Project Prius Truck Pickup Trius conversion.

Bill, I checked out your Firebird Project too.
Whew, that is ambitious. It will be fantastic.

 

Today I was able to install rear side glass.
Also, I was not pleased with the fabrication of the C post I was building so I cancelled that and started looking around my junk for something to build a C post.
It needed to stay back from the door panel by about 3" and come back closer to the top door (window) frame.
So I walked out back and saw some pipe stuff in a box and it had curved pipe in it.
With very minor alteration, the legs of a truck bed ladder rack fit really nice.
Some things just come together and this did.

I then took the black door (window) frame upright B post from the parts car stuff I bought from AutoBeYours in Scottsburg Indiana - Hybrid car rebuilder Steve Woodruff.
They are substantially the same as the part I used to end the rear door window frames.
All welded in and strong.
(Welder ran out of argon gas. So some welds look nasty. I rewelded after getting tank filled.)

I'll create a sealing piece between the two and create an outside trim piece of plastic to matchup with the factory parts.
Today was a good day.
Best regards.
GaryK
Manchester TN
"Be Kind - the lesson of Covid One Nine".

 

I had one of these and had -0- money in it.
(There is a second set of legs... Perhaps for another Trius TRX.)
This curved lower section worked great.
Mine was steel, not aluminum (as pictured).

 

I'm not familiar with plasticdip except to dip tools in. What's beneficial with plasticdip please ?

 

Minor update.
Because I installed the round tube C pillar support I had to redo my 12V battery mount.
I did not like it anyway since I had made it out of a pc of the rear hatch rail.
It was strong and effective but really looked hacked. Had planned on redoing anyway.
Now the C pillar is strong, the battery secure, the brake box mounted, wiring for rear cargo light from Sport Trac wired and installed, and the rear up/down slider center section sealed and installed.
I have shortened the two outer small windows (part of slider tri-window) by 2.5" on each side.
Believe me, removing the tempered glass that is bonded in the rubber surround frame is a pain. But I used urethane to install the cut lexan windows I fabricated.
Pic below.
I also cut the headliner and test fit both sections. I am going to install the back section after striping the cloth and either fibreglassing the cardboard backing or may coat with truckbed liner. Or do both.
It's not needed but will be better looking.
I am also planning on using the spare tire cover from the Prius tho fit a back platform cover over hybrid battery and 12V.

I still need to get the cooling fan system ductwork rebuilt to my satisfaction.

Does anyone know when it kicks on; I'd like to troubleshoot before major driving.

Is the electric device in the fan "out" duct a temp sensor?

I have a spare fan; can anyone advise if I will cause a problem if I hook it up on a separate 12V switch and fuse as a puller fan on the "out side"? I could have it on in run mode all the time.

Is there an issue with healthy air if the cooling air is simply recycled in the cab or must it be ducted to the outdoors? (Are there battery fumes from hybrid battery?)

Electric note: given how finicky the system seems to be, I thought as a caution I'd wire any extra stuff direct to 12V with fuse and switch and not put any non-factory draw through Prius wiring.
Re: cargo light, second fan, any other accessory additions.

Notice Prius logo panel from back hatch.
I thought I'd mount on or in the tailgate (pic).
Opinions?

Gary K
Manchester TN
May 9 2020.

 

I could use help removing duplicate pictures again. I don't know how that happen. I don't know how to delete.

Thank you.

 

Thank you much.

 

Sunday evening May 10 2020:

Today I was able to tackle a tough job I had put off...
The electric up/down slider for back of cab needed finishing along with "C" post construction.
I shortened the two side slider panes yesterday.
I installed them today.
I also fabricated the "C" post outer panel that attaches to those windows.
I made a paper template and was going to fabricate from flat sheet metal when I decided I'd rather have something curved or with some shape other than flat.
I spotted the cutoff section of rear hatch fly-rail of the roof.
And as things go, with a lot of cut and fit work, I was able to install them with screws. I'll weld tomorrow.

As of now the rear doors still open and close which makes access good but fabrication tougher. (Not having those C post door frame upper sections to attach to.

Of course the "ugly" gets painted and covered with a trim piece still to be fabricated.
Thanks for your interest.

Here's pictures:

Best regards,
GaryK
Manchester TN.

 

Update: Sunday 5-17-2020.
Took a week long break to work on land stuff.
Going back to work Tuesday on the "Trius TR-X." Project.

 

I have two options. However, I am not blending the sport Trac fenders to the Prius.
They will bolt on. The sport Trac fenders are fibreglass and detach from the bed section.
By unplugging the lights and removing 5 bolts on each fender the fender lifts off.
Both rear doors still open for good access to both 12V and Hybrid Battery and misc.
I am not welding them shut.
I have built a strong "C" post and the black round tubes inserted and welded into roof rails also bolts to the Prius frame through the bed.

So, "How do I plan to transition the Prius body into the bed..."

Option 1: I will form the bed's front wheel arch to match the Prius arch. This means extending the flat 2" wide area all the way back about 6".
If I do not like that;
Option 2: I will take another fender from another Sport Trac bed ( I have 3)
And I will cut the fender at the top center of the wheel arch opening and remove the front lower section which is too long now.
I will take the back 1/2 lower section of the driver's side extra fender and graft to the passenger's lower front section. This provides a matching shape of the back section on the front. A symetrical arch opening. But the finished fender will bolt on. I may use some 3M tape between the fender and the Prius door. I expect the need to open the doors will be quite rare.

Adding picture.