1975 Toyota Chinook
Ok, so this the 3rd entry for the same project. I did not realize I needed to submit a multi step entry. I apologize for the redundancy. As mentioned this is my 1975 Toyota Chinook. I bought it in my early 20s with plans of “van life.” A decade later I decided to take a year off and pursue that dream. I accepted a job with the USFS as a wildland firefighter in northern ID. I spent 3 weeks getting the camper ready for the journey. I rebuilt the motor, replaced the suspension, installed a new carb and troubleshot various issues. Together with my wiener dog we left WI for ID. Enroute to ID we lost a tire going 75 mph. The fiberglass shell, passenger window, interior, leaf springs and rear brakes all suffered damage. My brother rented a U-Haul and transported us the rest of the way. I spent a month camping/broke down 10 miles from where I work. Every morning I would bike to work. Often we woke up to fresh snow. It was wonderful. Currently I’m parked behind a coworker’s house. As I save money I continue to peck away at repairs. The current project is fabricating new inner fenders to fit larger batteries. Eventually I will replace the rear floor and repair the broken fiberglass. Obviously the journey has been a bit devastating. However my dog (Worms) and I survived losing a tire. Realistically the camper came out better than expected. Possibly I should have abandoned the project, but the Chinook has sentimental value to me, and I’m not known to give up easily. Hopefully we will be roadworthy by the end of the summer.
Step 1
In a friend’s garage, without power or heat, I dissembled and repaired the motor. Due to budget constraints I resurfaced the head and block by hand. The cylinders were honed in place. The valves and valve seats were lapped with grinding compound, a drill and some tubing (to act as a torque limiter).
Step 2
In order to achieve better fuel economy I upgrade to a 5 speed manual transmission. I installed the corresponding axle and drivetrain. The drivetrain had to be shortened to fit. The crossmembers for the transmission and carrier bearing mounts had to be fabricated. The components were pulled from a 1987 SR5 that requires a new frame (see photos).
Step 3
Following the accident we needed to replace the rear brakes (the backing plate was sheared), bearings and leaf springs. Replacing the leaves required adding a couple leaves to a set of later pickup springs (the originals were not available). I cut and drilled add-a-leaves, as well as some aftermarket spring clips. The rear shackles were upgraded to aftermarket boomerang shackles with greasable pins. Total lift of 3 inches. The brakes were replaced with larger disc brakes. I’m still designing/prototyping a front brake upgrade. The bearings were replaced with OEM bearings and pockets. I pulled the axle shafts and had a local shop press the new bearings on (I did not have access to a press).
Step 4
As mentioned, we lost a tire on the freeway near Fargo, ND. The State Patrol was quite friendly. The loss of the tire was quite devastating. The once perfect fiberglass shell was damaged. The rear bearings and leaf springs required replacement. The outdated drum brakes were scheduled for replace my already… the passenger camper window was shattered and some of my tools/possessions were lost. Luckily my older brother was able/willing to tow us the rest of the way. Unfortunately he had to return to work before he could assist with repairs. The U-Haul blew a spark plug in MT. We had to wait 15 hours for U-Haul to provide us a replacement. It was kinda funny.
Step 5
Not a critical step; the original fuel sender was rusted and old. Since I was already replacing the brake lines, I replaced the fuel lines as well. In the process the nipple on the original sending unit broke. I was unable to find a direct replacement, so I retrofitted a new unit to work with the original tank. It also provided provisions for adding a gas powered heater/boiler.
Step 6
Currently we are broke down in my friend’s back yard. As I save funds I will continue repairs… First will be fitting new batteries and electronics under the hood. This was a planned upgrade before the damage occurred. Prior to the trip I had already purchased the components. After fabricating/painting new inner fenders I will begin installing the new electric. Later I will repair the camper shell and floor. Fiberglass is not one of my talents. However I will have to master it in order to repair the Chinook. I have many plans following these upgrades/repairs but I am constrained by time and budget. With luck we will be road worthy by the end of the summer.
