As soon as I saw the similar dog's breakfast taillight wiring to mine, I knew I had to sub. This is the first video I've (well currently am watching) watched, and yep. I can relate. I bought an 05 V6 4.0l RWD auto Hirider crew cab with an aftermarket 1800 x 1800 aluminium tray, and man, yeah, the rewiring was dodgy as. Some useless trivia: My 2005 (and all the others of course) was one of the earliest models that had the bodies manufactured at the Ford/Mazda plant in Thailand, and then were shipped to South Africa to have the V6 SOHC 4.0 litre fitted. Then they were shipped over here. Mine is the 'Hi-Lifter' version. It is a 4WD chassis and suspension etc. but is only RWD. I've done a lot of work to it over the past year or more to make it reliable enough to be my mobile mini-home. I plan on making a video soon that covers everything I've done so far but I'm a procrastinator when it comes to editing. I've got a couple up on my channel though.
@@Finndawg Haha. Yep. Mine is still coming along. I've pulled out the back seat and have my solar 12/240 system in there. A flat, 100-litre water tank will go where the seat was so I can spread the weight around. I'll be doing another wave of work on it in the coming weeks.
@@Finndawg I'm actually going to be living in it. I need to get back on the road and see other places again. I've got the ideas for the back sorted. All my workshop (tools, small welder and compressor etc) will be on the tray and I'll have an elevated platform for my bed/tent or whatever I work out. At this rate, I'm also looking at fixing up a trailer as well, to carry stuff. I've got a gas hot water system and pump, as well as a few other luxuries (stove, dual zone camp fridge etc) so I'm pretty sure my workshop will end up in a trailer.
Just find it so funny, you can basically do all these mods to a courier and never get pulled over...Yet a pod filter upgrade in some states gets you a green or pink sticker lol
Hahaha you're not wrong, I do get pulled over but I'm never doing anything too wild so they don't really dig deeper. To be fair I think most of the shit I've done looks pretty tidy so there's nothing blazingly obvious that'll draw crazy attention.
What model xr6 was the intercooler from?, i definitely need to increase mine to lower temps, i did change the standard one to the slightly bigger pk one which helped a lot but under load towing it climbes to quickly.
One more comment about wiring. Because the '05 V6 Couriers were first introduced in early 2005, the wiring looms installed in Thailand were dual-purpose. There is a lot of redundant wiring and plugs etc in the engine bay and under the dash.
18:15 My jigger still has the original AM/FM radio/cassette player, and the original (I'm replacing them) speakers. I'm going to keep the original player because it has a line-in jack and I want to try to keep the dash original, just for old-school fun's sake. I've placed my spotlight and cooling fan switches in unobtrusive, yet easy-to-reach spots. My next project is to remove the old light control panel from the old Bedford bus I live in. It has a row of 5 push/pull switches along the top, a cigar lighter, on the side, and a door that opens to the fuse box. It's made of that really old-school crackled powder-coated gal steel with brass fittings, so I want to use it in the ute. I'm also salvaging the lever handle for the air-operated French doors of the bus. If I get an air-locker rear diff, I'll use the lever handle to go all Steampunk.
16:58 As I said, this is the first video of yours that I've seen, so didn't realise how much work has gone into this old jigger. Power mirrors too? Geez, mate. Compared to what you've done to that ute, my 05 is a povo pack. Manual mirrors, manual windows, no airbags. BUT, it has the coldest aircon I've felt in an older vehicle for a long time. The problem is, if you use it, you can also watch the fuel gauge drop.
8:38 Your interior looks schmick, mate. When I got my ute dropped off when I bought it, the previously functional instrument cluster had failed. At some point between my committing to buying it and the two-week period before I could get it on a truck to be delivered, water had got onto the back of the cluster...essentially on the plastic circuit board and blew transistors and stuff. I tried to source the specific year/model/engine capacity cluster online and all I could find was a repair service that charged around 600 bucks to fix it. I then went hunting further. There were some 6000 RPM diesel clusters online, and then there were some 7000 RPM diesel clusters. I called a well-respected vehicle recycler in Brissie and they only had clusters from the diesels and said emphatically that they wouldn't suit my vehicle. So I looked closely at my 7000 RPM cluster and there was zero difference between the diesel cluster and mine. Well, really, the only difference was mine had White backgrounds for the tacho etc and the others had Blue. All signals are fed to the cluster via the ECU anyway. During my hunt, I'd found one in a WA dismantler's online store for $350 bucks (the Brissie one was $250). So, I ordered the Blue 7000 RPM cluster from the store in WA as a gamble. And BINGO! Plugged it in, and the 360000 km odo worked, as did everything else. All I had to do was swap a few warning light bulbs around to match my no-airbag configuration.
Hey mate I have the same set up as you and have a problem with turbo lag and have the custom intake plenum from Gareth. How much quicker did it spool up with stock air intake? Robbie
Hey Finndawgs Driveway, can you please explain how wastegate opens when engine is revving but throttle pad is off, I am asking this because I am planning to install turbo charger on a W9 engine
The waste gate opens when a certain amount of pressure (set my a spring inside the waste gate) reaches the gate, once it hits say 10psi the gate will open stopping the turbo from producing more boost than it can handle. Sorry for the late reply I hope that helped
Hi, i have noticed from your previous video you installed an oil catch can and i noticed in this video no oil catch can insatalled. Is not good? Reason why you uninstalled it?
I ended up just removing no it, no particular reason, but all it really did was stop oil pooling in the intercooler, they're much more important on engines with EGR's present
Hey mate just wondering what turbo you have? I have a high mount setup aswell but running Gareth's turbo with the td04 internals suited for 40psi. Goes nice but want something a bit more response and a lower peak power as I'm not too keen on getting the 5600rpm(I think) govern spring. Other than that, wicked car man looks great!
I'm running the same turbo mate, I have a fully built pump but it's not in the car any more ended up putting a stock pump in. I am actually currently rebuilding a turbo and putting my own internals in it, should be interesting gonna make some vids on it
I'm looking at getting my hands on one of these - is yours completely mechanically injected or is it the electronic version? Seems to be hard to find the older ones without the EGR and no electronic injection.
Wow. I thought a full alloy would bring them down. Ive just noticed that the coolant level was a bit low. Mechanic may not have waited for the thermostat to open to top it up. Just saw I may be able to install original airbox in engine bay as its opening is located away from the exhaust manifold. It may also help with engine temps. @@Finndawg
that's pretty sick love everything you've done to it, im slowly making my way through replacing everything making everything new again on my pg, how much did it cost you in parts for the rebuild. Also not sure if you've said anything about the exhaust manifold but was that a custom job? or did you find them somewhere
Thanks mate and good luck with your build, they're custom made by a guy off Facebook called Gareth Brunt mate, no easy way to put you in contact with him sorry.
Love the content man! Any videos of you hooking up the a/c ? I’m trying to fit a Intercooler at the moment and the a/c filter is in the way. I wanna fuck the whole thing off but reckon I’ll regret it in summer. Cheers!!
Hey mate love the build thing is looking incredible, fingers crossed you get to enjoy it this time. Just a question are you planning on putting in a diff drop after you lift it or just going to deal with it?
Hey mate, I am probably not going to lift it, I have the lift kit there from the other ute but I'm kind of loving the way it sits at the moment, I don't really do anything that would require additional lift further than the extra clearance the bigger wheels provide. But when I did have the lift kit on the Bravo I just dealt with the CV angles.
@@Finndawg hey mate, I was just wondering if you still had the motor that you took out the one with a snapped glow plug and what not? Need to rebuild a motor to put in mine but don’t want to pull out the motor to rebuild it so if I can get a second one to rebuild slowly while the other still runs I’ll be laughing.
@joshshipp4735 that's exactly what I did mate! But unfortunately I sold the spare motor to a fella for parts. Best bit is finding somebody wrecking one and try snag one cheap.
It's just my old radiator man, OEM stock as a rock. The alloy one I fitted by "alloyworks" or a similar name was just Chinese trash, causing 100+ degree celsius temps on the highway.
Single handedly made me want to build my 2004 XL dualcab, I think I'm in love.
Hahaha I'm happy I provided some inspiration for your build 😁 thanks for watching and commenting it means alot.
As soon as I saw the similar dog's breakfast taillight wiring to mine, I knew I had to sub. This is the first video I've (well currently am watching) watched, and yep. I can relate.
I bought an 05 V6 4.0l RWD auto Hirider crew cab with an aftermarket 1800 x 1800 aluminium tray, and man, yeah, the rewiring was dodgy as.
Some useless trivia: My 2005 (and all the others of course) was one of the earliest models that had the bodies manufactured at the Ford/Mazda plant in Thailand, and then were shipped to South Africa to have the V6 SOHC 4.0 litre fitted. Then they were shipped over here.
Mine is the 'Hi-Lifter' version. It is a 4WD chassis and suspension etc. but is only RWD.
I've done a lot of work to it over the past year or more to make it reliable enough to be my mobile mini-home. I plan on making a video soon that covers everything I've done so far but I'm a procrastinator when it comes to editing. I've got a couple up on my channel though.
Thanks so much for the comments mate! I'm glad somebody can relate to my dogs breakfast wiring drama's hahahhaa
@@Finndawg Haha. Yep. Mine is still coming along. I've pulled out the back seat and have my solar 12/240 system in there. A flat, 100-litre water tank will go where the seat was so I can spread the weight around. I'll be doing another wave of work on it in the coming weeks.
That sounds great, going to be a handy bit of kit to have on board, the water will be great too, is that all for camping?
@@Finndawg I'm actually going to be living in it. I need to get back on the road and see other places again. I've got the ideas for the back sorted. All my workshop (tools, small welder and compressor etc) will be on the tray and I'll have an elevated platform for my bed/tent or whatever I work out. At this rate, I'm also looking at fixing up a trailer as well, to carry stuff.
I've got a gas hot water system and pump, as well as a few other luxuries (stove, dual zone camp fridge etc) so I'm pretty sure my workshop will end up in a trailer.
Good job mate loved watching the build hoping you the best for the rig 🤙🏼💯
Thanks brother, fingers crossed 🤞 I don't have anything happen to this one.
Just find it so funny, you can basically do all these mods to a courier and never get pulled over...Yet a pod filter upgrade in some states gets you a green or pink sticker lol
Hahaha you're not wrong, I do get pulled over but I'm never doing anything too wild so they don't really dig deeper. To be fair I think most of the shit I've done looks pretty tidy so there's nothing blazingly obvious that'll draw crazy attention.
What model xr6 was the intercooler from?, i definitely need to increase mine to lower temps, i did change the standard one to the slightly bigger pk one which helped a lot but under load towing it climbes to quickly.
One more comment about wiring. Because the '05 V6 Couriers were first introduced in early 2005, the wiring looms installed in Thailand were dual-purpose. There is a lot of redundant wiring and plugs etc in the engine bay and under the dash.
Yeah it was the same in my ute, just didn't have the same loom going from the dash to the windows.
18:15 My jigger still has the original AM/FM radio/cassette player, and the original (I'm replacing them) speakers. I'm going to keep the original player because it has a line-in jack and I want to try to keep the dash original, just for old-school fun's sake. I've placed my spotlight and cooling fan switches in unobtrusive, yet easy-to-reach spots.
My next project is to remove the old light control panel from the old Bedford bus I live in. It has a row of 5 push/pull switches along the top, a cigar lighter, on the side, and a door that opens to the fuse box. It's made of that really old-school crackled powder-coated gal steel with brass fittings, so I want to use it in the ute. I'm also salvaging the lever handle for the air-operated French doors of the bus. If I get an air-locker rear diff, I'll use the lever handle to go all Steampunk.
16:58 As I said, this is the first video of yours that I've seen, so didn't realise how much work has gone into this old jigger. Power mirrors too?
Geez, mate. Compared to what you've done to that ute, my 05 is a povo pack. Manual mirrors, manual windows, no airbags. BUT, it has the coldest aircon I've felt in an older vehicle for a long time. The problem is, if you use it, you can also watch the fuel gauge drop.
Hahahaha I have the same problem when I use my aircon 😆
love your work mate looks great
Thank you ✌️
8:38 Your interior looks schmick, mate.
When I got my ute dropped off when I bought it, the previously functional instrument cluster had failed. At some point between my committing to buying it and the two-week period before I could get it on a truck to be delivered, water had got onto the back of the cluster...essentially on the plastic circuit board and blew transistors and stuff.
I tried to source the specific year/model/engine capacity cluster online and all I could find was a repair service that charged around 600 bucks to fix it. I then went hunting further. There were some 6000 RPM diesel clusters online, and then there were some 7000 RPM diesel clusters. I called a well-respected vehicle recycler in Brissie and they only had clusters from the diesels and said emphatically that they wouldn't suit my vehicle. So I looked closely at my 7000 RPM cluster and there was zero difference between the diesel cluster and mine. Well, really, the only difference was mine had White backgrounds for the tacho etc and the others had Blue. All signals are fed to the cluster via the ECU anyway. During my hunt, I'd found one in a WA dismantler's online store for $350 bucks (the Brissie one was $250). So, I ordered the Blue 7000 RPM cluster from the store in WA as a gamble. And BINGO! Plugged it in, and the 360000 km odo worked, as did everything else. All I had to do was swap a few warning light bulbs around to match my no-airbag configuration.
Hey mate
I have the same set up as you and have a problem with turbo lag and have the custom intake plenum from Gareth. How much quicker did it spool up with stock air intake?
Robbie
Sorry for the late reply, but it spooled up alot faster with the stock intake over the big intake plenum
Great job are you able to take a photo of the brackets that hold your bullbar on
All done worked it out thank you
hey mate where you get the pillar pod from and is it for the couriers or just a universal one ?
Sorry for the late comment, it's from a pj/pk ford ranger, easier to look it up like that and it just fits over the stock plastics.
16:55 I was gunna say, "Power windows. That's a bit flash!"
Hahahaha very flash
hey mate where did you get snorkel from?
This snorkel came with my old ute, but I recently changed it out too a tjm airtec.
Hey Finndawgs Driveway, can you please explain how wastegate opens when engine is revving but throttle pad is off, I am asking this because I am planning to install turbo charger on a W9 engine
The waste gate opens when a certain amount of pressure (set my a spring inside the waste gate) reaches the gate, once it hits say 10psi the gate will open stopping the turbo from producing more boost than it can handle. Sorry for the late reply I hope that helped
Hi, i have noticed from your previous video you installed an oil catch can and i noticed in this video no oil catch can insatalled. Is not good? Reason why you uninstalled it?
I ended up just removing no it, no particular reason, but all it really did was stop oil pooling in the intercooler, they're much more important on engines with EGR's present
Hey mate just wondering what turbo you have? I have a high mount setup aswell but running Gareth's turbo with the td04 internals suited for 40psi. Goes nice but want something a bit more response and a lower peak power as I'm not too keen on getting the 5600rpm(I think) govern spring. Other than that, wicked car man looks great!
I'm running the same turbo mate, I have a fully built pump but it's not in the car any more ended up putting a stock pump in. I am actually currently rebuilding a turbo and putting my own internals in it, should be interesting gonna make some vids on it
Loving the content🤙
Thanks legend 🙌
I'm looking at getting my hands on one of these - is yours completely mechanically injected or is it the electronic version? Seems to be hard to find the older ones without the EGR and no electronic injection.
Completely mechanically injected, nah its not too bad just look for ones pre 2004-2003 most of the ones 1999-2003 are purely mechanical.
Good work. Do you run a standard radiator to assist with keeping engine temps down at high work load?
Exactly right, I put on aftermarker alloy rad and my load temps shoot way up
Wow. I thought a full alloy would bring them down. Ive just noticed that the coolant level was a bit low. Mechanic may not have waited for the thermostat to open to top it up. Just saw I may be able to install original airbox in engine bay as its opening is located away from the exhaust manifold. It may also help with engine temps.
@@Finndawg
What's your fuel consumption? I find mine to be horrendous, at less than 400km per full tank, and I'm not even pushing it.
I get 500-550 a tank, though I attribute that too the upgraded turbo and increased power
that's pretty sick love everything you've done to it, im slowly making my way through replacing everything making everything new again on my pg, how much did it cost you in parts for the rebuild. Also not sure if you've said anything about the exhaust manifold but was that a custom job? or did you find them somewhere
Thanks mate and good luck with your build, they're custom made by a guy off Facebook called Gareth Brunt mate, no easy way to put you in contact with him sorry.
that's all good man i'll find a way around it
Looks nice bro. What Tyres you got on them? Trynna get those too, looks sweet.
Thanks! They're Firestone AT 1s, I rate them highly.
@@Finndawg bet, thanks bro
Where did you get that turbo manifold from
It's custom made off a guy on Facebook, no easy way to put you in contact with him but his name is Gareth Brunt.
Love the content man! Any videos of you hooking up the a/c ? I’m trying to fit a Intercooler at the moment and the a/c filter is in the way. I wanna fuck the whole thing off but reckon I’ll regret it in summer. Cheers!!
Hey mate, nah no footage of the a.c but it's relatively straight forward
Hey mate love the build thing is looking incredible, fingers crossed you get to enjoy it this time. Just a question are you planning on putting in a diff drop after you lift it or just going to deal with it?
Hey mate, I am probably not going to lift it, I have the lift kit there from the other ute but I'm kind of loving the way it sits at the moment, I don't really do anything that would require additional lift further than the extra clearance the bigger wheels provide. But when I did have the lift kit on the Bravo I just dealt with the CV angles.
@@Finndawg hey mate, I was just wondering if you still had the motor that you took out the one with a snapped glow plug and what not? Need to rebuild a motor to put in mine but don’t want to pull out the motor to rebuild it so if I can get a second one to rebuild slowly while the other still runs I’ll be laughing.
@joshshipp4735 that's exactly what I did mate! But unfortunately I sold the spare motor to a fella for parts. Best bit is finding somebody wrecking one and try snag one cheap.
@@Finndawg yeah no worries thanks anyways mate
can you link the new radiator please?
It's just my old radiator man, OEM stock as a rock. The alloy one I fitted by "alloyworks" or a similar name was just Chinese trash, causing 100+ degree celsius temps on the highway.
Your gearbox ever get stuck in reverse?
Nah it doesn't mate, I'd say it would be a worn linkage, could be even really dirty oil, worst case something is damaged internally.
that's awesome!
Cheers 🍻!