Okinawa Express, 4dr iO overland build
Ok, so I’m gonna start a build thread for anyone who may want pointers on how to turn a compact SUV deemed “Too Hard to Modify” into the perfect compact overlander using hoopty, backwoods logic. I use the term “overlander” very, very loosely. Why? I live in Okinawa Japan. What does this mean? Many many things, but the most importantly one can drive around the Island in less than 24 hours. This means the cliché overland build supporting 2+ people for multiple days away from civilization is waaaay over the top.
Choosing the proper platform, for me, was the easiest task. Toyota Surfs/HiLux (4Runner/Tacoma), Full size Pajeros, Prados/Land Cruisers, and Delicas (4wd van) are plentiful. However, drive on the average Okinawan street and it soon becomes very apparent that these trucks may be too large and impractical for daily use. This along with the annual road tax (the larger the motor, the larger the tax) push me towards a smaller vehicle.
This leaves me with also a large pool; Jimnys, Wild Winds, etc are smaller, very capable vehicles. Most have solid axels up front, a good following in the aftermarket, and of course smaller motors. But they are a bit too small for what I want to do. Then I come across my current truck.
The vehicle; a 1999 Pajero iO w/ super select 4WD. It will seat 4, its not terrible looking, gets good gas mileage, and has a 1.5 liter motor, giving it a 500 series plate (cheaper road tax).
First let me explain, a stock Pajero iO ( with a reasonably capable driver) can handle any trail this island has with-in reason. If the truck/driver find themselves over there head off-roading you probably shouldn’t be there in the first place. So I plan to only enhance the vehicals stock capability and concentrate on tailoring the truck to meet my daily needs.
The truck as I bought it (August 2012):
And how she sits now (May 2013):
First to go in was some Bosh fog lights. I will try to post up some night shots here soon.
*EDITS: I'm revamping the build thread to follow better what has been done so far. had to edit the first post as goals have changed since wheeling here in Okinawa.
So i stand corrected. the
So i stand corrected. the motor in the car is the 4G93. here are its specs (pulled from wiki)
4G93 DOHC 16 Valve GDI
Gasoline Direct Injection (GDI)
Total Displacement - 1834cc
Bore - 81.0mm
Stroke - 89.0mm
Compression Ratio - 12.0:1
Maximum Output - 96 kW (131 PS; 129 bhp) @ 5,500 rpm / 96 kW (131 PS; 129 bhp) @ 6,000 rpm / 110 kW (150 PS; 148 bhp) @ 6,500 rpm
Maximum Torque - 181 N·m (133 ft·lbf) @ 3,500 rpm / 177 N·m (131 ft·lbf) @ 3,750 rpm / 178 N·m (131 ft·lbf) @ 5,000 rpm
mitsu did make a turbo varriant found in the lancer (other names depending on the market) so i may be swinging through junk yards to source parts to solve my under-power issue.
As far as being the only one from japan, it wouldn't surprise me. the local guys here like the Jimny/Samurai, Surf, big boy Pajero, and Land Crusiers. I've only ever seen one decked out iO and it seemed all show, no go.
As far as japanese regulations regaurding cars it is vastly different here. essentially they have "JCI" inspections every two years. they check everything from break pads to engine function to ensure it is safe to drive. the car can be old as dirt so long as it passes the inspection. this is the reason there is a high turn over in cars. sometimes it is cheaper to buy a new car with current JCI than it is to fix up issues found on the inspection. but that makes it good for me. why? because the junk yards are filled with cars for sourcing parts.
on my list so far: FTO wheels x5, 1st gen paj transfer case, and now the 4G93t.
Fantastic, nice to have a
Fantastic, nice to have a member from Japan! Welcome.
Nice little machine you have there! Cant wait to see your build and more pics!
I have seen quite a few youtube videos of iOs in Japan, I just went to have a look and post a couple but couldnt find them :(
You have some nice parts available for the iO in japan! Infact, I want to get some of the wheel arches that are not available here!
Like these. Made by http://www.jaos.com/, Not listed on the site any more tho :( Maybe you can find out for us? :)
Edit: they are listed on teh Japanese website http://jaos.co.jp/class_pc/products_catalog/detail.php?products_id=217
They sell quite a few bits for your car http://jaos.co.jp/class_pc/products_catalog/list.php?grp_id=28&mode=vehicle
Claud, I believe they can drive cars of any age but must pay a tax for the older ones?
Storage
Quick and easy upgrade. Two Pelican boxes for storage. I choose boxes over building drawers (for now as I plan on building a storage solution for scuba gear in the future) for several reasons: Despite the iO having 4 doors, the actual trunk is small. this makes storage space premium. I also wanted something modular. having the ability to move the boxes around is perfect for this application. In the even i have 4 people they will slide back fitting perfect behind the seat, or for extended trips I will be able to tie them down to a roof rack. And lastly, they are great campsite sitting apparatusi .
For obvious reasons Pelican boxes are the best money can buy. I use them frequently in my line of work, and have never seen one fail. I've seen handles and latches break off but that never seemed to affect the performance of the box. The obvious selling points being water tight, crush proof, lifetime guarantee, lockable, etc... but one that really sticks out in my mind is the automatic pressure venting port (not required if you live at sea level like i do now). If you have ever tried to open a box that has been depressurized you know it can be a pain in the ars due to the vacuum created inside. so if your on the fence about getting some, and live at altitude (New Mexico, Colorado, etc.. just do it. they aren't cheap, but they will be the last set of boxes you'll ever have to buy. and they can double as a suitcase (they have integrated wheels and pull handle.)
So I sourced a rack from Mr
So I sourced a rack from Mr Miyagi. Literally. The man even fit the profile (one exception being his mustache). Long story short I happened to drive by his car lot and saw the rack sitting in the back of his car lot. I asked him how much he wanted for it. He told me 10,000 yen (roughly $100usd). I told him that was a bit pricy and I would consider it. A few days later I went back, 10k yen in hand and offered him 7k yen. Well as luck would have it, Mr Miyagi’s son was there, whom he consulted with on the price. He came back and told me he’d give it to me for 5000 yen and through in a free can of black spray paint to “cover the rust” (I’ll get to that in a bit). I thought this story was worth mentioning for two reasons; one, I’ve never been lowball’d by the seller in life. Second; I’m in Okinawa, and current political states is less than desirable which makes the first point even more significant. Mr Miyagi was a great guy.
I digress…
So the rack was heavally rusted, I knew this before I bought it. So I went down to the local hardware store and scooped up all new acid dipped aluminum hardware, 2 rust wheels, and 5 rattle cans “Rust Tough” Rustolleum in satin black. All this set me back another 5000 yen.
The second problem was the actual rack itself. It was designed for a Dihatsu utility van, so I would have to modify it slightly to get it to work. Easy problem, easy solution. I simply bent the support feet at about a 90* angle, and bent the securing latched to conform to the door frame of the Pajero (slightly more rounded).
Car Cancer. This rig will be a 4 year car, I would not normally ever mess with this stuff. but for this build, it is what it is. Some spots were rusted all the way through. lets hope the "Rust Tough" will keep it at bay for a few years.
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Test fitting, and bending needed parts before paint. After and Before.
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laid out nice and first few coats of paint
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Plasti dip on all the parts that contact the car.
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Loctite is probably the most important part. don't want your parts rattling free
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After two days of work (test fitting, sanding, painting) I now have a full length rack. I don’t know how much it will hold, but I’m guessing around 300 pounds if the weight is evenly distributed. This cost me slightly over $100 bucks, and I’m pleased with the outcome. Some of you may say, “you know that sits high above the roof line, aren’t you worried about lift at speed if it loaded?” Well I plan on fabbing up a fold-down ladder which in its stowed position will be under the actual rack. Also, there is enough room to stow our standup paddle boards if the rack is loaded. Also the extra height will help when it come to mounting a DIY awning to the passenger side.
and finish product:
New update. So the other
New update. So the other weekend I went back to get the mud terrain tires I found at a local junkyard. Alas, it was not meant to be. As luck would have it, a recent arrival had 4 Dunlop Grandtrek AT2s with reasonable wear. A bit more luck, they had one more already on the shelf with similar wear and the same size for my spare. So after some haggling I got all five tires for 25,000 yen (about $250usd). He never came down on the price, but the set of four tires were mounted to Jimny wheels adding to the cost of the set (40,000 yen for the wheel/tire set). At first he refused to put them on the wheels I wanted to supply…. But my rabbit in the hat, “I apologize that my Japanese is poor” in very broken white-man dialect won him over I think. I find humility goes a long way here.
Earlier I found two Mitsubishi FTO wheels, they have 3mm more offset (+43) over stock. While this doesn’t translate much in the functional category; just a small amount of weight loss over stock. However it does look a lot better; getting the tires flush with the fender. Also I really like the 5 spoke pattern, reminds me of an older Land Rover. I also think they give the truck a much more burly style. Now I just need to keep my eyes peeled for 3 more!
Some quick pictures:
I must say that the he was very precise. Checked the beads and valve stem for leaks, cleaned the rim’s lips with steel wool, and ensured the inner tire surfaces were clean before install. I truly appreciate the attention to customer service as well. Where else would you buy used tires, and when driving off look like you bought brand new ones?
The prerequisite parking lot flex test. I was worries that the right, rear tire would rub the fuel spout (tucked inboard of the fender-well), cleared it by about ¼ inch.
So after going from 215/70/R16 worn-the-sh*t out Geolander ATs (which were great by the way) to these Grandtrek AT2s sized 205/80/R16, I gained about 2 inches in overall diameter (about 27 to 29 inches) but the weight dropped due to the rims and the narrower tire by about 0.5 lbs. I am happy with that for this truck. I failed to measure fender-to-ground at all 4 corners, before and after but I will post them later as compared to a stock Pajero. And of course I will post up dates following an outing.
Syndicate
Okinawa Japan
Welcome to the forum, and I hope that you will find some good info....and bring some at the same time!
I think that you are the first from Japan....Glen's little forum is growing....
I don't have much knowledge on this engine,or seen it in the io before. If you have more info, pictures that would be nice. How many kms does it have? I am not sure but I think the Japan law doesn't authorised older engine...for pollution problem, do you have something like that ??
Welcome again, and Happy io
My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io