What started as a mechanical failure quickly turned into a full custom build—driven by persistence, creativity, and a clear vision to create something completely different. This 1990 Pajero Gen 1 project is not just a restoration; it’s a transformation into a one-of-a-kind pickup designed to stand out.
The Beginning: A Breakdown That Sparked a Build
The journey began in 2023 when the original 2.5 diesel engine developed a bearing knock. Instead of simply repairing it, the decision was made to strip the vehicle down completely and tackle years of wear—especially rust that had taken hold across the body.
At this stage, the plan was still focused on restoration. The goal was to clean it up, fix the damage, and bring it back to life. But as the stripping process continued, the vision started to evolve into something far more unique.
A Pause in Progress
Like many long-term builds, this project hit a major pause. Due to illness, the vehicle stood untouched for about a year and a half. Work only resumed in 2025—but with a completely new mindset and direction.
The Vision Changes: From SUV to Pickup
When the build restarted, the idea shifted from restoration to transformation. The decision was made to convert the Pajero into a custom pickup—something bold, different, and guaranteed to stand out.
The rear section was reworked entirely:
- The back door was removed and blanked out
- The body was cut and reshaped
- The structure was adapted to suit a pickup-style layout
This marked the start of a full custom fabrication process.
Rust Removal & Structural Rebuild
Rust repair became a major focus. Every affected section was cut out and replaced properly to ensure long-term strength and durability.
One of the worst areas was the lower rear section of the body. To rebuild and reinforce it:
- An 80x80 x 8mm angle iron was used
- This provided added strength and rigidity
- It also helps support weight distribution in the new pickup configuration
This approach ensures the build is not just visually unique, but structurally sound.
Handcrafted Wide Wheel Arches
One of the defining features of this build is the aggressive wide stance.
The wheels originally sat outside the standard body line, which led to the idea of creating wider arches. Instead of using bolt-on flares, everything was handcrafted:
- Built completely from scratch
- Shaped through trial and error
- Welded directly onto the body
- Designed to match the vehicle’s natural lines
The process took time and patience, but the result is a clean, seamless wide-body look that gives the Pajero a strong, custom presence.
Engine Evolution: From Diesel to Lexus Power
The Pajero originally ran a 2.5 diesel engine, which overheated and later developed a bearing knock. This led to a Lexus engine conversion, bringing more power and a better overall driving experience.
After plenty of use and enjoyment, the converted motor also eventually developed a bearing knock. Rather than seeing this as a setback, it became another turning point that pushed the project further toward its current custom build direction.
Current Progress & What’s Next
The project is still ongoing, with fabrication work continuing steadily.
Current goal:
- Get the body back onto the chassis by the end of July
Once that milestone is reached, the next steps will include:
- Final bodywork refinement
- Paintwork
- Reassembly
- Finishing details
The End Goal: A One-of-a-Kind Build
This is not a factory restoration—it’s a fully custom build with personality and purpose.
Key highlights include:
- Custom pickup conversion
- Fully repaired and reinforced body
- Hand-built wide arches
- Unique styling throughout
Final Thoughts
This project shows how a simple mechanical issue can evolve into something much bigger. From a bearing knock to a full custom rebuild, this 1990 Pajero Gen 1 is a reflection of determination and creativity.
When it’s complete, it won’t just be another vehicle on the road—it’ll be a true head-turner with a story behind every detail.
