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Old 9th October 2012, 14:41   #1
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Default 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

It all started with a call. Mostly everything does nowadays. So, we catch a flight and go to Delhi to have a look at the barren piece of flat land that will need to be converted into a 4WD track for the upcoming Toyota Bootcamp.


The piece of land:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-01.jpg


Mostly sandy in nature:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-02.jpg


Doodling plans over lunch:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-03.jpg


More doodling:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-04.jpg


Rough sketch of the track:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-05.jpg


Final outlines of the track:

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Superimposed on Google Earth:

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Pdf of plans, layout, brief mailed for approval:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-08.jpg


Plans approved and we reach the venue a week ahead of the event to start work on the track:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-09.jpg


Track marking with JCB starts:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-10.jpg


Track outline done:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-11.jpg

Last edited by Tejas@perioimpl : 9th October 2012 at 14:59.
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Old 9th October 2012, 15:14   #2
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Obstacle preparation starts:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-12.jpg


Supervising the work:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-12a.jpg


Obstacles being prepared:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-14.jpg


Ditch Preparation:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-15.jpg


JCB hard at work:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-16.jpg


Filling the water ditch prior to testing:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-17.jpg


Work and testing goes on till late night:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-18.jpg


Testing clearances:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-19.jpg

Last edited by Tejas@perioimpl : 10th October 2012 at 11:25.
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Old 10th October 2012, 11:45   #3
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

JCB finalizing the deep ditch:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-20.jpg


Testing ditch clearances:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-21.jpg


Clearance is just fine!:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-22.jpg


Axle twisters (“axle breakers”) being chalked out:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-23.jpg


Checking axle twister clearances:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-24.jpg


Rubble arrives for the base of the mound:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-25.jpg


Work on the mound starts:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-26.jpg


The mound rises:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-27.jpg


More soil on the mound:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-28.jpg


Another layer of rubble sandwiched on the mound:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-29.jpg
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Old 10th October 2012, 12:17   #4
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Watering the mound as the JCB compresses the soil:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-30.jpg


If it’s compacted enough for the JCB to climb, it’s good enough for the Fortuner:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-31.jpg


Testing with the Fortuner:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-32.jpg


View of the mound from water ditch:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-33.jpg


Work on slush area starts:

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Adding grass to the slush area to make it “slushy”:

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Water added and lots of runs by a tractor with a plow to make it even more slushy:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-36.jpg


And bingo! We have slush!:

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Old 10th October 2012, 12:32   #5
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

The Tyre Obstacle:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-38.jpg


Logs arrive for the log obstacles and crossings:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-39.jpg


JCB helps with the parallel log crossing:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-40.jpg


The log rumblers:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-41.jpg


Testing the slide incline. Yeah, we increased the inclination further; ask any participant how tilted the car was!:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-42.jpg


Testing clearances of the alternate mounds and dips:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-43.jpg


Yup, more clearance required here:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-44.jpg


Getting the manual labour to help with the approach, departure and ramp over angles:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-45.jpg
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Old 10th October 2012, 12:39   #6
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Late night at workshop to test the see saw ramp:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-46.jpg


Yes, the welds hold!:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-47.jpg


The ramp skeleton:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-48.jpg


Works progresses through the night:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-49.jpg


Ramps get delivered in the morning for final assembly:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-50.jpg


First ramp in position:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-51.jpg


Both ramps in place, joined together by a few bars welded prior to testing:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-52.jpg


Fortuner approaches the ramp:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-53.jpg


Ramp works!:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-54.jpg
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Old 10th October 2012, 13:06   #7
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Here's a video of the track obstacles that was shot by Toyota:




Last edited by bblost : 10th October 2012 at 13:20. Reason: Removed the www part in the url.
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Old 10th October 2012, 13:18   #8
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

A few pics of the track while it was being prepared from a nearby building:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-image-1.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-image-2.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-image.jpg

Last edited by bblost : 10th October 2012 at 13:55. Reason: embedded the pictures.
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Old 10th October 2012, 13:52   #9
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

A few photos of the event off the web:

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-47558_10151106044133650_1833713513_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-61423_10151106043863650_1095125453_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-66145_10151101961183650_476727568_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-150161_10151106044318650_1376988223_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-199555_10151103432898650_1273223027_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-223260_10151103089083650_2116134531_n.jpg

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2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-254465_10151103087823650_279722087_n.jpg

2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!-254617_10151103086373650_1882105168_n.jpg

Last edited by bblost : 10th October 2012 at 13:55. Reason: embedded the pictures.
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Old 10th October 2012, 13:58   #10
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Thread moved from Assembly Line

Thanks for Sharing.
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Old 10th October 2012, 17:52   #11
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Brilliant thread, thanks for sharing how the course got conceptualized from scratch!

I only wish Toyota would train the ASCs to cater for the offroading crowd.

When I had done this course in Bangalore, and went to the ASC later, they didn't have an clue on what to check and what/how to maintain after such slushy offroading. E.g. proper tightening, greasing etc. Or for that matter, checking the alternator, starter motor...my starter motor was affected later because dirt/mud/water would have gone inside and created some sort of coating, and it started malfunctioning after a few months. A simple check-up and wiping/cleaning would have prevented what happened. I didn't know then what I know now, and many folks like me would be left at the mercy of the incompetent ASCs for post-bootcamp maintenance and check-ups.

Perhaps you can pass on the message to the organizers - to create a checklist of things to do and things to check after such a bootcamp at the ASC.

Last edited by nilanjanray : 10th October 2012 at 17:54.
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Old 10th October 2012, 18:39   #12
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Feels like having been there all this while, right from ground 0 to the actual event. I would have thought, such things (the planning and execution) etc were not to be made public but the public event could be. But seeing them here, maybe it is not so. Isn't there confidentiality etc involved, not that it seems to be big trade secret. But loved it absolutely. Thanks a ton for sharing complete detail, especially since it involves the favorite SUV TFort in the new Avatar.
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Old 10th October 2012, 22:04   #13
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Thanks a lot for sharing this information. Well deserved 5 stars on the same. After reading your thread - it felt like I was there and felt each and everything happening there.

Wondering when this will come back to Mumbai/Pune... My ride needs to flex a bit!
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Old 11th October 2012, 02:50   #14
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

brilliant job done boss. i am at a loss of words

i think dentists make some of the best engineers!!
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Old 11th October 2012, 10:14   #15
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Default re: 2012 Toyota Bootcamp : How to convert barren land into a 4WD Track!

Excellent Track by Allan, Dr. Tejas and the team. The event was very well organised and I hope to see the guys next year with even more challenges.
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