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1999 AZ Trooper project

37K views 105 replies 29 participants last post by  Enemigo 
#1 ·
Figured I would start a thread showing the ongoing project that will be my new trail rig.

I found myself in the need of a reliable off-roading SUV to get into areas most hunters would take their side-by-sides or ATVs. I loved my 2002 Tahoe, but wanted something a little narrower. It came down to the Trooper, Mistsubishi Montero, or a 4Runner. After doing my research, I quickly ruled out the 4Runner, and saw the advantages the Trooper had over the Montero. So, I went with the Trooper. I picked this frog up a little over a month ago. It has 215K miles, and only cost me $2200. It's super clean, and so far seems reliable.

Here is the BEFORE pic.


After tinting the windows, new muffler, new brakes, new tires (255/85/16), powdercoating then painting the rims, ball joint flip, new locking hubs, KYB shocks all around, and Grand Cherokee coils in the rear (Moog cc782), I figure I may as well start documenting the transformation. So pics will continue to follow for my custom rock sliders, custom roof rack fab and install, front receiver hitch fab and install, grill mounted 22" LED light bar, aux radiator fan, dual battery install, stereo upgrade, and paint.

Here is where she sits after the first 5-6 weeks with her. More to come as I tear into her!
 
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#27 ·
Finally spent a day and half welding up supports for the rock sliders I built earlier in the summer. They came out great, except don't stick out quite far enough to make a solid step. I think I'll get some steel diamond plate and create a bigger pad on the top of the slider for the spot you'd put your foot while entering each door. This is how they look all mounted up.


 
#28 ·
My brother caught me leaving our day of shooting in the desert. Rest assured this hill was MUCH steeper in person (40-45deg). That's a gunshot towards the end, and not my motor throwing a rod. Also, I think his phone picked up unheard frequencies, because my Trooper doesn't sound quite as "tinny" as in the vid.

[BBvideo 560,340:16nh4d2d]http://vid1236.photobucket.com/albums/ff457/AZ_cheekymonkey/Trooper/FAD1C45E-A756-4A52-9F73-B94B5C6993BD.mp4[/BBvideo]
 
#31 ·
Here's the roof rack. I bought it from a guy who custom built it for his '15 4Runner, but never mounted it. It's 44" x 75"ish. I fabbed up 6 mounting brackets out of 2" flat stock, and welded directly to the tubing. It's getting powdercoated right now, then I need to mount all my directional lights to it before installing it. Hopefully, it'll be complete within a week.


 
#35 ·
Took it out for a little 4 wheelin'. We had a blast, and more importantly, got to test the capabilities of the Trooper. Didn't get much video unfortunately.




[BBvideo 560,340:12kv1vo5]http://vid1236.photobucket.com/albums/ff457/AZ_cheekymonkey/Trooper/9AE53BF3-F97B-40E3-B652-768A40971579_3.mp4[/BBvideo]
[BBvideo 560,340:12kv1vo5]http://vid1236.photobucket.com/albums/ff457/AZ_cheekymonkey/Trooper/DA28F756-7622-43CB-9049-53B9D95A9AE9_4.mp4[/BBvideo]
[BBvideo 560,340:12kv1vo5]http://vid1236.photobucket.com/albums/ff457/AZ_cheekymonkey/Trooper/2CFD38C6-9FB3-423B-9460-1EE98541D731_7.mp4[/BBvideo]
(The ruts on both sides of this trail were very impressive. The video doesn't do it any justice.)
 
#39 ·
The trooper is looking awesome!

Those seat covers are looking great. They look like a perfect fit. Would it be too much to ask you for more details on your order from wetokole? Since I´m outside of the U.S I really need to be sure and double check everything before buying anything, and I would really like more details of those covers. The headrest covers look like perfect fit too.

That roof rack turned out awesome too. :thumbright:
 
#41 ·
beto said:
The trooper is looking awesome!

Those seat covers are looking great. They look like a perfect fit. Would it be too much to ask you for more details on your order from wetokole? Since I´m outside of the U.S I really need to be sure and double check everything before buying anything, and I would really like more details of those covers. The headrest covers look like perfect fit too.

That roof rack turned out awesome too. :thumbright:
 
#42 ·
Great, thanks for the seat cover's info!
 
#43 ·
Got new rubber today (285/75/16 Cooper Discoverer ST Maxx). Much wider than the 255s.

I also added a top plate and some traction tape to the rock sliders so they work also as a step.

OLD TIRES


NEW ONES



ROCK SLIDER STEPS
(BEFORE THE TOP STEP)


AFTER - With black traction tape and a glow-in-the-dark white strip. It's a piece of 2"x3" angle iron laying over the top and welded from the back.

 
#46 ·
I ditched the plan to use a winch in a cradle, for front and back winching. I just won't have enough cargo space to haul it around once you consider all of the other normal recovery gear, plus a dog, and maybe a few guns, and ice chest. So, instead, I decided to see if I could mount a winch behind the factory bumper. Once I started eyeballing the available space through the lower bumper vent, it looked like it could be done. So with grinder and welder in hand, I got to work!

I already had this front hitch fabbed up. As it turns out, the top of this hitch, as it sits between the front frame rail ends, is the perfect height for the winch to sit on and line up with the vent opening.


Next, I welded some 2" x 3" (3/16") angle iron to serve as tabs, on the front of the hitch. The winch bolts feed through the bottom of the tabs, through the winch tray, and into the bottom of the winch feet. I ended up drilling holes through the hitch for some grade 8 bolts to bolt the tray down in the back.


The next step was to do a little cutting.
Cut the vent grate out.



Cut some of the bumper reinforcement out to allow the top of the winch to clear.



I had to extend the front of the winch tray so that the fairlead would sit flush with the front bumper opening.


Here the winch is sitting in it's new home. I replaced the steel cable with a synthetic rope. I also clocked the freespooling handle forward so I could reach it through the bumper opening.


I had the perfect amount of space behind the bumper to mount the winch control box next to the winch. I had to drill a 1.25" hole in the bumper for fitting the winch remote cord. As it sits here, the plug connector almost touches the backside of the bumper (where the hole is drilled).



Here it is, all finished!



I also ran in-cabin switches. The left switch turns on power to the toggle switch on the right.




It turned out exactly as I hoped. It took close to a week to get it done, putting in a few hours each day. All of the customizing really takes a lot of time!

Let me know what you think.
 
#47 ·
This is awesome. I've been eye balling this idea with a which behind the factory bumper but on my 95 rodeo. I doubt there is nearly as much room compared to yours.. Just have to be more creative with the angle grinder. :p
 
#51 ·
Was out wheelin' with friends and family. This little hill was remarkable tricky due to its steepness and how sandy it was. It looks a little tame in the video though.

[BBvideo 560,340:2k9pr1kc]http://vid1236.photobucket.com/albums/ff457/AZ_cheekymonkey/Trooper/01C777DB-F788-4F16-B624-AF08C1F8327D.mp4[/BBvideo]
 
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