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Old 22nd May 2017, 15:49   #106
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

Here are some pics of the Jerry can fitted on the roof rack.

Even mounted the tow strap temporarily on top using a quick fist mount.

Will soon have an SS or Aluminium custom case fabricated and mounted for recovery accessories.

And a few pics from last saturday's drive.

Mitsubishi Pajero SFX - Project Overland Conversion-img_0889.jpg

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Old 30th June 2017, 11:50   #107
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

After a long time finally got a chance to fit the snorkel. This snorkel was ordered from Tushar Amin (Amin Sons - Baroda - contact given earlier). It's a TJM clone and costs approx 12k, whereas the original TJM one costs 30k.

What's different?

The TJM one definitely has better finishing with the TJM logo embossed on the body. The snorkel head grill is also better.

The original has "magic grooves" to divert away rain water that gets sucked in while driving. This clone is supposed to have it. Time will tell.

Others who have had this snorkel installed on their Pajeros for over 2-3 monsoons have no water issue and this gave me the confidence to get this one. Else no way i would have risked water ingestion.

After installing yesterday, i drove in heavy rain back home (30kms) and then checked the air box. Was dry and so was the filter.

But will periodically keep checking in the rains.

The other thing that the clone doesn't have is a 'firma' or guide or stencil to guide you to make holes.

All my work for the vehicle is done at my friend, Allan's garage and he refused to do trial and error lest some hole goes wrong.

So i requested a friend who would one day get this pajero (he already had the snorkel installed from someone else who had done many previous installs) to Allan's garage and allan took the stencil copy from his vehicle.

Thanks Harshil

Step by Step Procedure


1. Here's the stencil cutout:

Mitsubishi Pajero SFX - Project Overland Conversion-00stencil.jpg

2. Masking tape on the vehicle to aid marking and avoid paint damage while drilling

Mitsubishi Pajero SFX - Project Overland Conversion-01-masking.jpg


3. Stencil positioned on the vehicle. It's then secured by tape and then the marking transferred.

Mitsubishi Pajero SFX - Project Overland Conversion-02-firma.jpg

4. Marking transferred.

Mitsubishi Pajero SFX - Project Overland Conversion-03-hole-marked.jpg


5. Airbox and internal wheel well cladding to be removed. Even side indicator light needs to be removed.

Mitsubishi Pajero SFX - Project Overland Conversion-04-remove-airbox-wheel-arch-cladding.jpg


6. Drilling holes. Due to the contour of the body panel, one large drill could not be used.

Mitsubishi Pajero SFX - Project Overland Conversion-05-drilling.jpg

7. The holes:

Mitsubishi Pajero SFX - Project Overland Conversion-06-holes.jpg

8. Joining the holes using a metal cutting shear

Mitsubishi Pajero SFX - Project Overland Conversion-07-joining-holes.jpg

9. Removed the centre part:

Mitsubishi Pajero SFX - Project Overland Conversion-08-removed-centre.jpg

10. Finishing with an angle grinder

Mitsubishi Pajero SFX - Project Overland Conversion-09-smoothening.jpg

11. Smoothening with a file

Mitsubishi Pajero SFX - Project Overland Conversion-10-filing.jpg

12. The hole for the snorkel:

Mitsubishi Pajero SFX - Project Overland Conversion-11-clean-hole.jpg

13. Next is to make a template for the screws and position it on the vehicle to transfer markings:

Mitsubishi Pajero SFX - Project Overland Conversion-12-firma-2.jpg


14. Drilling screw holes:

Mitsubishi Pajero SFX - Project Overland Conversion-13-screw-hole-drilling.jpg

15. Checking position of the bracket on the A pillar:

Mitsubishi Pajero SFX - Project Overland Conversion-14-checking-position-bracket-pillar.jpg

16. Checking final position:

Mitsubishi Pajero SFX - Project Overland Conversion-15-checking-fit.jpg

17. Fitting the internal coupling that connects the snorkel to the air box. Forgot to take pics of the same:

Mitsubishi Pajero SFX - Project Overland Conversion-16-fitting-internal-coupling-connects-snorkel-airbox.jpg

18. The coupling end towards the snorkel:

Mitsubishi Pajero SFX - Project Overland Conversion-17-coupling-end-towards-snorkel.jpg

19. This again where the clone is not good as the original. We had to cut off a bit of the extension from the snorkel to get a good fit:

Mitsubishi Pajero SFX - Project Overland Conversion-18-cutting-snorkel-attachment.jpg
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Old 30th June 2017, 11:57   #108
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

All the hole edges were then painted with a brush to prevent any rusting.

This is the part that connects to the inside of the coupling and the air box.

Although it has a rubber gasket, after fitting we resealed with silicone.

Mitsubishi Pajero SFX - Project Overland Conversion-19-internal-fitting.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-20-fitting-internal.jpg

All other connections also resealed with silicone before final fitting

Mitsubishi Pajero SFX - Project Overland Conversion-23-silcone.jpg

The bracket on the A pillar is riveted using supplied rivets:

Mitsubishi Pajero SFX - Project Overland Conversion-21-pillar-bracket-rivet.jpg


Again, hole is touched up with paint and a rubber strip inserted before fixing the rivets to minimize water ingress:

Mitsubishi Pajero SFX - Project Overland Conversion-22-rubber-gasket-belwo-bracket.jpg

Fitting everything back:

Mitsubishi Pajero SFX - Project Overland Conversion-24-fitting-box-back.jpg


Snorkel is ready:

Mitsubishi Pajero SFX - Project Overland Conversion-25-ready.jpg


Close up of the fit:

Mitsubishi Pajero SFX - Project Overland Conversion-26-close-up.jpg


Parting shots:

Mitsubishi Pajero SFX - Project Overland Conversion-27-parting-shot-1.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-28-parting-shot-2.jpg
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Old 4th July 2017, 12:57   #109
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

A few snaps clicked during some events we did in and around mumbai over the past few weekends.

The foxing awning is a boon!

Mitsubishi Pajero SFX - Project Overland Conversion-img_1276.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1279.jpg

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Mitsubishi Pajero SFX - Project Overland Conversion-img_1656.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1698.jpg

Last Photo clicked by Manan Patel (garrett_t16 on team-bhp).

The other Pajero is owned by Amol Sethi. Known as Sun_Chaser on team-bhp.
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Old 5th July 2017, 11:53   #110
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Tejas, very informative thread! Many thanks for all the details.

Have you honed on the CB radios and what is probably a good one ? Can you guide me as well please
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Old 5th July 2017, 13:56   #111
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

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Originally Posted by getsurya View Post
Tejas, very informative thread! Many thanks for all the details.

Have you honed on the CB radios and what is probably a good one ? Can you guide me as well please
Thanks.

Not yet got the time with regards to the CB radio. But it's on the list. A couple of months i should be finalising what i need to buy.
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Old 6th July 2017, 14:45   #112
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

Some fun while making the Mercedes Track recently:

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Old 18th July 2017, 12:38   #113
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

Quote:
Originally Posted by Tejas@perioimpl View Post
After nearly 6 months of fixing the KC lights, finally got some time to wire them.
Just wired the KC Hilites and the LED bar.

The internal rocker switches are too bright. Need options to cut down the light intensity. Either using a resistor or a black marker on the LED bulb itself.

Attachment 1640183

The lights:

Attachment 1640182


Not too happy with the spread of the light bar as i had hoped.

The KC's are brilliant as driving lights though.

Still have to wire the HID lights on the roof rack.
Not sure if installing the lights on the roof rack are a good idea. I had to remove 4 auxbeam led lights from the roof rail because the traffic cops objected to it here in Gurgaon. I looked up the CMVR and also found that installing auxiliary lights above 1.5 meters from the ground is not allowed. Can you guys provide your inputs on the law as well?
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Old 18th July 2017, 12:49   #114
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

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Originally Posted by Hondaism View Post
Not sure if installing the lights on the roof rack are a good idea. I had to remove 4 auxbeam led lights from the roof rail because the traffic cops objected to it here in Gurgaon. I looked up the CMVR and also found that installing auxiliary lights above 1.5 meters from the ground is not allowed. Can you guys provide your inputs on the law as well?
It is true. Aux lights must always be below headlight level.

I'm in the process of getting covers made for the roof lights. These lights will be used only during offroad expeditions.
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Old 18th July 2017, 13:08   #115
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

Some snaps from a recent day picnic to an offbeat location.

Mitsubishi Pajero SFX - Project Overland Conversion-img_0880.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_0881.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_0887.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_0914.jpg

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Mitsubishi Pajero SFX - Project Overland Conversion-img_1760.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1777.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1778.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1781-copy.jpg

Mitsubishi Pajero SFX - Project Overland Conversion-img_1816.jpg

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Old 19th July 2017, 16:03   #116
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Wow! Super pictures there Tejas
Could you please share the location if you don't mind? Would love to take my truck there.
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Old 19th July 2017, 16:15   #117
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

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Wow! Super pictures there Tejas
Could you please share the location if you don't mind? Would love to take my truck there.
It's a private trail and i'll have to ask my friend if i can give coordinates. Sorry.
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Old 25th July 2017, 01:07   #118
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

Quote:
Originally Posted by getsurya View Post
Tejas, very informative thread! Many thanks for all the details.

Have you honed on the CB radios and what is probably a good one ? Can you guide me as well please
Quote:
Originally Posted by Tejas@perioimpl View Post
Thanks.

Not yet got the time with regards to the CB radio. But it's on the list. A couple of months i should be finalising what i need to buy.
I am also looking for solutions to have a 2-way comm link in a convoy. Not a pressing need for me, this one. It's more like a good to have thing.

How does a basic 2-way radio fare in such conditions? A basic 0.5-1W doesn't have any license needs afaik, but still I remember reading about walkie talkies being restricted items and incoming packages being withheld. Also, with such low power, wonder if it will be able to receive/transmit effectively.
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Old 3rd August 2017, 13:07   #119
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Default Re: Mitsubishi Pajero SFX - Project Overland Conversion

I believe it would be a good idea to powdercoat the rear ladder and tail light guards black. It will make your already impressive looking Pajero even better looking.
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Old 3rd August 2017, 19:10   #120
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Great job Tejas. Following the post since you started it. Iam interested in the front bumper job, the rack and lights for my Pajero 2009 black done approx 65K. Sparingly being used now and requires some change of appearance now. Based in Chandigarh I have limited options. Looking forward to here from you.
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