Modifying a 2003 Mitsubishi Montero for Vehicle-Based Adventuring
Rocky Road Outfitters Rock Sliders
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With the running boards removed the sills and rocker panels are vulnerable to damage from high centering. Rocky Road Outfitters in Heber, Utah, make a stout pair of rock sliders for the Montero.
Having driven my share of westward returns at golden hour I've wanted to black-out the hood getting rid of that double whammy reflection. The contour of the Gen III's hood lines flow nicely to the grill leaving the popped round fenders to flank the black, framing it up nicely. But I wanted to break up the mass of the black with a graphic, deciding on the Dakar logo to tie in the badges I added. Here's how I did it: I googled the graphic and projected it on a wall where I hung some newsprint. I traced the logo... ...and cut it out of the newsprint creating the template. I taped the template to the hood and masked the exposed area... ...and then trimmed the mask through the template. I masked the rest of the hood and removed it, suspended and shot it with Dupli-Color flat black trim paint, three coats. Peeled off the masking. And this is the result. I also shot the rest of the grill to blend the lines form the hood. I had previously painted the grill inse...
I've considered alternate roof racks but for the time being want to put the serious money into suspension and recovery. The stock rack has served its purpose fine with a Thule system that holds the RTT and awning, but I want a tray in between the stanchions to hold other recovery and camping gear. To this end I removed the headliner. It's pretty straightforward, removing all the hardware of grab handles, interior lighting modules, sun visors, etc. The only hang up is in removing the sun visor clips with tabs that tend to break easily. Remove the weather stripping on all doors. The A-pillar covers snap out being careful to keep retention clips in place, and second row seatbelt mounts on the B-pillars need to come off to remove the covers. The rear covers that surround the wing windows between the C and D-pillars snap out, again being careful to keep the retainers in place. With the headliner free, the last step is to remove the electrical connection from the sunroof j...
I pulled off the plastic body cladding and decided to coat the exposed area with a bedliner, Duplacolor's Bed Armor with Kevlar. Got the kit on sale at Autozone for $75. To prep out, I thought I'd fill the holes left by the cladding. I ground out and reamed each with a Dremel tool. Filled each hole with a fiberglass filler. Use this sparingly to save yourself an enormous amount of sanding. It's been too long since I've done body work, and trying to beat the setting filler I got sloppy. Sanded down the excess and found that some took... and some didn't. I filled those that didn't with a Bondo filler, and sanded it down after setting. 80 grit. I didn't finish-sand knowing the liner would make it a moot point. I had sanded enough. After cleaning everything up, I masked the bodywork and removed the bumpers. I was sure to mask interior lines as well. I shot the grill and the driving light holes with the same bumper-black I used on the uppe...