If not once but perhaps a few hundred times most 4WD enthusiasts have had a very similar dream. No, I’m not referring to the Swedish Bikini Team coming over to wash the ute, although that would be nice. I’m referring to the one about the ultimate ride. In our mind’s eye we are drawing up the plans for what each of us would consider to be a truly wicked 4WD. Maybe it’s a highly polished bling-mobile that, heaven forbid, may never see a day off the tar seal. On the other hand it might be a competition vehicle and it’s your every intention to keep it buried up the axles in mud every weekend for years to come. My dream falls somewhere in between although I do lean more toward the mud than the tar seal. In my previous article the opportunity arose to build such a vehicle and since this opportunity may only come once, I met it head-on with a plan that began with very basic wants and needs and grew into something quite extraordinary. The project starts with a stock standard 2008 Toyota Hilux Double Cab SR5 and it quickly gets a strip down. Then a complete rebuild from the ground up using strong, durable equipment designed to conquer the demanding and often unforgiving terrain where this vehicle is getting ready to go. Since this was the first major overhaul I had ever attempted I knew it would be wise to get some professional advice from the very beginning so during a weekend trip to Christchurch I dropped into Peter Munro Commercials and met Andrew Thompson. I found Andrew to be VERY familiar with the new Hilux model and when I shared the details of what I wanted to accomplish he listened with great enthusiasm. The wheels were turning, so to speak, and the project began. Differential Locks This model Hilux comes with a limited-slip rear diff. Now, many may find this to be enough for their own intended use of this machine, but a slip-diff just wouldn’t cut it for me. So, not only the rear diff went but I replaced the front diff at the same time with locking differentials. ARB manufactures the AirLocker; the compressed air actuated locking differential. With the clever placement of a few switches in the cab, either the rear alone or both the front and rear diffs can be locked and unlocked effortlessly. To accomplish this an ARB High Output onboard air-compressor was mounted in the engine bay and air lines were routed down along the chassis and axles to the diffs. An added feature of this robust air compressor is that tyre inflation tools can be attached and used in the field. Suspension As a road going utility the stock suspension that Toyota provided the Hilux is fine. However, I intend to spend a whole lot of time off-road in this vehicle so this was the next area to be addressed. Old Man Emu (OME) was the answer. OME offers a complete range of suspension options so it wasn’t difficult sorting out the right combination of shocks, struts, coils and leaf springs. In doing this the ute got a 45 mm lift and improved the ride on and off-road tremendously. Wheels and Tyres With the drive train and suspension sorted it would have been an awful shame to have let it go to waste without upgrading the rubber as well. The stock 15 inch alloys and the H/T radials were next on the chopping block. Again, Andrew assisted with providing numerous options. After some deliberation 16x7 CSA Stampede rims coupled with the Maxxis 265-75R16 Bighorn treads were fitted. Here again, with a slightly higher profile in the rim/tyre combo the vehicle was lifted just a pinch more. Every little bit helps and by this time things were really beginning to look the part. Bull Bars and Body Protection Toyota has built a very smart looking Hilux with its sculpted lines and chromed features but I’m more interested in function over fashion, so some of the bling had to go. The plastic front bumper was replaced with an ARB deluxe winch bull bar. Designed especially for the Hilux, this bull bar not only allows the original fog lights to be remounted but more importantly is also fully airbag compatible. Next, a rear step tow bar was mounted which added much needed protection under the rear corner panels and tail gate. ARB has even provided very practical dual towing eyes on this piece of equipment. And once the alloy running boards were replaced with proper steel side rails and steps, the approach, departure and ramp-over angles were all improved. Winch When I thought about adding a winch I easily recalled how many times I wished I’d had one. Not that I have ever been so stuck that I needed it, but on occasion progress was halted and the use of a winch would have proved most useful to proceed. A Warn WD9000 winch was soon added to the “want” list, and then bumped up to the “need” list. Snorkel As I mentioned in the previous article, one of the few pieces of equipment ever added to my earlier 4WD was a snorkel. Best money spent improving that wagon. Getting to some of my favourite fishing holes often means “water-over-the-bonnet” river crossings. Remembering that it only takes a spoonfull of water to hydraulic an engine, a snorkel makes for an inexpensive insurance policy with only one premium to pay. Naturally this would be the next addition to the Hilux. Coming up in the next article the final adjustments are made, the last pieces of equipment are installed and the “proper” testing of the vehicle takes place.