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D90 Rebuild......

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LandyAndy
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D90 Rebuild......

#1 Post by LandyAndy » Mon Jan 30, 2012 6:41 pm

Thought I'd post a few pic's of my D90 rebuild... decided that I would never get what I've spent on it over the years if I sold it, so.....

Start off with a simple RHD to LHD conversion....

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Decided whilst I'm at it, might as well go to 100" wheelbase & add a rear winch too, that I happened to have spare :wink:

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Now to add the rear winch tray, steel parts were cut at 'Custom Cut' in S'Arm from drawings developed in Bendtech Sheet Metal

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Finally will add an extension to the exo-cage to give better protection off-road, still in design stage until I get the cage mounts welded onto the chassis

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'85 ex-MOD D100 with 5.3 GenIII power.

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#2 Post by franko » Tue Jan 31, 2012 8:01 am

Looks great love the rear winch tie in. So what's the plan for this on,still road friendly?

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Steering conversion

#3 Post by ANDYD » Tue Jan 31, 2012 8:17 am

Thanks for sharing the photos Andy.

Please take lots more of the RHD to LHD steering conversion as I know there is lots of people thinking about doing it!
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

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#4 Post by LandyAndy » Tue Jan 31, 2012 8:52 am

franko wrote:Looks great love the rear winch tie in. So what's the plan for this on,still road friendly?
I can't take credit for the tray design, sort of based it on Devon 4x4's and saved over $700 in shipping costs in the process :D

Plan to keep it on the highway, no point in making it a trailer queen would be too restrictive then & I don't have a trailer to haul it around on. There's no chance of getting one in the near future too, as the wife's just lost her job at RMR.... :evil:
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: Steering conversion

#5 Post by LandyAndy » Tue Jan 31, 2012 8:56 am

ANDYD wrote:Thanks for sharing the photos Andy.

Please take lots more of the RHD to LHD steering conversion as I know there is lots of people thinking about doing it!
The actual conversion is not that hard... getting all the parts is the real PITA, espically the LHD dash bits if you want to keep it looking 'stock'. To be honest I'm in two minds to just make a new dash as the bits I've got are not in the best condition being ex-mil. abd quite old. The dash vinyl is rather hard & brittle, so spending $$ on getting it recovered might as well be spend on getting a new alum dash fabricated that will offer better storage space & look just as good.
'85 ex-MOD D100 with 5.3 GenIII power.

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#6 Post by HeadDamage » Tue Jan 31, 2012 1:07 pm

I thought that BC had some odd rules about frame modifications on street legal trucks?

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#7 Post by LandyAndy » Tue Jan 31, 2012 1:33 pm

HeadDamage wrote:I thought that BC had some odd rules about frame modifications on street legal trucks?
Not as far as I'm aware, just on frames that are heat treated as part of the manufacturing process. You can't weld on them, LR frames are just regular mild steel.
'85 ex-MOD D100 with 5.3 GenIII power.

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#8 Post by HeadDamage » Tue Jan 31, 2012 1:48 pm

It looks like a good project, I was asking because when I lived on the Island there seemed to be a lot of concern related to frame mods with the non-rover 4x4 crowd. Back here in Alberta I think it is much more anything goes as long as you can get private insurance for it.

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#9 Post by LandyAndy » Tue Jan 31, 2012 1:54 pm

HeadDamage wrote:It looks like a good project, I was asking because when I lived on the Island there seemed to be a lot of concern related to frame mods with the non-rover 4x4 crowd. Back here in Alberta I think it is much more anything goes as long as you can get private insurance for it.
From what I understand, alot of the domestic trucks have frames with the heat treated 'C' section profile to give them the rated load capacity, as these are also used under alot of the SUV's in one form or another it can be a bit of a headache when your doning mods. I guess that's why you see alot of 'bolt on' stuff here, doesn't cause heat stresses in the frame from welding.

Good point though :wink:
'85 ex-MOD D100 with 5.3 GenIII power.

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#10 Post by LandyAndy » Sat Feb 04, 2012 12:53 pm

Umm.... things seems to be snowballing..... as I need to remake the rear 'A' frame for the new wheelbase, why not just 4 link it.... like this one :wink:

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Will need to mod the rear axle with a truss & mount but that'll get rid of the restrictive ball joint too.... win win :D

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'85 ex-MOD D100 with 5.3 GenIII power.

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#11 Post by LandyAndy » Mon Feb 13, 2012 8:06 am

Steady progress this past couple of weeks, rear winch cage all completed.

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Main hoop cage mounts done & swapped the outer side plates into ones that tie into the frame rails.

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Now working on the design for the rear axle top link mount. Have replaced the lower trailing arm mounts with std. 2 5/8" brackets for Johnny/Creeper Joints.

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Hopefully get the rear axle back under the truck in the next week or so & can then start the general rebuild & finish off the LHD conversion.

Other plans include fitting hydro assist to turn the 35's, kit is from GP in the UK.

http://gigglepin4x4-shop.co.uk/epages/e ... 2/Steering
'85 ex-MOD D100 with 5.3 GenIII power.

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#12 Post by LandyAndy » Wed Mar 21, 2012 7:52 am

Made some new mounts for the rear 4 link setup

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Cleaned up & painted the bulkhead

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Finally get to start bolting bits back on rather than taking them off :D

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'85 ex-MOD D100 with 5.3 GenIII power.

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#13 Post by LandyAndy » Sun Apr 01, 2012 8:49 am

Bit of progress this last week or so, got the rear bulkhead reinforced and the top capping tidied up. Now to work on the new twin battery cradle that'll sit just behind it.

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Rear axle is just waiting for the order of Jonny joints to arrive so I can finish up the 4 links and finalize the pinon angle. Once that's done it can be final welded, painted & rebuilt.

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Then we can get it rolling again & start work on the cab rebuild, wiring, brake lines and get the engine running under Mega Squirt :wink:

Plan is to have it drivable as a chassis cab then finish the rear cage and tube front wings :D
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#14 Post by LandyAndy » Mon Jun 04, 2012 9:02 am

Slow progress.... but, rear axle back in on the 4 link to check out the flex & work the shock upper mount location out.

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X-Eng helper springs set to 99% extension, should keep it all tight & less rattly

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Cab back together :D

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Time to get the dash in & make up some new brale lines.

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Megasquirt is also coming along, ECM mounted into the waterproof box & mil-spec connectors wired up

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Till the next time.... happy rovering !
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#15 Post by mepham55 » Tue Jun 05, 2012 9:37 pm

Wow nice build! That welding is a work of art.

Matt

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Re: D90 Rebuild......

#16 Post by BCROVER » Sun Oct 21, 2012 4:31 am

Hi Andy,

I just found your rebuild on here, how did it turn out in the end??
Looks fantastic do far.
I am looking at doing a RHD-LHD conversion on my defenders, I just wondered how difficult it really is? Do you need a new bulkhead? or can you just reverse it? I am in the UK for a while and am sourcing some spares. What components wont reverse? is there anything I should get whilst I am over here that would make it work?
I am down in Kelowna and frequently pass through Revelstoke, One day we will have to hook up, It would be great to see the finished article.

Cheers

Will

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Re: D90 Rebuild......

#17 Post by LandyAndy » Sun Oct 21, 2012 2:04 pm

Hi Will,

Still working on the truck, have had to take a break to get some more outside work finished on our house before the snow arrives.... and it's almost here !

Doing the conversion is not hard, it's all nuts & bolts like any 90/100 job, hardest bit is getting all the LHD handed trim items as there getting scarce now and any decent stuff fetches a premium price. Check out some of the dashboard for sale threads on D90.com (http://www.d-90.com/forum/index.php

Depending upon the D90/110 year the bulkhead may be handed, can't remember when the cut-off was for universal LHD/RHD ones.

For the main mechanical items your best option is to find a older classic range rover (in Canada) that's being parted out, you'll get the complete swivel hubs, axles, drag link, power steering box etc., from that or just get the complete front axle and all the steering parts. If it's a later one and the vehicle had ABS you can either get some blanking caps made for the ABS sensor holes (as I did) or just leave the sensors in there & cut the cables off.

PM me your email address & I can send you a list of parts needed for the conversion.

Cheers,
Andy
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#18 Post by LandyAndy » Sun Nov 18, 2012 11:25 pm

Got allot of the house work done recently so.... back to the fun stuff :D

Time to get the tube bender out & put it to good use....

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More work to do on the rear tub frame but happy with the progress so far, keeping it looking D90'ish is the challenge :wink:
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#19 Post by LandyAndy » Fri Nov 30, 2012 11:14 am

Bit more done on the rear bodywork skin supports, will be able to hang some decent demountable h/d truck mud flaps off the rear corner frames for daily use :)

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Front will get some tubular 'challenge' style wings made next.
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#20 Post by LandyAndy » Sun Dec 02, 2012 9:52 pm

Been rain'in all weekend.... so, made a start on the front tubular wings :D

Bulkhead bracket & inner tube.
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Outer tube being trimmed to size, front will get cross bracing across the slam panel. Wings will be skinned with diamond plate on top.
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Can you guess what this'll be :wink:
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Last edited by LandyAndy on Tue Dec 04, 2012 7:20 am, edited 1 time in total.
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Re: D90 Rebuild......

#21 Post by tait » Mon Dec 03, 2012 9:57 pm

LandyAndy wrote:Been rain'in all weekend.... so, made a start on the front tubular wings :D

Bulkhead bracket & inner tube.
Image

Outer tube being trimmed to size, front will get cross bracing across the slam panel. Wings will be skinned with diamond plate on top.
Image

Can you guess what this'll be :wink:
[img]http://i946.photobu
Hmmm...rear-mounted turret, a-la Batmobile!? :lol:
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Re: D90 Rebuild......

#22 Post by LandyAndy » Tue Dec 04, 2012 7:21 am

Link fixed :wink:
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#23 Post by DBrands » Tue Dec 04, 2012 8:02 am

Spare tire mount?
David B

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Re: D90 Rebuild......

#24 Post by discojonny » Tue Dec 04, 2012 10:09 am

What size is that tubing? 1 1/2" 1/8" wall?
looks great.

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Re: D90 Rebuild......

#25 Post by LandyAndy » Tue Dec 04, 2012 3:18 pm

DBrands wrote:Spare tire mount?
Yup... :)
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Re: D90 Rebuild......

#26 Post by LandyAndy » Tue Dec 04, 2012 3:19 pm

discojonny wrote:What size is that tubing? 1 1/2" 1/8" wall?
looks great.
No, 1 7/8" x .120 wall DOM for all the main stress areas, HREW for the front wings.
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#27 Post by HeadDamage » Tue Dec 04, 2012 3:59 pm

What bender are you using?

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Re: D90 Rebuild......

#28 Post by LandyAndy » Tue Dec 04, 2012 4:22 pm

HeadDamage wrote:What bender are you using?
JD2 Mk3 with a 6.5"CLR die & Bendtech Pro V6 for design.
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#29 Post by ANDYD » Wed Dec 05, 2012 12:24 am

Its looking great Andy, thanks for sharing the build ... when do you expect to "launch" her?
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

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Re: D90 Rebuild......

#30 Post by LandyAndy » Wed Dec 05, 2012 8:03 am

ANDYD wrote:Its looking great Andy, thanks for sharing the build ... when do you expect to "launch" her?
Prob not until the spring.... still allot of work to do on the fabrication and then all the wiring needs to be sorted out plus the engine is getting Megasquirt and that's a whole other mini-project :roll:
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#31 Post by LandyAndy » Sun Dec 09, 2012 8:51 pm

Bit more work done on the spare tire carrier...

Spare is held up nice & high, leaving access to the rear winch & tow hitch.
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Will mount a 3rd brake light into the middle of the carrier frame.
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Made it easy to load too, the darn thing is rather heavy to lift.... or I'm just getting old !
Image
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#32 Post by Dave_F » Sun Dec 09, 2012 9:54 pm

Looking great.

The tire carrier in the load position could be used for a table...or a toilet...with a little modification :lol: :lol: :lol: :lol:
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1991 x-MoD 19 KK 88 Defender 110 ~ daily driver
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Re: D90 Rebuild......

#33 Post by LandyAndy » Sun Dec 09, 2012 11:28 pm

Dave_F wrote:or a toilet...with a little modification :lol: :lol: :lol: :lol:
Umm.... reminds me of the Top Gear bumper dumper :mi7:
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Re: D90 Rebuild......

#34 Post by skeena river rover » Thu Dec 13, 2012 8:49 pm

I like it! Can't wait to see when it is finished!

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Re: D90 Rebuild......

#35 Post by e.prevost94 » Thu Dec 13, 2012 9:07 pm

Looking great! Are you planning on making the rear "Defender Like" for lack of better words?
Keep Honking... I'm Reloading.

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Re: D90 Rebuild......

#36 Post by LandyAndy » Thu Dec 13, 2012 9:53 pm

e.prevost94 wrote:Looking great! Are you planning on making the rear "Defender Like" for lack of better words?
The back will get some alum skins over the steel framework, not sure if I'll put a roll on the top of the sides or just follow the angles... still some more tubes to add to brace the back corners and then can draw up some diamond plate lockers.
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#37 Post by LandyAndy » Fri Feb 15, 2013 9:41 am

Bit more done.... mounted my ground anchor, started to get the front fenders on the wings & got a few Carling switches, just need to design a custom LHD dash now to put them in :roll:

Image

Image

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With the front & rear fenders on it's starting to look well chunky :D

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#38 Post by LandyAndy » Wed May 08, 2013 8:13 am

Got some more done, inbetween rebuilding a 4.6 for the D2 & getting ready for the NWOR in June.....

Hydro assist & harness mounts kits

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Rear shock & bump stop mounts made

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Air temp sensor adaptor fitted to old AFM for the Megasquirt install

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New front lower shock mounts and bump stop mounts made

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Next to finish the front upper shock mounts, panel tabs & brackets on the cage then it's all apart for final welding & paint. Then to design & build a custom LHD dash to incorporate the Vintage Air AC unit I've got :D
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#39 Post by LandyAndy » Thu May 09, 2013 7:23 am

Front shock mounts made, this is the drivers side... it's kinked to clear the alternator

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Passenger side mounted up

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Tops will be tied into the wing tubing with bolted tabs for extra bracing & easy wing removal

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#40 Post by LandyAndy » Thu May 23, 2013 6:09 pm

Finished off a few bits, made a spare tire strap & fitted the rear bump stop mounts up.... fronts ready to go on too... steady progress :)

Image

Image

Image

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#41 Post by Strange Rover » Thu May 23, 2013 8:53 pm

This may be the coolest thing I have ever seen, and as an avionics technician I can't help but want a set of those switches for myself :bounce:

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Re: D90 Rebuild......

#42 Post by LandyAndy » Sun May 26, 2013 11:01 pm

A bit of a side project here, assembling the Staz Works double bead lockers is a right royal PITA, so.... I made a stand to pull the two rim pieces together & then it's just a case of putting the bolts in around the edge & torqueing them up. So much easier when you can sit & work at a reasonable height with both hands free.

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#43 Post by LandyAndy » Sun Jun 16, 2013 11:25 am

A few more little details worked out... headlight mountings, rear quick release mudflaps & hi-lift jack secured. All these little bits take the longest :roll:

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#44 Post by franko » Sun Jun 16, 2013 12:44 pm

Man she is looking great!

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Re: D90 Rebuild......

#45 Post by LandyAndy » Tue Jun 18, 2013 7:26 am

Rear mudflaps finished :D

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Re: D90 Rebuild......

#46 Post by Dave_F » Wed Jun 19, 2013 6:03 pm

Stellar work so far...looking like it will be quite the beast....Baja or Dakar? Need a navigator? :D

It must just be the angle but the tire looks huge...hows the rear visibility?
1956 Series 1 86 Hardtop 173601415
1991 x-MoD 19 KK 88 Defender 110 ~ daily driver
2006 LR3 HSE HD



1955 Series 1 86 Hardtop 57130577 ~ just a heap o' parts now

1985 Series III 109 x-MoD BATUS 77 KC 63 < sold lives in Calgary
1965 x-MoD 35 ET 73 Sankey Narrow Track Trailer ~ sold

http://www.freewebs.com/83s3109/

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Re: D90 Rebuild......

#47 Post by LandyAndy » Wed Jun 19, 2013 6:10 pm

Dave_F wrote:Stellar work so far...looking like it will be quite the beast....Baja or Dakar? Need a navigator? :D

It must just be the angle but the tire looks huge...hows the rear visibility?
More like local power line cuts.....

Rear visibility.... forgot what that was driving the D2 with all the storage rack in the back..... I've got side mirrors :D
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#48 Post by LandyAndy » Tue Jul 16, 2013 7:38 am

Finished off the front wings & had the centre section of the cage blasted to remove the old powder coating, added some additional top corner tubes, last few triangulation tubes to be added to the front screen hoop next.

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#49 Post by 99Disco2 » Fri Aug 16, 2013 9:46 pm

Very awesome project and very impressive fabrication skills.
I noticed you are going to be running Megasquirt system on your project and was wondering what are you running for a transmission?
I have been thinking of running MS on our 99 D2 but have still to figure out how to control the ZF4.

Chris

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Re: D90 Rebuild......

#50 Post by LandyAndy » Sat Aug 17, 2013 11:16 am

99Disco2 wrote:Very awesome project and very impressive fabrication skills.
I noticed you are going to be running Megasquirt system on your project and was wondering what are you running for a transmission?
I have been thinking of running MS on our 99 D2 but have still to figure out how to control the ZF4.

Chris
Thanks... am running a RaRo ZF4-HP22 so it's all manual shift. If you want to keep the HP24 the guys back in the UK use Compushift... http://www.hgmelectronics.com/products- ... mpushiftii

Search on the D44 board, think there were some threads on there about using & setting it up.
'85 ex-MOD D100 with 5.3 GenIII power.

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