Bodi Raj

Mechanical and electrical work

Two Japanese kei trucks, imported, restored and rewired

I imported a 2005 Suzuki Carry and a 2006 Daihatsu Hijet from Japanese auction, restored them, and designed and built custom relay lighting circuits for both. Both trucks passed the Manitoba safety inspection. I then turned the process into a complete business plan and website for an import company.

2005 Suzuki CarryFinished. 4WD, five-speed manual.
2006 Daihatsu HijetFinished and sold.

The import

I ran both imports myself. I arranged the purchases with an exporter in Japan, who handled the Japan side through to loading the trucks onto the ship. From there I took over: I engaged customs agents in British Columbia, prepared the CBSA documentation, completed the federal import exemptions, and arranged inland transport to Winnipeg and delivery to my home. I then restored the trucks, marketed them and sold the Hijet.

  1. Sourcing

    Chose each truck by reading its auction inspection sheet and pricing the noted defects.

  2. Export

    Purchase and export paperwork arranged with an exporter in Japan, through to loading on the ship.

  3. Customs

    Customs agents engaged in British Columbia. CBSA documentation prepared and filed.

  4. Federal exemptions

    Import exemptions completed for vehicles over 15 years old.

  5. Inland transport

    Transport secured from the coast to Winnipeg, then delivery home.

  6. Safety and registration

    Manitoba safety inspection passed and registered with MPI.

  7. Restoration and sale

    Bodywork, paint and wiring, then marketing and sale.

Electrical

Suzuki Carry: daytime running lights on a ground-switched headlight

Problem. The Carry's H4 headlights are switched on the ground side, while standard daytime running light modules output +12 V. Off-the-shelf kits do not work on this system without cutting factory wiring.

Solution. A two-relay harness that mounts entirely at the headlight corner. Relay 1 converts the module's +12 V signal into a ground path for the low beam. Relay 2 watches the high-beam wire and tells the module to drop the running lights, so two filaments are never lit at once.

Result. Three tap points only (the wiper circuit, the H4 plug and a chassis ground), joined with Posi-Tap connectors. The harness does not run to the battery or cut any factory wire, and it unplugs to return the truck to stock.

Daihatsu Hijet: a four-relay lighting circuit

Problem. The Hijet's factory combination switch was faulty: selecting high beam blew the headlight fuse, and the truck did not have daytime running lights.

Solution. Four relays, each with one job: a running-light relay, a five-pin selector relay that switches between running lights and low beam, a tail and park relay, and an "OR" relay that holds the selector during high beam. The circuit has its own 12 AWG battery feed with a 15 A fuse within three inches of the positive terminal.

Result. Running lights, low and high beams all work correctly. The wiring follows the factory harness, passes through factory grommets, is grounded on a factory bolt sealed with dielectric grease, and is hidden behind the original trim.

Bodywork and paint

Structure and repair

  • Surface rust treated, sanded and sealed. The frame and underbody were free of structural rust.
  • Front bumper rebuilt with layered fibreglass mat over old bracket damage, the factory clip re-moulded and refitted, then filled and sanded to 800 grit.
  • All trim and rubber removed before paint, so the metal underneath is coated too.
  • Wheels sandblasted, powder coated and clear coated.

Paint, chosen by what each surface does

AreaFinish
BodyFactory-correct 26U white, basecoat and clear
Roof and hoodGloss black two-tone
Bed and cab rearGloss white enamel, easy to touch up
Bed floorRubberised liner for abrasion
Lower trimMatte black to hide chips and salt

Finished with machine correction and a multi-layer ceramic coating.

Keystone Japan Import Co.

After importing both trucks, I designed a business around the process: an agent that imports Japanese auction vehicles, machinery and parts to order for Winnipeg customers. I wrote the full business plan and built the website from the ground up. The business is complete and ready to launch.

The business plan

  • A 29-page plan and operating model.
  • An agent model rather than a dealer model: the customer chooses the vehicle, pays a flat fee and sees every invoice.
  • A ten-step pipeline from auction to delivery, with the unit economics, market position, partner arrangements and risks set out.
  • Fleet pricing for customers who order three or more trucks in one container.

The website

  • Designed and built from scratch, with an English and Japanese language toggle.
  • Separate pages for kei trucks, tractors and machinery, cars and parts, plus an auction guide, pricing and a step-by-step explanation of the process.
  • A quote request flow and a fleet pricing offer.

How I work

Every change adds function

Each modification was made to improve how the truck works, not only how it looks.

Everything is reversible

Factory wiring is tapped, not cut. Lights are magnet-mounted, not drilled. Switches use the blanks the factory left empty.

Documented end to end

Every circuit has a wiring diagram, and the work was photographed as it was done.

Get in touch

I am open to IT, QA, health technology, laboratory and technical roles in Winnipeg or remote.

Email me See the MCAT app