World Traveler III
Honda Pilot TLC Build for Trail & Overland Use
- Thread starter aggrex
- Start date
Fog light project: eBay fog light kit comes with lights, metal brackets and trim covers. Followed OEM instructions for where to cut was a bit unnerving but once you start you got to finish LOL. Add a custom mount plate to install the Baja Design amber wide lights. The HF oscillating tool cut and Astro pneumatic rivet nut tools made the job simple. 
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Spent the day making a custom mounting bracket via trial+error to attach onto OEM style metal bracket. Probably will discard the crappy eBay lights that came with the kit. Rattle can the lower bumper trim and fog light trim. Next step will be a satin clear coat. The small tires are starting to annoy me since the wheel wells need to be filled. 
Wanted a low-profile roof rack to replace the OEM roof rack but nobody makes them for the Pilot. The Prinsu roof rack came off a 4Runner whose owner was switching brands and I must have said SOLD as it’s mine now. With 65-70 degree winter weather it was time to work on some custom brackets. Experimented with different size angle stock, spacers and bolt extensions until the right combination worked as the middle mounts differed from the rear mounts or front mounts as well as the angle of the roof from front to rear. There will be 4 mounting points per side to secure the Prinsu roof rack with no new holes drilled into the roof. Plan was to make sure the mounts were overbuilt to ensure a secure load. One major bonus of the custom mounts was the ability to separate and remove the roof rack at any time and leave the custom mounts on the roof as well as reinstalling the OEM roof rack (NOT).
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Finished installing the Prinsu roof rack with 4 different attachment mounts on each side. The front mount was challenging to make because cutting the angled shape and small size with a sawzall is never safe. The third mount was the easiest to make and last one to install because everything else had to be tightened down first. Ordered a few Prinsu accessories like the “load panel” and twist on stainless loops that easily mount anywhere on the roof rack.
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Thanks. Should be enough room for a roof top tent. Just have to watch my weight limits static versus dynamic. Stay safe and keep on adventuring with the family.
I love how this is shaping up. I have a 2011 Pilot that I'm thinking about diving into, and that Prinsu roof rack looks amazing. Any chance you have details on how you mounted it to the roof? I know you said "four points on each side", but you mentioned you weren't cutting into the roof and I'm just curious how that worked out. Keep it up, and I appreciate the posts! It's great motivation!
Not sure what changed on the 2011 Pilot but you have to remove your roof rack to see what bolts or nuts are there. My ‘04 had bolts in the drip channel. The Prinsu mounts were close but did not match the bolts on my Pilot so custom brackets were made to mount the Prinsu. On the pic 3 Pilot bolts secure a custom angle bracket to meet the Prinsu. After my installation it seems other brands like Victory had bolt on mounts for their rack which could reduce the amount of custom work.
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Tackled the CV axle due to grease being flung everywhere down under. U-tube says it pops out easily….nada not if you live in the rust belt. FSM says to tap it out with drift pin and hammer…nope. Shout out to @HondaPilotOverland @b0wfin aka Aaron for his special axle puller idea. CV axle popped out instantly. OEM axle slides back in with little drama.
Can’t ignore the compliance bushing with the plumbers crack anymore. Time for some new PROFORGED LCAs. Pics show the crack, tools used and out with the rusty and in with the new.
