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Navara hits the BIG time!

Text: Danie Botha
Photography: Jannie Herbst

After Leisure Wheels’ long-term Nissan Navara 2.5 dCi 4x4 was involved in a small on-road incident, an idea was born. That original idea has now developed into something rather big. 37-inch wheels big. This is how it happened
The Navara is comprehensively insured. Following the mandatory hat-in-hand moment with Nissan’s officials, we were armed with a comprehensive list of Nissan-approved panelbeaters. Shortly afterwards, we had acquired the necessary three quotes. With the repair bill ranging from R37 000 to a whopping R54 000, we conceded that panelbeating must indeed be a much more lucrative business than journalism. And that’s where the first seed was planted. If it was our bakkie, we reasoned, wouldn’t it just be easier to replace the shattered bumper with an aftermarket bullbar, replace the headlight, and let a friend of a friend of a panelbeater sort out the little bit of damage to the fender and bonnet, rather than face higher insurance premiums, lost bonuses, and so on?The little seed soon germinated, and evolved into something bigger. We shared our ideas with Nissan South Africa. We spoke to LA Sport’s Lionel Lewis. We spoke to other knowledgeable people in the aftermarket industry. But we’re also going cream-of-the-crop when it comes to suppliers and product partners, and the team that will build the ultimate Nissan Navara 4x4. Firstly, the team is the highly experienced crew of LA Sport in Pretoria. Under the direction of Lionel Lewis and TJM’s Louis van Niekerk, the team will set about creating a unique machine. Possibly the most “ultimate” Nissan Navara 4x4 the world has seen.

PROJECT NAVARA update: when the going gets BIG!

We recently went to visit the project Nissan Navara 2.5dCi 4x4 in Pretoria, where it is currently being given a new coat of paint, and custom side body panels. But let’s first go back a few weeks, to LA Sport’s shop in Pretoria. There Lionel Lewis’s henchmen fitted a complete TJM off-road suspension, along with a 60mm body lift. The TJM brand hails from Australia, and LA Sport is the official local distributor. The company started manufacturing off-road equipment in 1973 for the Aussie market, where 4x4s are often used in tough and extreme conditions. The TJM XGS suspension, as fitted to the Navara, consists of new springs up front, springs and shock absorbers at the back, as well as polyurethane bushes. The springs are not just any old springs. The TJM XGS Suspension lineal and progressive rate coils are manufactured to TJM’s exacting specifications on computer-controlled coiling machines, then spot peened, load tested and finally, powder coated.

The springs are designed to provide a smooth and comfortable ride when the vehicle is not carrying a load, and improved stability and load-carrying capability when that heavy load is added. The TJM XGS shock absorbers are also specially developed for extreme 4x4 usage. The 60mm diameter expanded body, with its large oil capacity and high-temperature oil seal, can keep its cool, even when the going gets very heavy duty. It also features fully welded mounts, polyurethane bushes, and extra strong, twin-tube construction. This is one shock absorber that relishes a tough work-out. The TJM XGS polyurethane bushes are also a high-grade component, manufactured specifically for tough 4x4 applications, and offering a far longer life than rubber bushes. Next up is the TJM Airtec snorkel system. But a snorkel is a snorkel is a snorkel, right? Yes and no. Yes, they all perform the same function, and that is to keep water and dust out of engines. But there is more to the Airtec snorkel’s case than just being a handy off-road accessory. All Airtec snorkels are designed according to a specific vehicle’s profile, and according to its styling, and looks. So you get a specific snorkel for a Navara, a specific snorkel for a Hilux, and so on. The result is a snorkel that not only does its job very well, but also looks good, fitting in with its host’s profile. The wheels… now this was more of a challenge to fit than the suspension and snorkel. The LA Sport crew had to manufacture a special adaptor for the Mickey Thompson rims to fit the Nissan’s standard hubs. They also had to modify the body in places to enable the front wheels to turn as they should. Soon, the bakkie will go in for its new coat of paint: a camouflage-green, in a matt finish. Then, in time, the rest of the accessories will be added.

This Nissan Navara is going to be a beast. A beautiful 4x4 beast.

PROJECT NAVARA update:
With the custom wheel arches in place, the snorkel fitted, and the bullbar modified to fit in with the wider front-end, the Navara is… jaw-droppingly imposing, even without its new coat of paint!
The bodyshop team will now focus on finishing all the modified surfaces and doing the final preparation before the bakkie goes for its new coat of paint. Custom LA Sport side-steps will also be added to the package. Indeed, the Navara project is looking bigger and more imposing by the day! But those big Mickey Thompson tyres and wheels sure do make a difference to the Navara picture. The 38-inch Baja MTZ 5269 tyre is designed for serious off-road use, especially for extreme mud conditions. Specialised LA Sport adaptor plates anchor the eight-stud Mickey Thompson wheels securely onto the Navara’s standard six-stud hubs.

PROJECT NAVARA update: The final countdown

January, 2009. The Leisure Wheels Nissan Navara 2.5 dCi 4x4 is involved in a bumper-bashing incident in the Hartbeespoort area. Ai tog!
February, 2009. Damage seems superficial, but quotations for the repair of this damage range from R37 000 to just over R50 000. The idea is born: instead of replacing the bumper and other damaged parts, why not fit an aftermarket bullbar and custom headlights? It seemed like the perfect opportunity to do a project vehicle, something we’d always talked about, but never came round to actually doing.
March, 2009. After some research our idea of a bullbar and custom headlights evolves into something significantly bigger: why not build the ultimate 4x4 Navara? There are a lot of custom Toyotas, Fords, Isuzus and other bakkies out there. But not Navaras. We share our idea with Nissan South Africa, the owners of the Navara.
April, 2009. We meet with Nissan representatives, and discuss the possibilities.
May, 2009: We meet with Lionel Lewis from LA Sport 4x4 Megastores to find out if we are completely out of our minds, or if there is any feasibility in a project such as this. Lionel has built countless “specials” over the years, and this is the kind of thing that gets him all excited. He says that it is not only possible, but adds that he has done lots of research on the specific look we have in mind (an Arctic truck is the closest thing), and always wanted to build one. “Bring it on. We’re in,” he says
June, 2009: We discuss more options with Nissan South Africa. There are a lot of technicalities and administrative red tape to deal with.
July, 2009: We receive the go-ahead from Nissan South Africa. Project Navara is officially underway. By chance we receive a phone call from an ATS representative. They inform us that Mickey Thompson (MT) tyres will in future be sold through local distributor ATS. They want to know if we have any long-term vehicles that need a set of MT tyres. We say: “well, we have a plan with a Nissan Navara. What are the biggest Mickey Thompsons you’ve got?”
August, 2009. The Nissan Navara is delivered to LA Sport’s Pretoria-North branch. The Navara gets a set of the latest and greatest TJM XGS shock-absorbers and springs, special bushes and a 60mm body lift. A TJM Airtec snorkel is fitted, while Lionel Lewis and his band of technicians experiment with different bullbars to find the one best suited for the Navara’s new look.
September, 2009. The massive 38-inch tyres arrive at LA Sport after being imported from the US. Now Lionel and crew have their work cut out to make those tyres work for the Navara. Several options are considered, including widening the Navara’s standard 17-inch wheels. In the end, Lionel commissions specialised adapter plates for 16x12 Mickey Thompson rims to fit the Navara’s hubs.
October, 2009. With the big Mickey Thompson wheels in place, the Navara is delivered to S&J Panelbeaters in Pretoria-North. This is Lionel’s preferred body shop, and S&J’s Quinton Fourie has, over the years, built many special project vehicles for LA Sport. This includes LA Sport’s Monster truck.
November, 2009. Custom Navara parts from Autostyle Motorsport are delivered to S&J Panelbeaters. Meanwhile the body shop team, under Lionel’s direction, is taking to the Navara, constructing custom wheel arches, widening the bullbar, and adding fibreglass finishes where necessary. We meet with Lionel to discuss final colour options, the location of the massive spare-wheel, and other customising matters.
December, 2009. At the time of writing the final finishes are about to be completed on the Navara’s new body panels. It will be stripped, and painted in RAL003 – a military green. The panels will be completed in a specialised matte finish, to compliment the Navara’s off-roading character. After the painting process is done, the vehicle will be returned to LA Sport, for the fitment of accessories such as the winch, and custom spotlights. Also on the menu is the powder-coating of the chromed Mickey Thompson wheels.
January, 2010. The plans for the next phase in the Navara’s transformation look like this: engine tuning, a special high-performance air filter, and the addition of a free-flow exhaust; a Ferodo DS Performance brake upgrade; and the interior, which will include full custom leather, and a sound and in-car entertainment upgrade.

Indeed, now we are in the home straight with Project Navara. And soon there will be some really, really exciting news regarding the bakkie in the offing too. Watch out for the March issue of the magazine to read all about it.

Navara shopping basket (to date):

· 5x Mickey Thompson 16x12 rims (R2 680 each)
· 5x Mickey Thompson MTZ 5269 38-inch tyres (R4 930 each)
· 1x TJM Airtec Snorkel
· 1x TJM bullbar (custom unit)
· 1x LA Sport 60mm body lift
· 1x TJM suspension upgrade
· 1x LA Sport custom-made sump and engine guard
· 4x LA Sport custom-made PCD adaptor plates for wheels (R2 750 each)
· 1x Autostyle Motorsport Navara Angle Eye headlights
· 1x Autostyle Motorsport Navara LED taillights
· S&J Panelbeaters, various custom body panels, and paint

R13 400
R24 650
R4 750
R10 995
R6 499
R15 300
R2 499
R11 000
R2 495
R1 995
R48 000

Total (to date)

R141 583*

*Excludes some labour and fitment, which will be calculated once the project is completed)

Watch out for the March issue of the magazine to read all about it.

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