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DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

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  • DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

    OK, so after much research without success, I decided to be the first person (I believe) to attempt and document a Safari Snorkel installation on my TD 150 GXL.

    Here's my photo step-by-step guide (until I spat the dummy, read on!) if anyone is considering doing it themselves...

    Remove - Airbox SImple.


    Fill the Airbox drain holes with silicon. I used general stuff per this photo but actually went and purchased some Sikaflex to ensure a permanent job. I glued the drain valve lips together using rubber cement (aka puncture repair kit glue). It worked a treat...


    Remove front drivers side mud flap. This is attached with 4 self-tapping screws and 2 clips. Pop the center of the clip out to remove the clip.


    Remove the inner wheel arch guard. This is held in place with a few bolts and 11 plastic clips. This clips are a pain in the arse and the only way you can remove them whole is to pinch the tabs with a set of pliers from behind. You can do this with about 4, but you will need replacements for the rest. You will need to cut or lever them until they break apart.

    I went to Toyota to buy these clips, but when we looked on the drawing it only showed 6. Hence, this is the reason I had to leave the last two in. Having the arch still attached didn't hinder the majority of the operation, but in hindsight removing the whole liner and the wheel might have created more room to work.


    Template. This is a two person job. Given the curve between the arch and the main wing body this needs as many hands on it as you can. Even with the tape, the template still lifted. This was the most important part of the job...


    Marked with a felt tip pen. Remove template. Install template check again about 3 time. This may sound irrational but i have to say I wasn't at my most rational knowing I was about two drill 5 holes and 2x 3 1/2" wounds into my $65k pride and joy.

    Marked and centre punched... Eeek! I felt a little bit sick right now!

    Pilot holes. The only way is forward from here.


    Hole saw. Let's get the big gun out of the way first. 89mm. Slow and steady is the key. Very light pressure otherwise it has a tendency to pick up and lock. This is especially apparent when cutting the second hole as the saw liked to pick up on the cut edge from hole 1. My advice would be to angle the cutting force towards the front of the car for the second hole.

    SLOW and STEADY...




    Step drill. What a tool! Made light work of every hole. clean, simple and fast. Didn't even leave a burr...



    I used a grinder and cutting disk to remove the points. The instructions call for a electric saw but the grinder did a perfect job.
    Even a Dremel with a cutting disk could do this.


    De-bured using my Dremel and mini grinding wheel. Then all treated with a coat of rust proof primer.

    Install the S.S. studs into the snorkel with loctite.

    Mount the top bracket to the snorkel and do a trial fitment. It fits...HOOORAAA! Perfect first time! Maybe this "measure three times, cut once" the wife keeps talking about might have some merit!!!
    *Note the oval shape of the snorkel...

    This is a two person job again, hold the snorkel in place and align the A pillar part of the snorkel equally with the door edge. Mark the bracket (critical this is done well) and remove. Remove the bracket from the snorkel and place it over your location markings. Once centered, mark the three hole centers. A second pair of hands also can come in handy for this too..


    Center punch, pilot and 8mm step drill. Job done.

    Install plastic screw mounts. These are the square kind that fit into the round hole and provide a guide for the S/S self tapping screw to screw into. I decided to fill each of these with ample quantities of silicon. I can just imagine water getting inside of the A-pillar as this is full of sound-deadening foam as found in the footwell compartment.

    Fit bracket, install snorkel! PERFECT! I even surprised myself. Every hole lined up perfectly and even the holes with slots for added adjustment were dead center. I was very pleased with myself. I used plenty of silicon on the rear rubber washers just to make sure if I missed any primer that the steel edges were fully rust-proof.


    Grind off the tabs on the airbox using the Dremel. This allows for the rubber hose to go on instead of the normal suction port.


    Install hose! This is where I stopped taking photos. What a mission!!! The trick is to install the oval end first before the airbox is reinstalled. Getting a good fit top and bottom on the oval hose was near on impossible. We either had a gap at the top or a gap at the bottom. Once we had it even all the way around with a minimum 3mm gap, you then tightened the hose clamp... You read it correctly, a round hose clamp on an oval pipe.
    The hose clamp would slip forward, the hose clamp would slip backwards, if you overtightened it it would slip back and cause the hose to pop off. We eventually got it (i can't take credit, a mate did it for me as I had spat the dummy, so I shampooed his Patrol interior for him whilst he figured it out) but I'm not impressed with the whole concept. Basic logic tells you that the pressure is all on the two ends with very little force on the top and bottom sealing surfaces. With this in mind, I hopped in the wife's car to Supercheap and picked up a tube of Sikaflex. This wasn't in the instructions but I've gone to too much effort to get this water tight to let a leaking hose clamp ruin my engine. This is an over exaggeration as the hose is on there tight, but I smothered the whole seal area with a good coat of Sikaflex. I am now covered in the stuff and though paint thinner did remove some of it, I think I'm going to have to wait for a new layer of skin to grow!

    Air box in, round hose fitted. Hose clamp perfect (almost as if it's designed for a round hose!!!) I removed the second battery to create some more room. Job done!


    DONE!


    Result? I'm very pleased! I must say I would like to know what ARB do with the oval hose clamp seal. I am much happier knowing i have 6mm of SIkaflex over the whole seal.

    Would I do it again? Yes! Would i recommend others to do it? Yes! (at your own risk of course!) Did I feel like I wanted to throw up when I put the first centre punch in the wing? Yes!

    I am convinced the pickup power has increased significantly! The wife tells me it's probably in my head, but there is definitely a dramatic increase. I can't actually believe that Toyota think the best place to put a suction port of a 4x4 engine is directly above the driver's wheel. Until tackling this job, I didn't really understand just how much dust my engine must have been sucking when diving on dirt roads!

    Go on, give it a go! 89mm Hole cutter and step drill cost me $80 (I already had the arbor) but I will definitely use the step drill many times over again. I'm happy to help or lend my tools to any WA PPer that is up for the challenge.

  • #2
    Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

    Good job, I couldn't bring myself to put a hole in my Prado. Did the instructions say to glue up the drain valve? I filled the holes in the airbox up but kept the drain valve intact for getting rid of bugs and crap that find their way in there.
    [url=http://www.myswag.org/index.php?topic=12264]My Prado[/url]

    Comment


    • #3
      Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

      You're a better braver man than I am, Gunga Din!

      Comment


      • #4
        Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

        Originally posted by D4D
        Good job, I couldn't bring myself to put a hole in my Prado. Did the instructions say to glue up the drain valve? I filled the holes in the airbox up but kept the drain valve intact for getting rid of bugs and crap that find their way in there.
        The instructions highlight the two sets of holes (triple and single) and the drain valve and say that it is upto the installer if they want to seal these drains... Interpret from that what you will. I decided to seal it but each to his own.
        I do intend to open it up every few 1000kms to check for water etc. I was shock at the amount of sand and junk in the air box after only 20,000kms.

        Comment


        • #5
          Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

          great diy darren, keep them comming. cheers samo
          had an 03 gx 120 with some gear now got a 2013 bt 50 GT auto some ARB gear.

          Comment


          • #6
            Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

            Nice work Darren.

            How did you go with access to the top back nut? Is it any better in the 150? I just did a 120, and gave up with that top nut. No way I could get my big boofy hand in there to get it done up.
            IMO it isn't required anyway, so I left it.
            2008 Diesel Prado with extra stuff added. I drive it on the road and other places too.

            Comment


            • #7
              Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

              Very good work Darren.

              Well presented 'how too' and the workmanship was top notch !

              Cheers,
              [CENTER][B][U]Matt
              [/U][/B]2012 Silver GXL TD 6 Speed manual with some stuff..
              [/CENTER]
              [CENTER][SIZE=2]My 2008 Lifestyle 360i camper - [URL]http://myswag.org/forum/index.php?topic=21797.0[/URL]
              My 4WD Action write up 2004 120 V6 Prado - [URL]http://www.4wdaction.com.au/articles/2012/complete-package[/URL][/SIZE][/CENTER]
              [SIZE=2]
              [/SIZE][CENTER][SIZE=2]
              [/SIZE][/CENTER]

              Comment


              • #8
                Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                Originally posted by Auto-Craft
                werent you only coming back "mr 4x4" to finish organising the GTG ?

                I cant see a connection to GTG, and this thread ?
                And I can't see the connection between this thread and your comments!! Seriously move on Darren (autocraft)

                Good work on the install Darren 253.
                [b]Rob[/b]

                [b]2016 Toyota Hilux SR5 D4D Auto Company Cruiser... [/b].
                [url=http://www.pradopoint.com/showthread.php?23866-Hutch-s-2012-150-GXL-V6-petrol-Auto]Hutch's 2012 Build up[/url]
                [SIGPIC][/SIGPIC]

                Comment


                • #9
                  Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                  Thanks for the pics. Though most of us wouldn't do the install ourselves, it's good to know what will be and should be done by the 4x4 workshop.

                  Hutch: I had the same thought.

                  Cheers
                  [COLOR="black"][b]William[/b][/COLOR]
                  [SIZE="1"][COLOR="gray"]Prado 150 GXL D4D Auto in White![/COLOR][/SIZE]
                  [url=http://www.pradopoint.com/showthread.php?18483-William-s-150-GXL-D4D][U][COLOR="blue"][SIZE="1"]My Rig Build-up[/SIZE][/COLOR][/U][/url]

                  Comment


                  • #10
                    Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                    :roll:

                    Comment


                    • #11
                      Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                      Originally posted by Davros
                      Nice work Darren.

                      How did you go with access to the top back nut? Is it any better in the 150? I just did a 120, and gave up with that top nut. No way I could get my big boofy hand in there to get it done up.
                      IMO it isn't required anyway, so I left it.
                      Thanks... No real issue with the top back nut. Not a massive amount of room but enough for my sausage fingers followed by a ring spanner.

                      Comment


                      • #12
                        Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                        When my one was installed the drain valve lips were left and only the other holes were sealed. I was concerned but not sure if I should close this off. Does anyone else have any comments on closing this or leaving it open?

                        Any experience with water getting in this during water crossings?
                        Stephen Bloomer
                        I did have - 2010 GXL D4D Auto, ARB bullbar, rails, sliders, winch, 40mm lift, Brown Davis bash plates and long range tank

                        Comment


                        • #13
                          Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                          Ive had my 120 with a wave up to the windscreen a couple of times, it was a DIY install and i left the drain valve lips open, you'd be suprised how much crap comes out of it , insects, dust, seeds ect . I will be installing one on my 150 and will also leaving it the way it is, you can always carry a couple of clips to put on there if you are worried on a deep crossing but i would take them off after.
                          [size=1]2011 GXL D4D Auto | ARB Deluxe winch bar | Bilstein/Ridepro platinum lift | MT ATZ P3's | Dick Cepek Torque rims | Airtec snorkel | Lightforce Genesis 55w HID | GME UHF | 55w HID high beam | Rhino Rack bars & Cage | ISI extreme rack | Dual Optima Batteries | Milford MXV-70 cargo barrier | ARB onboard air | Prodigy P3 | Drawers & Black widow fridge slide | Waeco CF-50 | Kaymar rear bracket and LED light | EscapeGear seat covers | Sandgrabbas and more...[/size]

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                          • #14
                            Re: DIY 150 Safari Snorkel Installation... Eeeek (Pic Heavy)

                            Cool head Darren :shock: :shock: :shock: My 120 is getting its safari Wednesday after Easter, but no way would I be brave enough to drill into a perfectly good guard! ARB can have MORE ofmy hard earned. Well done
                            Dennis

                            Ag Nomad

                            Comment


                            • #15
                              Thanks Darren appreciate your posting helping new owners go into the unknown. Yes after reading your post need to get a supply of the Toyota plastic lugs for the guard liner before starting the job! Hanging on to the 89mm hole saw is a bit of a challenge, am yet to fit the oval pipe fitting though, today.
                              Cheers

                              Comment

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