Custom 4x4: Hilux pre-runner

What can be more rewarding than taking the 4x4 you’ve built with your own skills, and blasting it all over the outback? In the case of Joel Fowler and this 2014 Hilux SR, that blasting is conducted at high speed and regularly off the ground.

Joel originally started his 4x4 life with a single-cab N70 Hilux, which he duly modified and enjoyed for more than six years before reverting it to stock and trading in on a rally-inspired 2014 WRX hatch. Combining the ability to conduct spirited driving and all-wheel drive proved the little hatchback a winner in Joel’s eyes: “It was probably the best car I ever have had, but you just couldn’t do much in it.”

Missing the beach and bush driving had Joel scanning the classifieds only six months later for another Hilux. “It had to be exactly what I was looking for, but this time it had to be auto, and maybe a TRD if I could find one,” he explained.

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The aim being to build an off-road rig in a pre-runner style capable of maintaining high speeds across the rutted and frequently washed-out Kalgoorlie dirt roads which Joel calls home. A short time later Joel spotted this untouched 2014 Tidal Blue SR example sitting in a car yard. So the Rex was swapped over and Joel was back in a Hilux again.

With Joel being the talented metal fabricator (Fowler Fabrication) that he is, you could borrow money to bet that his new whip wouldn’t stay standard for long. “It was bone stock, so I dropped by the workshop on the way home from the dealer and chopped the exhaust off. Just to make it sound a little better.” That exhaust now exits racer-style just below the right rear door, now upgraded to a three-inch diameter with a J-pipe/resonator and hotdog.

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UNDER CARRIAGE

That took care of the aurals, but 4x4 looks matter and a more aggressive stance was needed for the high-flying antics Joel had in store for the Hilux. A set of D-Hole steel rims where chosen for strength, before being wrapped in 285/70R17 Sailun Terramax ATs. The -22mm offset pushing the ensemble an extra 52mm wider on each side than standard and, according to Joel, gives a much more stable ride at speed. Keeping those tyres off the 'guards and bodywork was paramount, with Joel lifting the body and tub two inches before setting about building the suspension to suit.

Just bolting on a set of steelies and tyres isn’t going to get you sailing over rampant undulations, Joel instead building something with longer than standard suspension travel and much more damping control. Starting with the front, a pair of Dobinson MRA remote-reservoir struts with 2-inch taller coils were installed. These allow for the adjustment of both slow- and high-speed compression control, making suspension tuning a far easier task.

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When it came time for the rear suspension Joel went to the next level after experiencing some failures with his first Hilux. “I went with a kit which was a basic off-the-shelf bolt-on,” he tells us, because, “It was probably too hard, as the eyes of the shocks were breaking off and the seals were blowing out. The overall ride was just way too hard.”

To remedy those failures with this build Joel upgraded to a Profender 10-inch triple bypass shock set-up in a custom shock cage that also houses the remote reservoirs. The length of these shocks required holes to be cut in the tub floor and the cage mounted inside the tub itself. This does nothing for the sealing of the tub inside the canopy, however the benefit being it allows a far greater range of movement from the currently standard leaf packs.

Keeping in mind Joel’s intention was to be able to jump his ’Lux regularly, a pair of four-inch hydro bumps were installed along the outside chassis rails, providing a far better form of bump stop when slowing down the almost maxxed-out compression travel when coming back to earth.

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ENGINE MODS

While the majority of owners would go for the most power they can afford, Joel has made the engine modifications more in line with his own philosophy. “Your car’s useless if you can’t get the power to the ground,” he says. “If you go out bush and you want to go fast, having all the power in the world means nothing. I tell everyone, sort the suspension out properly and you will go faster.”

With those wise words in mind the engine mods were kept modest, delivering a safe raised boost level via a Stage 2 ProCharge GTX turbo. A generic front-mounted intercooler found its way behind the Bmesh grille, with the pipework taken care of by Joel himself.

Connected to his own four-inch snorkel, a custom air box was next, with a cone filter element complete with clear Perspex cover and lobster-back joins on the curved four-inch turbo intake pipe. Combined with an ECU remap, the turbo now funnels 23psi in to the stock engine. While Kalgoorlie is currently devoid of a dyno, Joel estimates the power to be in the 190hp-550Nm range.

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CABIN RENO

Once the suspension and power were working together, Joel turned his attention to making the interior more fit for purpose. Anyone who has taken a standard Hilux for an extended journey would agree the standard pews tend to turn into cement slabs after a short amount of time. Remedying this, a pair of leather and suede-covered Toyota 86 GTS buckets were chosen, with the standard seat rails modified to suit.

Keeping his passenger entertained is a Kenwood 919 head unit pumping vibes to Kenwood Stage Sound six-inch speakers and eight-inch sub/amp combo. Letting his mates know where he’s gone after leaving them behind is a GME TX3100 radio and stubby antenna.

Making space for a fridge and some recovery gear saw the rear seat deleted and a false floor installed, hiding an ARB compressor complete with external power switch and hose connection. As a lucky charm, a Chuck Norris DVD and a mate’s holed Hilux piston is kept in the rear firewall’s storage bag at all times.

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Hopefully with the undefeatable power of big Chuck, those currently stock pistons will stand up to all the pounding the turbo and trails serve up to them. Rounding out the rear end, an ARB fibreglass canopy houses three XTM drawer sets bolted down alongside a pair of MaxTrax recovery boards.

If the stance and colour wasn’t enough to get him noticed, Joel took to the bonnet and fitted an FG Falcon bulge. Complementing the new look are a pair of 60mm Utemart flares, along with some aggressive trimming of the standard front bar. The absence of a steel bullbar keeps the front end light, increasing the ability to leave terra firma. Rounding out the front are a pair of halo headlights, a 22-inch light bar and a Stedi 50-inch curved light bar up high.

Keeping in mind his rig gets taken anywhere and everywhere, Joel would like to thank Regan Carter for keeping it looking top notch, and James Hitchcock from Hitchcock Engineering and Powder Coating (Broadwood, WA) for his assistance. Seeing the way Joel has adapted his Hilux using his own fabrication skills to get it doing exactly what he set out to achieve, only bodes well for what he has planned for the future. We can’t wait to see where that takes him.