool

Might be on the road at the end of the week beerchug

Still some small things to deal with after that but at least will be able to get some miles on it and make sure everything is working correctly.

October 4, 2015
5:17 pm
mungyz
Guest

Replaced bump stops with lower profile units and made custom solid steering rack bushes to reduce bump steer to just half a degree toe in on droop only, zero on compression :D

Now fully road legal and legally defined as a brand new car :D

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20151002_125325_zpsl9maasoj.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20151003_172549_zpsfh7yrxhu.jpg

Still a little to do, need a final tune, am gradually tweaking colds start etc on the way to work every morning getting it just right, just one little two minute window with a tiny hesitation on acceleration now, should have that sorted tomorrow. (it's an ultra fussy eng to tune on warm up it seems!!!)

Need to paint the rear panels again after the final tidy up, what you see there was just enough to make it shiny & close to the right colour and water proof for the cert process.

October 16, 2015
7:08 pm
mungyz
Guest

So I took her along to NZs biggest mini truck event:

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20151010_131849_zpsgfj9jlof.jpg

http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20151010_131915_zpsszqauhmt.jpg

Went pretty well on the drive down and back given the final tune is not yet sorted, used about 13L per 100Kms in fuel, for a two ton brick with a V8 that's not bad IMO :D

A couple of days later I'm told I earned something while I was there:
http://i182.photobucket.com/albums/x296/mungyz/D40%20Navara%20build/20151012_151604_zps9q5kmevh.jpg

Much happiness :D

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