THE ULTIMATE OFF-ROAD RE-BUILD
Two years of major mods resulted in a tricked-out 1976 Toyota Chinook that was refined to perfection one piece at a time.
My foray into the nomadic lifestyle started in the spring 2017. It was not a simple decision but following my gut instinct, I listed my house for sale and started shopping for a new vehicle that would ideally suit my desire for off-road travel. I have always been partial to Toyota rigs and 1970-era vehicles, which eventually narrowed my choice down to a 1976 Toyota Chinook due to its size, functional space, and styling.
The change happened quickly. I sold my house in Western Canada, located the perfect Toyota Chinook in the fall of 2017 (800 miles away in Chico, CA) and I was on my way to fulfilling my perfect build. Not only was I planning to modify the Chinook, but I was aiming to achieve a minimalized nomadic life of traveling endless dirt roads.
To make a long story short, the Chinook was hard to insure and the motor knocked so bad that I feared that it would meet its demise after climbing every large hill. Despite these challenges and the long, exhausting drive, I made it to the Canadian border and was ready to import the vehicle.
To me, the golden words in the automotive world are “from California” and my new-to-me 1976 Toyota Chinook was the epitome of those words. I planned the build around the exceptional body and frame, which meant there was an incredible amount of custom modification to the drivetrain and suspension.
The axles, pulled from a 1984 Toyota pickup that I purchased for parts, were completely rebuilt by Disturbed Industries that specializes in Toyota vehicles (and several other makes and models). The front and rear differentials feature Yukon Zip Lockers that run a 4.56 gear ratio. Now new from end to end, both axles include upgraded brakes and the front features RCV 30 spline axle shafts, while the axle gussets, differential armor and high-steer conversion were supplied by Trail-Gear. Disturbed Industries also recommended the ideal engine, but more on that later.
When the axles were completed, I drove my imported (and now legal) Canadian Toyota Chinook to Big Country Customs that specializes in customizing 4x4s. This is where the real transformation began.
The Suspension, Drive Train and Exterior Styling
To start with, modifications were made on the frame to accommodate larger leaf springs at the front and rear. After some trial, error (and some creative fabrication), the suspension
consists of 1985 Toyota OME Dakar front leaf springs with 2012 Toyota Tacoma All-Pro Expedition rear leaf springs to accommodate the increased weight.
In addition, the driveshafts were built to length; airbags were added to the rear; and Bilstein 5100 shocks were placed on all four corners. I also picked up 17” steel rims (from a 1970s Land Cruiser-styled reproduction) with chrome center caps, wrapped in 34 x 10.5” BFGoodrich KO2 tires (with a spare under the truck). With the new suspension in place, the Chinook was loaded on a flatbed and sent to yet another local shop, Cruisin Off Road.
With the creative expertise of owner Jason Hugh, the Chinook pretty much underwent a complete exterior face-lift. The front bumper was designed to enhance its classic profile (complete with a Warn CTI 12000 lb winch with synthetic line), while welded sliders were added from the front fenders to the back bumper, thus protecting the fibreglass shell and strengthening the frame.
Aluminum storage boxes were also incorporated, utilizing the empty space behind a fibreglass facade mounted above the sliders. The factory frame extension, which was replaced by a fully boxed tube frame, interconnected with the sliders and rear bumper so I could tow more effortlessly and accommodate a swing-out motorcycle carrier, custom fitted for my 1973 Yamaha RT3 360cc.
Hugh’s work didn’t stop there. A custom aluminum roof rack was mated to an internal aluminum sub-frame on the roof to eliminate “roof sag” (that’s common with these vintage Chinooks) or any load bearing, thus preventing the chance of water leakage in wet weather (or damage to the fibreglass). Powder-coating was added all-around as were some slick limb risers featuring custom-formed plates where they attach to the truck and camper. Following these mods, I returned the Chinook back to Big Country Customs.
Keeping it Toyota
With the exterior and suspension now modified, it was time to focus on the engine. The original plan was to build a hybrid 20R/22R with a new power-steering pump. However, due to the weight of the truck at 3,311 kg (7,300 lbs), the final choice was a 3.0L Toyota turbo-diesel, a 1KZ-TE from a 1995 Toyota JDM Hilux Surf.
Rebuilt and shoe-horned into the engine bay, the turbo diesel was mated to a Toyota R151F transmission. With a final gear ratio
of 4.56, the Chinook now provides ample power and torque. An entirely new and custom engine harness was also added, along with remote battery isolation and custom gauges.
Other parts that are now in the harness include an ARB twin compressor, variable speed electric fans, a Switch Pros remote switch pod, HID/LED headlights plus a Blue Sea Systems remote battery isolator for multiple charging. Additionally, the engine bay conceals a full stainless custom exhaust, KRAE TDOX-HD Turbo, a mechanical injection pump, an aftermarket intercooler, a Wilwood master cylinder, and a large, 3-core aluminum radiator. A secondary fuel tank was also added to achieve a total fuel capacity of 120 L (32 gal).
Lighting and Exterior/Interior Comfort
While I had input on most of the mechanical build, I did most of the interior and exterior wiring and aftermarket installations myself. Lights surround the truck. Some are only accessible from the camper while others, such as the flood lights, are controlled from the driver’s console.
For added illumination (and some bling) I mounted Baja Designs' S2 Sports to the roof rack, rear bumper and camper sides. I also included Squadron Pro fog lights to the front and RTL-M's for additional braking visibility in the rear.
Of course, including the utmost comfort and function was an important part of this
build. I mounted a Rhino-Rack Foxwing Awning as well as a Jeep tailgate shelf to house an external barbeque. Concealed in the external compartments are a 20 lb propane tank and two 12V Gel deep-cycle batteries, as well as recovery gear, essential tools and other supplies. For quieter and comfortable rides, the interior is lined with Dynamat and Soundmat insulation, heavy carpeting, along with new aftermarket seats. A 50W Kenwood VHF radio and RetroSound stereo and hand-sewn leather accents were other necessary appointments.
The Camper
Gutting the interior provided a clean, blank slate to build upon. Materials were sourced throughout the two-year build process and most, if not all, are now in the truck. From the 100 percent wool lining (provided by Havelock Wool, Portland OR) to various types of cedar used for the accents, paneling, and the countertop, the camper provides a warm and comfortable space.
What can’t be seen is the central wiring hub that houses a solar controller, 600W inverter, battery monitor/isolator and the lighting controls. Also tucked away are an Eberspacher D2 Airtronic diesel heater, multiple USB ports and even a 75 l (20 gal) freshwater tank. Further, removing the original A/C converter allowed the addition of a hard-mounted deep-cycle charger. Combined with 300 watts of the roof-mounted solar panels, the batteries are maintained at all times, no matter the demand.
Some functional features include roof ventilation, dimmable lights, four corner mounted
lamps, a custom pull-out bed and mattress, as well as pull-out drawers and cabinets to offer ample storage. I also installed a Dometic 12V fridge and propane stove to add function to all the comfort.
At the end of the build, never did I imagine I would have this opportunity to custom create my dream truck. As with all builds, there are still a few ongoing tweaks, but as of March 2019, it was finally completed and ready for the road.
While we still haven’t taken our dream trip, we have traveled more than 15,000 kilometers (9,320 mi) and always find the time to get out and explore new off-road destinations. Of course, it’s enjoyed in renewed style and the utmost comfort.