View Full Version : 1989 Daihatsu Hijet Van Project

04-01-2015, 09:45 PM
Hi, my name is Guy, I live in South Eastern Fl. I Have been into off-roading rock-crawling and motorcycles pretty much my whole life. Most of my projects were Land Cruisers with a few Motorcycles thrown in there. My new project is a 1989 Daihatsu Hijet Van that i picked up last year just for a around town car. It ended up being a billboard for my business after painting it and having it lettered.
The original engine is a 550cc 3 cylinder engine that made 35 hp and was designed to putt putt around on Japans roads at 35-50 mph. That wasnt much fun so i tinkered on it and was soon hitting speeds of 80mph and soon there after started melting plug electrodes. As fun as it was like that I wanted something I could rely on and had some real power. I decided to re-power it with a motorcycle engine, started looking at a few and they all were missing reverse and the engines needed to be turned sideways or needed elaborate chain drives etc. I finally ended up choosing the Gold Wing GL1800 engine mostly due to how smooth and vibration free it is but also because of its shaft drive and reverse.
I found this site by doing research while working the bugs out of my wire harness, i found a post on a Goldwing Site that showed a picture of someones buggy with the same engine in it, I followed the link back to one Bdkw1's Photo Bucket and found a trove of pictures of his build, I finally found this site with a google search on the Baro sensor, it seems that Bdkw1 had a problem with on his project as did I .
So here I am, Ive gotten the engine running but the injectors were in the need of a cleaning service and the fuel pressure regulator was shot so I am waiting for that stuff to arrive here and then the project will be able to move ahead. I have been putting the parts together since Sept last year. I will see if i can load up a few pics of the van/engine/etc.

04-01-2015, 09:48 PM
http://gl1800riders.com/forums/attachment.php?attachmentid=319665&d=1426185271 http://gl1800riders.com/forums/attachment.php?attachmentid=319657&d=1426185287 http://gl1800riders.com/forums/attachment.php?attachmentid=319649&d=1426185325 http://gl1800riders.com/forums/attachment.php?attachmentid=319641&d=1426185347 http://nfcruiserheads.org/forum/index.php?action=dlattach;topic=4366.0;attach=1531 9;image

04-01-2015, 10:10 PM
Pretty cool project, welcome to the site.

What part of south FL you in? I'm in west palm.

04-01-2015, 10:26 PM
Pretty cool project, welcome to the site.

What part of south FL you in? I'm in west palm.

Im in central Port Saint Lucie, About an hour north of you, I use to Live down there but the traffic and 0 lot line homes... i had enough of the claustrophobia. There are some great areas down there but they are way to pricey. I now have twice the house and property at half the cost. What Area are you in?

04-01-2015, 11:11 PM
I remember when military trail was 1 lane in each direction..lol It's like Miami moved here.

I live by Forest hill and Haverhill.

I used to ride my stuntbike up in PSL with a few friends, by a stadium if I remember correctly.

04-02-2015, 01:27 AM
Yeah I use to live off of military and summit lake, back when the 2 hurricanes came back to back, it was pretty crazy marshal law at night, people breaking into publix and being shot with bean bags.... not where i want to be if the SHTF.

04-02-2015, 02:01 AM
I remember that, that's when I got my first generator..lol 10 days without power.

04-03-2015, 06:47 PM
I was going to go a different route on the drive shaft, build a yoke like Bdkw1 did by combining the Goldwing yoke spline section with a larger 1310 yoke. When i started to tear down the two shafts i have, the Daihatsu shaft and the Goldwing shaft, there were a couple things that i noticed, the universals appeared to be similar. Once i got them apart it was clear that the Goldwing used more meat in theirs but what mattered was that the bearing caps were the same size O.D. So i checked the length of them cap to cap and it was withing a 32cnd, i popped out the arbor press and together it went, now all that is needed is to shorten the shaft to the needed length when the instal begins.

On the right is the Daihatsu and left the Honda
https://scontent-mia.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11136706_1592746161012449_779726277826103596_n.jpg ?oh=d5b9b320268969611ab1a3e114a9e917&oe=55BC8D11

Here they are after
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10431543_1592746414345757_5488547770899264080_n.jp g?oh=04cf7fff72902971bdb7512b4b7b6c6a&oe=55B5F04B&__gda__=1438515739_566a46214a9e783fbc2306b6f7ed994 4

04-03-2015, 08:04 PM
I've seen video of a goldwing as a tow truck, so not really surprised it has the same size u joint as a small van..lol Hopefully the rest of the build will be as easy.

04-04-2015, 07:59 PM
I saw this and thought the engine was plenty powerful for my little van..


04-04-2015, 08:01 PM
I saw this and thought the engine was plenty powerful for my little van..

<iframe width="420" height="315" src="https://www.youtube.com/embed/lITCg_xJx4U" frameborder="0" allowfullscreen></iframe>

04-04-2015, 11:01 PM
Check out ''The Retriever''


04-06-2015, 09:51 PM
I saw those a while back, they must have some work done to them, they claim to tow 5500lbs, thats an American suv. Dont know that i would want to be the tow driver though....:eek:.... trying to stop then a possible sandwich situation.

04-06-2015, 10:28 PM
I think they mostly use them to get the road clear, they are small enough to get through a traffic jam and move the vehicle blocking traffic.

If they need to take a large vehicle far they call a bigger tow truck.

04-13-2015, 03:47 PM
Fabbed up some engine mounts while waiting on parts, these will be welded to a cradle that will be fabled up when the engine is under the van, they are loose and swivel right now allowing for any number of different mounting angles that may be needed once it is under the van.

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/s370x247/11053189_1597057587247973_3163484598797099670_n.jp g?oh=90f3d2fb42bbb2d05b7dde76a0f63897&oe=55AA2454&__gda__=1437271775_c1d5009873444a8ec742fcfce1e3828 7

https://scontent-mia.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10432946_1597057607247971_3638231893099889509_n.jp g?oh=f2cdf46d767bc4a2533edf0bb33a9673&oe=55A59D62

https://scontent-mia.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11149313_1597057627247969_6034687304259826042_n.jp g?oh=f3f904391e1d6b96336ed5092d24cc73&oe=55DF36C5

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04-14-2015, 08:38 PM
Got the injectors back today, should be able to fire it up tonight and see how it runs.
https://scontent-mia.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/11129209_1597808443839554_4965077259887456987_n.jp g?oh=6696276af94593d1b8b8e5830268e8c6&oe=55E357DE

https://scontent-mia.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11079651_1597808890506176_6068902364772635405_n.jp g?oh=e98afa87dd6292218606bd14d68140ae&oe=559FD24D

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04-15-2015, 05:47 AM
Stuff like this is my favorite. Take an insane idea. Everyone calls you crazy. When its done and working, everyone says how awesome it is. I can't wait to see how this turns out, keep up the good work!

04-15-2015, 11:00 PM
Lol, yeah Ive heard some naysayers before and you are right, they are pretty much amazed to see what a little bit of hard work and determination can do, its all about the challenge to me and the pay off at the end is second best.

04-16-2015, 01:04 AM
Had the time to install the injectors and fuel pressure regulator, heres the end result, an engine that runs on its own now.

04-16-2015, 12:28 PM
A running engine always helps with motivation.

04-20-2015, 06:42 PM
Well, pretty good day, got the new engine in the van and ready for mock up and fabrication of the cross members. Fabricated a bracket for the gas pedal so that is working. Test fit the motorcycle gauge cluster into the dash, mocked up the hydraulic clutch master onto the peddle. Still quite a bit left to do, i took the driveshaft to the shop today to have it shortened and balanced.
https://scontent-mia.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/11150460_1600437116910020_5151095848298695141_n.jp g?oh=85da7b97119f5c7ff1c57c6144cc8b2e&oe=55A194B5
Moved the E brake over to the right to make room for the throttle body. Removed all the Daihatsu garbage too.
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04-20-2015, 11:32 PM

So, how do you like the factory wiring harness? :D

04-21-2015, 04:59 PM
About as much as you did, the biggest problem I had with it was all of the extra crap and what to do with it. I ejected as much as I was comfortable getting rid of as to not cause any other wiring problems in the process, anything else that was in there stayed there and was just cleaned up by running the excess wires next to the main loom and taping it all up only leaving the plugs exposed making for a cleaner looking harness. Still dreading the extending of the gauge cluster, more time consuming than anything.

04-21-2015, 11:44 PM
LOL, a motorhomes worth of wiring on 2 wheels........

Did you keep all the reverse wiring? Are you planning on using it?

04-22-2015, 02:37 PM
Yeah the reverse will be used, it should work pretty good with the gearing in the van, it wont be fast but will work, BTW the reverse only works when the engine is running. If for any reason it doesnt work well I have an alternative, using a gas powered golf cart generator/reverse motor with a v-belt pulley mounted to the axle drive flange, will charge the battery while driving and be a reliable reverse if needed. I may have already posted a picture of it I believe. Got the drive shaft shortened 8 inches and balanced, had a 1/4 inch taken off the yoke to allow for the splines to run all the way up, they are an inch long on both the yoke and output shaft but only about 3/4 are mated because of a 1/4 inch on the front of the yoke that I removed. Now they will mate 100% and if they need to slide in and out due to suspension travel I wont have to worry, there will be plenty of contact area of the two splines, should only move a 1/4 inch total ever due to the setup.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10930095_1601582253462173_5152458184095745163_n.jp g?oh=c09bac33a1a6834178d253f09a3a4fbb&oe=5597B7E8&__gda__=1440817282_9c72d57d52149bd641b46f4c48670da d
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04-23-2015, 02:02 PM
Up late having fun......:rolleyes:
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Only about 70 more wires to go!
https://scontent-mia.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10346313_1602016473418751_3095016843596292918_n.jp g?oh=a7e98a6a1b0774d9aba8d3671b1b24ee&oe=5598E561

04-24-2015, 01:28 AM
LOL, I still need to do that to mine, it's about 2' too short......

04-24-2015, 01:57 AM
Lol, well 7 hours of cutting and crimping is worth it for 6 plus feet, 2 feet might be worth moving the engine forward instead lol. Here is the finished product.
https://scontent-mia.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/1528706_1602212033399195_8007056474566112266_n.jpg ?oh=f0515ed6b2518ef4c0a2f893f0188482&oe=559EAAD3

04-24-2015, 12:58 PM
Ever see a Traxxas RC truck with telemetry? The transmitter has a port for a smart phone, it gives you a full set of gauges on your smart phone.

Imagine a wireless dashboard.

04-24-2015, 02:35 PM
That would be to easy.... im sure in a few more years it will be the norm, the motorcycle programers already have a (plugged) iPad app for tuning on the fly.

04-25-2015, 03:08 PM
I was able to take advantage of the thicker upper mounts due to how they lined up, these will also aid in aligning the engine in the frame, they seen to be the only symmetrical mounting points on the engine and happened to line up with the main support beam under the seat. I will be making a similar mount for the rear like this as well.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/11174945_1602866806667051_1070385133600855994_n.jp g?oh=5387b915c6ac7a8eda9c7b3b5c027a97&oe=55D08C40&__gda__=1441047082_20768b040840c5c74ae2f7539970625 c
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https://scontent-mia.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11069428_1602867373333661_4773871738207956413_n.jp g?oh=a5611033f2fd7fafa700ba6b6ae5e8bc&oe=55DE98A8

04-25-2015, 08:38 PM
Those top mounts are pretty much what holds the motor in the frame on the bike. All those bottom mounts are for things like footpegs. I used both top and bottom mounts due to the anticipated beatings it would see.

04-27-2015, 02:10 AM
I worked on the rear mounts today. Got the engine mounted enough to put the van on the ground, its a little lower than I hoped
(3 inches of clearance) I lowered it 3 inches a few months back so I may have to undo the lowering job a little to get to my target clearance of 5 inches, the stock Goldwing has 4.9 inches of clearance with out a rider.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpt1/v/t1.0-9/1510653_1603461953274203_8659130470736499850_n.jpg ?oh=17cd7654999ef88ca0805a380dd427ac&oe=55D45006&__gda__=1436418306_b09cd2c9b76481a6c59e70878d7e4f0 c
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04-27-2015, 03:05 PM
This things gonna do wheelies..lol

04-27-2015, 08:23 PM
https://encrypted-tbn3.gstatic.com/images?q=tbn:ANd9GcT7l5chnsGN31TjDPPJ9B2dqIRWSK9qC YuH_s4bZdu1q-ax-jrP


04-27-2015, 10:45 PM
Can't wait for the video.:D

04-28-2015, 12:54 AM
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/22786_1603462063274192_3158429621697061968_n.jpg?o h=78fa5723c3f65772668482bf3e68bcb7&oe=559CAA90&__gda__=1440973457_4865e1c0e9687fa4904bfb7a822c266 0

Is that the installed height? Looks low. Anything you can do to suck it up into the body more so that you see less of it? Or is the floor in the way?

04-28-2015, 03:05 PM
Yes that is the installed height, the output shaft dictates the engine height, the Daihatsu is known for its high sides, the trucks are even higher, you can see the frames on them, keep in mind there is only 9 inches between the ground and the rocker,the van is 5 foot tall 9 ft long and 4 ft wide, not much extra room for a overall larger engine. The only reason you can see the engine so good in the pics is that i took the picture from grass level, at a normal viewing angle you cant see so much engine. Im probably just going to lift the van back up 2 inches, that gives me the same clearance as the Goldwing. Good thing is that it is in there mounted and rolling. Progressing....

04-29-2015, 01:51 AM
So what is the wheelbase of that versus the wing?

04-29-2015, 04:04 PM
72 inches on the Daihatsu, and 66.6 inches on the Goldwing , 5 1/2 inches difference, is not much considering the two different type of vehicles. Going over railroad tracks or speed tables the van would be more susceptible to bottom out before the bike but the bikes are not known to scrape unless there is a problem with the suspension. The van has a stiffer suspension than the bike, these Kei (Kay) trucks are the equivalent of the American 1/2 ton truck, they are made small for the roads of Japan but the payloads are up there 1400 lbs, I took some spring packs out of the rear when I lowered it just so it would ride smooth and not like a dump truck.

04-30-2015, 03:08 PM
Almost done with the mounts, just have to finish the front cross member frame mounts. I also did some calculations on top speed with a gear ratio calculator. The calculator puts the Goldwing at 146.27 MPH at 6000 rpm. The van came in at 108.23 at 6000 RPM. I guessing that what this thing lost in top end it will find in the bottom end which is what I was hoping. Imagine this little van embarrassing one of those new Camaros or Mustangs between the street lights, assuming I can keep the tires planted, may have to do a 4 link in the future.
https://scontent-mia.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/11162075_1605034326450299_5143083162960115602_n.jp g?oh=183a53398ad77abc1629c154a828b392&oe=55DFE518
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05-02-2015, 02:19 PM
Finished the engine mounts last night.
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05-04-2015, 01:53 AM
I got the fuel system completed today, ran the extended wire harness up to the dash to the gauge cluster, plumbed the coolant lines, mounted the clutch master and ran the hydraulic line to the engine. Whats left to do.... finish the exhaust, wire up the fuel pump to the Goldwing harness, wire the fuel sending unit, mount the key switch, build a switch plate for the on/off start and reverse switches, fabricate the shift linkage, clean up the electrical harness under the van, bleed the clutch, fill with coolant, probably forgetting a couple things.

05-04-2015, 02:04 AM
Whats that whining noise?

05-04-2015, 02:12 AM
His fuel pump.

Rubber mount that thing!

05-04-2015, 02:45 AM
Yeah the pump is a noisy little turd, I will be trying to quiet it down a bit if I can but I imagine i will need to do some research to find a better/quieter one.

BDKW! What pump are you using?

05-04-2015, 02:55 AM
Generic Vatozone cheapy. It was a 88 Bronco replacement one as they were not in tank units, Also had a lifetime warranty from an old Bronco of mine......

I was having problems with it locking up from the old fuel in My tank. Took it apart and made a billet housing with snap rings to hold it together. Now I can take the little bastard apart in about 5 min to clean it out. Also added a fuel filter and a can of Berrymans to the tank. Those seemed to help also........


05-04-2015, 08:51 PM
Do you know what the pressure output is, and how loud is it?

05-04-2015, 09:55 PM
I want to see it GO!!!

Nice work.

05-04-2015, 11:00 PM
Do you know what the pressure output is, and how loud is it?

They will run up to 90PSI. It's pretty quite. Rubber mount it and you probably won't hear it in the cab. If your the Junk yard hunting type, the factory frame mount from an 88 bronco is really nice. Rubber lined metal housing with 3 rubber isolated mounting bolts.

05-07-2015, 08:35 PM
Not to much to update but, I got the clutch bled (PITA) took about an hour and a mighty vac with 2 people, the reservoir was so small that i would have to have a buddy constantly filling it to keep from pulling air. Wired the fuel pump into the wire harness, wired the fuel gauge into the harness, dont know how accurate it is yet but I had a half tank before I parked it and it shows a half tank now on the Honda gauge. Put a flush valve in at the highest point in the cooling system to be able to burp the system. Mothers day is this weekend so I wont get much done except in little increments during the week, Sundays are my most productive days due to it being my only day off.
https://scontent-mia.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/11064827_1605842206369511_4177509714085205656_n.jp g?oh=8b6357f68a6fb400e562f6a2fc68d9da&oe=55C97615
The spot im going to mount the master cylinder.
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/11193335_1605842223036176_2342790532207451126_n.jp g?oh=b47ebd1774f1206eac8848f2e4f2adbb&oe=560B0BF3&__gda__=1440550819_54d86eb3ce8277f99bc3381c7890767 7
https://scontent-mia.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11204428_1605842249702840_9191380245375141927_n.jp g?oh=d6a947b1b195ef6d644fea7f4dbdaf56&oe=55D77096
https://scontent-mia.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11173314_1605842266369505_1197795485568445573_n.jp g?oh=208fd346cd8907f1af06326d16a90577&oe=55C6A8B1

05-07-2015, 11:54 PM
I put about a 2' hose on the reservoir, doubled the capacity........

05-08-2015, 05:43 PM
That would have been good for bleeding it but, may do that in that in the future, im going to leave it alone for now, I dont want to bleed it again anytime soon. I am working on the linkage for the shifter now. Will look something like this, add some mounting plate in there though. Im using the original foot shifter just with the toe part cut off, its already been a proven system, im just making the dog bone longer and mounting my cable to it.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10478708_1607608359526229_2031804714195082775_n.jp g?oh=46166a832be82543ba679a1080f9e80a&oe=560BB128&__gda__=1439114659_459a0f2430aee48571e39759c89edb8 d

05-14-2015, 03:57 AM
I finished the shifter linkage tonight, should be able to test drive it this weekend. BTW. Bdkw1, i bought that pump you suggested and it works great and its quiet. If you listen closely in the video you may be able to hear it fire up for a few seconds in the beginning. Thanks again.


https://scontent-mia.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/p526x296/11073823_1610002015953530_7203454151442105370_n.jp g?oh=69dbdec560d799351e70b8ce60607063&oe=55D77C83

https://scontent-mia.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/11120508_1610002032620195_4032638986426564075_n.jp g?oh=e6e2559fbb0e960ab68c4cf64e84e410&oe=55C2A2C9

Weld looks like dogsh_t my auto darken helmet was set to dark could barely see the work.

05-14-2015, 07:19 AM
TEST DRIVE!!!!! I expect videos come monday. Man, you have done a great job with this!

05-14-2015, 10:02 AM
I wanna see wheelies!!!!! lol

05-14-2015, 11:27 PM
Fook the wheelies, I wanna see how the reverse works........

05-18-2015, 08:52 PM
Test drove the van yesterday....first impressions...WOW! This thing moves... Teaser vid of me in the driveway doing a quick launch to see if anything was going to break, rather break it in the driveway. This little guy flies. Still have some bugs to work out, I think there is air in the coolant system due to the layout of tubes and such, also I need a new radiator cap to rule that out as a problem.


05-18-2015, 09:12 PM
https://scontent-mia.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/11008462_1611562992464099_6954476533912614012_n.jp g?oh=e253ca09e38850298bd73feb8d9aa8c8&oe=5607BA5F
Zoom Zoom....

05-18-2015, 10:04 PM
Wheel hops are the death of millions of rear ends and transmissions. Get yourself some traction bars, or whatever you have to. You have to keep the wheel hop from happening, or you will break something.

05-18-2015, 11:11 PM

Tried out reverse yet?

05-20-2015, 01:42 AM
Reverse is about useless with this gearing, can you say Powerwheels? the kid down the street with his Powerwheels "Heep" could beat me in a race in reverse. I am thinking about 4 linking and tubing out the rear and doing a narrowed rear and fuel cell. I will be talking to a trike company that builds kits for the Goldwing, it keeps everything geared the same even the speedometer, taller tires - I will need to tub it.

05-21-2015, 02:51 PM
Ok so I need a few ideas for an alternative axle to use, the stock Goldwing runs a 2.93 gear, I need to be in that neighborhood or a little taller with my smaller tires, or I will have to go with a ford 9 and build one, i dont want to go that route if I dont have to. I guess im looking for an easy out, may not happen. I have 53 inches to work with from outside tire to outside tire. BDKW1, this will probably fix my reverse problem. One of these would be nice, its a Goldwing trike kit but they are probably $$$, Thanks in advance.


05-22-2015, 01:23 AM
9" will get you close with a 3.0. Plenty of factory car housings floating around with that in them. If you need a narrow one, I have seen a few older electric golf carts with narrow 9er's in them.

Either that or a quick change rear...........

05-22-2015, 01:32 AM
BTW, that trike diff looks like a D44. Those also had factory gears in 3.08 ratio.

05-22-2015, 02:24 AM
Awesome. Just awesome. Well done!

I have a GSXR1000 engine sitting here, and after seeing this, i'm quite tempted to drop it into a samurai.

05-22-2015, 05:10 PM
I located and squared away 2 Ford 8.8 axles, one is from a Lincoln Versailles and has disc brakes and a ratio of 2.70 -3.0, I will narrow it to replace the axle I have now with it for minimal work, the only thing I will have to do is get 4 lug axles and find discs to fit. I want to keep the same wheels and tires if possible.

05-22-2015, 06:30 PM
That's a pretty sought after rear end, difficult to find one around here. My original thought was it will be over kill, but that's not always a bad thing.

05-22-2015, 09:59 PM
Yeah there just isnt anything that is smaller with different gearing options and brake options, it would be nice to be able to find a set of 2.93 gears and disc brakes for the Daihatsu axle but thats dreaming.

05-24-2015, 11:59 PM
I went a different direction with the axle, I found a Dana 44 from a 70s CJ5 Jeep (narrow trac) It is 51.5 inches wheel mounting flange to wheel mounting flange, the Daihatsu is 51.25 so it will be a perfect replacement size axle. The Dana 44s are used in the Roadsmith Trikes, it will be plenty strong, a little heavier but has plenty of aftermarket choices for gears, axles,LSD/Posi, and brakes. I will have to have the axle shafts machined down to fit the 4x100 pilot and have them converted to 4x100 4 lug but not that big of deal. A small setback but not to bad considering what kind of things that can go wrong with a project like this. Heres the axle I picked up today and all the junk it came with.
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11350792_1615322412088157_3677388343758836905_n.jp g?oh=0badbc8ba23d9f4042551c9281081daa&oe=55FA5796
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/11351180_1615322425421489_3065584333841376240_n.jp g?oh=f8aa880210ef6255ea96def0782f28fc&oe=55BF4E02
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/11350521_1615322452088153_2327278473662249644_n.jp g?oh=0119f989e038db4df537a6ba7a2d1982&oe=55C29832

05-25-2015, 12:48 AM
You'll be good if you decide to put a v8 in it..lol

05-25-2015, 02:54 PM
You mean like this?

Thats what this guy did, 1970 Daihatsu pickup, 400hp v8 direct drive no transmission, just a clutch.

05-25-2015, 03:39 PM
OK! Sell the Goldwing motor..lol

05-25-2015, 04:28 PM
Direct drive?! Like a sprint car? So you have to have a push car to get you going, to go to the store.

05-26-2015, 12:32 AM
Nah hes got a clutch and the front of a Saginaw that he cut off to make a bearing support for the output shaft. He rigged up a line lock to keep the clutch in when he wants to let it idle.

05-30-2015, 02:12 PM
I have everything ready for the machine shop for next week to get the axles and rear discs changed to 4 lug. I went with 2005 Ford Crown Vic rear discs and calipers, they just barely fit with the caliper inside the 15 inch wheel. Its the largest i could find that i didnt have to have to much taken off the diameter of the mounting flange where it would cut into the old 5 lug pattern ,only have to cut the o.d. Down 3/16 to fit into the back of the disc. The center bore of the disc was small enough to allow for the 4x110 pattern too. It was tricky to find the right combination. I will post a pic of the Very Little clearance of the rear setup.

https://scontent-mia1-1.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/p370x247/11351286_1617443551876043_2434035694454747218_n.jp g?oh=7eadb1cf06cd36a8c08736f86e0a4046&oe=560019CD
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/11391450_1617443581876040_9061056515612244660_n.jp g?oh=41155ac86b2342327f78011bc8566037&oe=560A7E73

06-04-2015, 09:36 PM
Made the air cleaner shorter to accommodate the new dog box (engine cover) i built. Just needs some foam gaskets to seal it to the floor and some sort of latch system. Im going to have two carb filters come out of the airbox, one on either side.
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/11390367_1620761991544199_4881128164201849576_n.jp g?oh=784dd6c8cce0038c757035cf72a27dd6&oe=56082B34
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/1908137_1620762018210863_3997422064083345162_n.jpg ?oh=9b1d66cda5bdabb8e24ef2ef07b64cfd&oe=55F018D6
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/11412241_1620762041544194_9129155876457840243_n.jp g?oh=7fa8f5f7c30a99eef24a5f3afb0c3441&oe=55ECE870
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/11329840_1620762061544192_2260449958313878475_n.jp g?oh=74ee0d2627f9683fd83423487d01c345&oe=5604B438
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xfa1/v/t1.0-9/11390331_1620762074877524_2655735305969626688_n.jp g?oh=780fa43fca90b1af01b51320276ec4fd&oe=55FD5BEC

06-05-2015, 01:07 AM
Those airboxes are pretty well designed. No way a taller dog house would have worked?

06-05-2015, 02:29 AM
subbed!! this is awesome!! On the rear end i probly would have opted for a toyota rear end like the dwarf car crowd uses. Either way good work.

06-05-2015, 07:51 PM
Yeah the airbox was about 6-7 inches taller than i wanted, i wanted to keep the dog box short as to not make the rear seating area even more crowded, the engine wont know the difference after i add the 2 carb filters, they measure out to be the same diameter as the original intake tubes that come out of the airbox. This way the rear seat can still be used. As for the rear axle, it was the perfect width and that keeps the cost down, the Cj5 narrow trac dana 44 is cheap and plentiful, didnt have to cut and weld the housing or have the axle shafts resplined, had lots of meat on the mounting flange to drill the 4x110 bolt pattern without interfering with the old wide 5 lug pattern, and parts are readily available and cheap, rear discs were easier to sort out to due to the axle shafts having large hub centric pilots that im turning down to accept the crown vic discs, which also the discs had to work with the 4 lug pattern and pilot etc. Im just glad I got it all figured out, the guys at Autozone hate me lol.

06-11-2015, 12:25 AM
Made my switch panel. From left to right, Start (Green) Key Switch, Reverse (yellow to match the reverse light) and the last switch is for the Fog lights (Blue)
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/11390247_1623128031307595_8824720617571509657_n.jp g?oh=2e82179980a508cd84a325d8e4e3d92a&oe=55FAA105
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/11427182_1623128051307593_8455971997224566554_n.jp g?oh=c8940f917ee3091bba9d49a4a96ad43a&oe=55F81245
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/11393104_1623128077974257_1608034196148070900_n.jp g?oh=7e2513a56c29a1a4040fd15d64cd5eee&oe=55F2146E
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/1689497_1623128101307588_4131494105614768698_n.jpg ?oh=33b24f3ea368112992a10b8ccf3bf3f0&oe=55FF2672

06-11-2015, 05:14 PM

I like those switches. That looks really nice.

07-10-2015, 06:31 PM
Couple updates, I have the electrical all done, the dash new buttons installed etc, the parts are back from the machine shop finally, there was quite a bit of machine work ahead of mine and my was pretty complex given the odd request. I have installed the air filters into the air box, I just need to put the axle back together, and fab up the caliper brackets, install the axle and measure for the Road Smith Trike driveshaft which they make for the GL1800 to Danna 44 in their kits.
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xta1/v/t1.0-9/11267176_1634474663506265_7795441497219746913_n.jp g?oh=db5eaa30112e939cd8b189ba784bd16c&oe=561ABC2F
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/11204968_1634474666839598_8458523057568923393_n.jp g?oh=631c959ed23c75a09491fd18a0c86002&oe=5623E6E8
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11169162_1634474690172929_2327830334508100022_n.jp g?oh=ccbc3b6b8953577652ee642f93766be9&oe=5614453C
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10986963_1634474700172928_4375454544721706954_n.jp g?oh=2a1df7929db28fc3bda8e2830ad4a08c&oe=5655C502
Welded up one hole the be re-drilled when going to 4 lug
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/p526x296/11709498_1634605586826506_1736939532815748591_n.jp g?oh=a00f6bc56372d2542626ac5a3a2145fc&oe=562AF2D7
5 lug to 4 lug conversion, drum to disc conversion, 1975 Jeep Dana 44 Short Trac with 2005 Ford Grand Marquis rear disc brakes.
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xat1/v/t1.0-9/11659467_1634605590159839_3741222966650721325_n.jp g?oh=26f9b6d3c96cc0c239d216bb4616c8f1&oe=5622CFD9
New Bearings
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/11701173_1634605613493170_1708845683489738740_n.jp g?oh=d4b86b22e8dd12baecef9821bf1e6cf5&oe=5627AA78
The outside lip of the axle flange had to be beveled to allow the disc to fit flush, the pilot on the axle had to be turned down to fit the disc pilot hole. The axle mounting flange had to be turned down on one due to it having run out, the rear of the mounting flange had to be turned down to allow for the studs to seat on a flat surface. Quiet a bit of work.

07-22-2015, 08:31 PM
Got the axle under the van last night, fits perfect, just have to finish welding up the spring pearches and shock mounts, measure for new drive shaft etc.
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/11750628_1639296649690733_7626812469680750381_n.jp g?oh=08f8cfb2a525355658076f861f5e89f3&oe=5646171C
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11059593_1639296693024062_2093376394166314697_n.jp g?oh=f7509e4f801e0210aed26ece96eff9a3&oe=565B3C16
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/11755203_1639296703024061_2871949329643666672_n.jp g?oh=6876bb1186893df7801dc158809e49bd&oe=565CC6BC
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xtf1/v/t1.0-9/11742659_1639296729690725_8242811630612459828_n.jp g?oh=566962eb0d59ff4bbdb8b9484bd0f9ca&oe=561A8D1D

08-07-2015, 01:19 PM
I mocked up the exhaust today just to see what it would sound like, the mufflers still need to be mounted . The mufflers are from a late model Harley Davidison FLH

08-07-2015, 01:26 PM

08-07-2015, 01:31 PM
Man it is really hard to embed a video on here.

08-07-2015, 04:21 PM
Man it is really hard to embed a video on here.Yea, I don't know why it's such an issue. Sometimes the little video window pops up, sometimes it's just the link. Bullnerd's probably the biggest hit and miss when it comes to this. (picking on ya bull).

When you do post, remove the s out of https - for some reason it screws with the framing of the posts and messes the layout up. You'll notice that I edit 90% of the videos posted, removing the s. What's odd is that it'll show up on some computers just fine, others - both my Mac and Windblows (sucks) powered computers have problems. Originally I thought it was a Mac issue, but...

I've heard that there's a vBulletin patch for it, but honestly, I'm a tad scared to screw with the site. I've broken it a couple of times trying to upgrade so. [smilie=ext_crutch.:

Cool sounding stuff, btw!

08-08-2015, 12:40 AM
Sounds good. when is the test drive?

08-08-2015, 01:53 AM
About another week, just have to finish up the exhaust, run the rear brake lines, and build the driveshaft.

08-10-2015, 12:39 AM
Got the exhaust finished today.

08-10-2015, 12:46 AM
https://www.youtube.com/watch?v=r755NEisghw (http://www.youtube.com/watch?v=r755NEisghw)

09-16-2015, 11:30 AM
Got the drive shaft yoke in hand, waited about a month, the guy who used to "make" the custom shafts for Road Smith Trikes has a shop near them, I contacted him originally to make a drive shaft for me but the price was $400. Road Smith sells the completed shafts for $290. but they were a bit longer and would have needed shortening and balancing. I compared the "junk" Jeep shaft I had that came with the Dana 44 and pictures of the Road Smith shaft and they were identical. I ordered the special yoke to be "made" from the expensive shaft shop and they told me it would take a couple weeks to order the part that they needed to "make" the yoke. They explained that they would use a blank yoke and bore it then breach the splined part and press fit them then weld them up. Well a month later I get the part, and its what I needed but had that Harbor Freight Chinese paint smell and upon further inspection i could tell that the whole piece was a cast piece, not custom at all, a shelf part from China, the paint had scratches all over it like it had shelf rash.... Man I dont care how you got It just dont lie to me and make me think Im paying for a "Made in America" part.
Anyway here is the completed shaft, and if the rain lets up I should have it installed tonight!
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/11215700_1661961297424268_1136855869734468_n.jpg?o h=8c123c13feffcc5c4539c3bcb69212e2&oe=56A67F01
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/12036656_1661643117456086_5871763399129288030_n.jp g?oh=34bd88ac3a21238112b46b28b04f9d53&oe=56A237E9
https://scontent-mia1-1.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/12033240_1661643100789421_5228906709291879308_n.jp g?oh=fe33b1e752455a5620db003592285cc5&oe=56A9F2B6

09-16-2015, 11:43 AM
Good to see you back.

Don't you love it when you get all sorts of b.s. about something instead of just hearing "Here ya go."


09-17-2015, 03:27 PM
story of my life.... I'm in business and when I have to order something or there's a problem I just lay it out for them. You never know what someone's expectations are so give them good info to plan from.
Anyway, I got the shaft in and tooled around a little last night, everything seems to be working like a real vehicle now. The brakes were a little spongy so I will have to bleed them again, but I will wait until tomorrow or Monday for the drift brake I bought for a parking brake solution. I got an inline hydro parking brake that the ricers use for drifting. Lost my cable e-brake with the rear swap. Couple more days and I will be daily driving it again, just a little quicker than it used to be.

09-17-2015, 04:31 PM
Couple more days and I will be daily driving it again, just a little quicker than it used to be.

aw man... come on Guy. you can't end a build thread with that statement. you have to say something like 'next up: chopping the top and dropping the suspension 6 inches' :)

by the way... cool ride. it sorta of reminds me of the Toyota Van i had to drive when I turned 16. I actually liked that Van.

09-17-2015, 05:12 PM
Wheelies please..lol

09-17-2015, 05:37 PM
Im sure something will come up in the future but I have so many more projects going on that this one has taken a back seat to this year Im surprised i got it done this fast, hey who knows (turbo) , also been looking at som VW split window sheet metal for the nose too! The shop is 30 mins from me.

09-25-2015, 05:27 PM
I got to drive the van tonight, its a blast, just need to finish a few odds and ends but its drieable and reliable.


09-26-2015, 09:27 AM
Nice. Does it feel fast? Is reverse really slow?

09-26-2015, 09:54 AM

09-26-2015, 09:54 AM
I liken it to the speed of a stock 87-90 mustang 5.0, it's quick. The reverse is a bit slow but it does work and is strong as well. Overall I'm happy with the end result, keep in mind I have 9 month old gas in the tank and old plugs in it, I will be doing all the final touches in the next week or so then driving it daily.

10-10-2015, 11:33 PM
I always thought the GL1800 could make an interesting swap. Yours is the first I've seen, though.