D90 Rebuild......

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99Disco2
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Re: D90 Rebuild......

#51 Post by 99Disco2 » Sat Aug 17, 2013 5:20 pm

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.[/quote]

Thanks for the Compushift link,I will do some research on it.
As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?
My wife wants to keep the auto box but doesn't mind shifting it her self, I would rather have a R3380 or LT77 instead.

Chris

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LandyAndy
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Re: D90 Rebuild......

#52 Post by LandyAndy » Sat Aug 17, 2013 8:17 pm

99Disco2 wrote:As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?
Yep, came out a RaRo years ago... haven't a clue what yr though... and manual shift as in... it don't need a computer to make it work like the HP24 :wink:
'85 ex-MOD D100 with 5.3 GenIII power.

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99Disco2
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Re: D90 Rebuild......

#53 Post by 99Disco2 » Sat Aug 17, 2013 10:04 pm

LandyAndy wrote:
99Disco2 wrote:As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?
Yep, came out a RaRo years ago... haven't a clue what yr though... and manual shift as in... it don't need a computer to make it work like the HP24 :wink:
Ah got it now, sorry I had a brain lapse there
My current tranny (HP24) is fully electonic and yours the HP22 is full maual like an old school Chevy Turbo 350, correct?
Now wasn't the HP22 used in the D1's as well?
Oh and the HP24's tourque converter won't fit in the HP22 right?
I was reading on "Paddock Spares" web site and they state the bell housings are different and not interchangable, what engine block are you running?

Sorry for bonbarding you with questions

Thanks also for your help

mojigglins

Re: D90 Rebuild......

#54 Post by mojigglins » Fri Aug 23, 2013 9:27 pm

Wow!! Amazing! Build!

I was just wondering what t-case are you running and gear ratio, LT230 1.667?

Thanks for sharing!!

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LandyAndy
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Re: D90 Rebuild......

#55 Post by LandyAndy » Fri Aug 23, 2013 10:12 pm

mojigglins wrote:Wow!! Amazing! Build!

I was just wondering what t-case are you running and gear ratio, LT230 1.667?

Thanks for sharing!!
Yup, with std diffs... Same as D44 run in their trucks. About the ideal ratio for 35's ;)
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#56 Post by LandyAndy » Sat Dec 14, 2013 12:23 pm

Not a lot of progress these past weeks, but did pick up a new alum rad whilst I was back in the UK... saved a bunch on tax & shipping :D

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As funds are a bit thin on the ground at present made a start on the custom dash, decided to use the Vintage Air A/C unit as I already had it (was going to use the OEM heater & mod it) & they get good reviews. So, made up a small cradle from 3/4" 100 wall tube & some strip stock to mount the A/C unit just off centre on the bulkhead.

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Will be keeping the dash top crash pad & the RHD instrument binnacle as it'll mount easily onto the dash front and why reinvent the wheel. Next to source some round facia vents & defrost ducts so I can lay the dash out, have already got the Carling switches and a 6 way mounting bracket for them also. Was thinking that the switches should go above the A/C unit as that space will become quite full once all the ducting is attached. Not sure about where there will be space for a radio... mine is actually mounted into the Laselle headlining but if anyone else wanted one it'd need to find a home in the dash..... ummm.... need to get the thinking cap on for that one :wink:
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#57 Post by LandyAndy » Sun Mar 23, 2014 9:52 am

Been a while since last update...... have spent many hours on the CAD getting the bulkhead & top crash pad models correct and the dash drawn up. Decided not to use any LHD dash parts in the build at all and just use what I had, any other LR parts needed are easily available on Ebay or the usual LR suppliers. Here is the model to date.

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After getting just the ends cut, adjusted & fitted the bulkhead model needed a few tweeks, then I finalized the main dash panel and made a cardboard mock up. A few more adjustments to the locations of switches etc and then off it went for cutting.

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Now here is the drivers side tacked up and in place. Will make some final adjustments to the model but nothing that means a recut of this part. :D

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The old heater control levers have been repurposed to open & close the bulkhead vent flaps using heater control cables and some custom brackets. I've added a side window vent for defrosting & 12v/USB charging points for phones etc. Now just waiting on hinges/catch for the passenger side glove box from Southco dealer and a D1 interior grab handle too. I can then get the passenger side finished off as the main panel is the same profile as the drivers side. After that I can focus on the centre section that covers the HVAC unit & the top pod that'll wrap up & over the top pad where the old ashtray was.
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Re: D90 Rebuild......

#58 Post by LandyAndy » Mon Dec 29, 2014 1:56 pm

Haven't updated this in a while, so here are a few more pics :

LED lights for the rear cargo area.
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LED lights to see where I'm going :D
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Limb riser tabs & couple more brackets for LED ditch lights.
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Got a bought a pair of new seats in the sales.
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Will use the Qt f/g seat mount.
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With some adaptor brackets to make them easy removable.
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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#59 Post by LandyAndy » Mon Dec 29, 2014 2:06 pm

Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
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And in it's place will be.... :D
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And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
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I'll also be fitting a Behemoth Drivetrain Strong Box between the NV & adaptor next, that'll give me a crawl ratio of 180:1..... :bounce:
http://www.behemothdrivetrain.com/STRON ... _KITS.html

So, I have a used NP241C to donate it's guts... not bad for a pack of beer :wink:
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Re: D90 Rebuild......

#60 Post by LandyAndy » Mon Dec 29, 2014 2:11 pm

Finally, progressed the custom dash to a point where it needs final welding & then powder coating.

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And that's about it so far....
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#61 Post by franko » Mon Dec 29, 2014 2:51 pm

So....you applying for Alaska off road warriors season 2 ;-)

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LandyAndy
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Re: D90 Rebuild......

#62 Post by LandyAndy » Mon Dec 29, 2014 4:03 pm

franko wrote:So....you applying for Alaska off road warriors season 2 ;-)
I doubt it'll be finished for then... lol
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99Disco2
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Re: D90 Rebuild......

#63 Post by 99Disco2 » Fri Jan 30, 2015 11:32 pm

[quote="LandyAndy"]Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
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And in it's place will be.... :D
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And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
Image

I'll also be fitting a Behemoth Drivetrain Strong Box between the NV & adaptor next, that'll give me a crawl ratio of 180:1..... :bounce:
http://www.behemothdrivetrain.com/STRON ... _KITS.html

So the adapter you are using, was it bought locally?
I am looking at an adapter for the Dodge 23 spline NV4500/NV3550 for a diesel conversion.

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Re: D90 Rebuild......

#64 Post by LandyAndy » Sat Jan 31, 2015 11:14 am

I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.
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99Disco2
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Re: D90 Rebuild......

#65 Post by 99Disco2 » Sun Feb 01, 2015 6:06 pm

LandyAndy wrote:I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.
You are right about the Dodge adapter, it's from Diesel Conversion Specialist for $599.
Does Nick on Defendersource still sell the GM one's.

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Re: D90 Rebuild......

#66 Post by LandyAndy » Mon May 04, 2015 12:20 pm

A few updated pics.....

Drive line assembled with the crawler box.
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Trial fit of the Goat Build PAS pump & Alt relocation brackets.
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Hi/Lo lever flipped round for easier cable shift hook up with the crawler box.
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Added the TD5 clutch pedal.
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Trial fit of the Vortec to check water pump clearance to the Allisport rad.
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Might need to swap the oil pan out for a Camaro one if clearance at full bump is an issue.
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Re: D90 Rebuild......

#67 Post by LandyAndy » Mon May 04, 2015 12:21 pm

99Disco2 wrote:
LandyAndy wrote:I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.
You are right about the Dodge adapter, it's from Diesel Conversion Specialist for $599.
Does Nick on Defendersource still sell the GM one's.
Yep... drop him a PM to reserve, he has another batch in manufacturing progress I believe.
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Re: D90 Rebuild......

#68 Post by HeadDamage » Mon May 04, 2015 1:35 pm

I forget, have you lengthened the wheel base?

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Re: D90 Rebuild......

#69 Post by LandyAndy » Mon May 04, 2015 1:49 pm

HeadDamage wrote:I forget, have you lengthened the wheel base?
Yes, to 100". Looks like if I fit a short drive shaft & carrier bearing off the 3 link x-member, I'll be able to have the same length drive shaft to the axles front & rear.
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Re: D90 Rebuild......

#70 Post by LandyAndy » Thu May 07, 2015 11:37 pm

Major milestone reached.....

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Good clearance to the front x-member too, so that won't need to be reworked.

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Well pleased :grin
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Re: D90 Rebuild......

#71 Post by TOLON » Fri May 08, 2015 5:26 pm

Nice! Will have to stop in for a looksee...I'll bring beer!
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Re: D90 Rebuild......

#72 Post by LandyAndy » Wed Jul 01, 2015 3:27 pm

A few small jobs completed, PAS pipes to the steering box.

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Moving the engine & drive line back an additional inch has given enough room for medium frame Spal electric fans on the Alisport rad :D

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Version 1 of the GM ECU mount.... version 2 has the fuse box mounted to the rear for a lower profile.

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Engine loom pruned out & modified for stand alone use, just the gauge wires to add then loom up.

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'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#73 Post by LandyAndy » Sun Jun 26, 2016 10:46 pm

Not been round here for a while, got a new job... working on the house... you know the score...

Anyway a few updated pic's... fuel system all plumbed up

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Custom schedule 40 exhaust manifolds being made

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Engine harness all finished

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Front propshaft centre bearing from Rakeway in the UK to get it over the 3 link cross member

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Heater fully plumbed & installed

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Started a new custom wiring loom to replace the old cracked one and all new switches etc

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And the seatbox is all back in with custom removable mounts for the seats to aid in servicing & cleaning

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And finally the exo cage is all powder coated & fitted

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That's about it really, been a very busy 7 months since starting my new job... hope to make a bit more progress over the next few before the snow flies !
'85 ex-MOD D100 with 5.3 GenIII power.

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Re: D90 Rebuild......

#74 Post by D Andersen » Mon Jun 27, 2016 10:44 pm

What fusebox did you use? I have to replace mine on my MOD 90

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Re: D90 Rebuild......

#75 Post by ANDYD » Wed Jun 29, 2016 9:52 pm

Looking really good Andy, very nice work. Thanks for the update.

Bet you cant wait to get all those nooks and crannies full of gooey, mucky mud!
I======IooooI
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Re: D90 Rebuild......

#76 Post by LandyAndy » Wed Jul 27, 2016 6:02 pm

Had a little time to finish off the exhaust manifolds...

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Working out the rad hoses...

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Got the front 8274 stripped, media blasted & partially rebuilt... treated it to a Giggle Pin HD main shaft & brake discs, will also get a idle shaft upgrade and finally a 6.5hp Xp motor :D

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Back to the gardening.... :(
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Re: D90 Rebuild......

#77 Post by LandyAndy » Mon Sep 12, 2016 10:05 pm

So, summer is coming to an end... the landscaping on our house is all about finished... time to get back to the D100 project.

Got the dash loom 99% completed.

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A few more fuses than original.... :D

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Got the rear 8274 stripped, painted & ready for rebuild. Was a real mess inside as it had sat with water in it, will need new bushes and bearings but then it'll be good as new :bounce:

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Next to finish the rest of the chassis loom and start to get it installed.
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Re: D90 Rebuild......

#78 Post by LandyAndy » Wed Oct 12, 2016 9:47 pm

Got the bulkhead loom test fitted & powered up, fixed a couple of small issues. Just got to rework the DRL's as the older 'dim-dip' module I used is kaput and there mega $$. The newer 'pink' version is cheap but needs a minor wiring alteration to work correctly.

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Re: D90 Rebuild......

#79 Post by LandyAndy » Mon Feb 13, 2017 8:05 pm

Not done an update for a while, so.... engine all completed with 'home' cooked EHT paint on the exhaust manifolds... the oven did smell a bit for a while :twisted:

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The wiring is 99% complete with just the lights to be installed once I get the new 'skins' drawn up & made. Rear loom is seen here.

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Now working on installing the dash after getting it powder coated in a textured satin black finish.

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Still lots to do but getting close to having the LS fired up for the first time :bounce:
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Re: D90 Rebuild......

#80 Post by LandyAndy » Fri Jan 26, 2018 4:41 pm

Very slow progress on the project for the last while, however.... exhaust system is made & away for final weld up at a buddy's :D

Few pictures of building it.
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Had to cut & shut the passenger side manifold down pipe by 1.5" to clear the front diff on full bump.... doh :oops:

Did the GM clutch master cylinder mod as I couldn't get enough stroke with the TD5 one.

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Re: D90 Rebuild......

#81 Post by LandyAndy » Fri Jan 26, 2018 4:48 pm

Forgot I'd taken this video of the motor running... open manifolds too :D

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Re: D90 Rebuild......

#82 Post by LandyAndy » Wed Jul 25, 2018 4:25 pm

Chipping away at those little jobs...

8274 fully rebuilt, 6hp motor & some Giggle Pin goodies inside :D

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Drive shafts all in, got a stubby from the t'case to the steady bearing on the front 3 link x-member

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Re: D90 Rebuild......

#83 Post by LandyAndy » Sat Nov 10, 2018 7:24 pm

Had the truck out under its own power for the first time in 6 yrs a while ago.

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Got to work on the 5052 skins.

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Re: D90 Rebuild......

#84 Post by LandyAndy » Tue Apr 23, 2019 10:14 pm

Been chipping away at all the little finishing jobs...

Custom triple sticks for the LT230 & crawler box

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Got the skins powder coated in closest green to the cab, will make repairs easy after a hard day on the trails :roll:

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Now to finish the trans tunnel mods & put the rest of the cab back together.
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Re: D90 Rebuild......

#85 Post by ANDYD » Tue Apr 23, 2019 10:43 pm

Looking Great Andy, so close to finishing now......you should be out on the road this summer!
I======IooooI
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Re: D90 Rebuild......

#86 Post by LandyAndy » Fri Jun 07, 2019 6:01 pm

Made a jerry can rack for the rear, skins all bolted on the back....

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Lots of little stuff to do & still gotta draw up the cargo lockers & new center tunnel top, inner fender skins....
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Re: D90 Rebuild......

#87 Post by LandyAndy » Fri Aug 16, 2019 6:25 pm

Nibbling away at the little things....

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Batteries wired & the jerrycans mounted up.
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Re: D90 Rebuild......

#88 Post by LandyAndy » Mon Aug 19, 2019 9:51 pm

Got the door bottoms cleaned up & threw some paint on them. Used the spray bed liner on the insides & on the 5 bar treadplate to reduce some of the glare.

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Re: D90 Rebuild......

#89 Post by bclandrover » Sun Oct 20, 2019 8:14 pm

Amazing vehicle! Amazing progress! I know all too well how long these projects can take!

Can't wait to see it out on the trail or at Founders Day.

Thanks for sharing

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Re: D90 Rebuild......

#90 Post by LandyAndy » Tue Nov 12, 2019 5:16 pm

Progress... sorta got side tracked on building a new rear axle...

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Decided wasn’t going to be on the road this year so might as well build a 609 for it, got the hubs & brakes about sorted to run my Stazworks headlocks.

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Used Dodge hubs as there flat backed and that allowed them to be redrilled from 8 on 6.5” to 5 on 6.5” with two holes plugged.

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And you may be wondering why, well here’s a 24 spline half shaft in the spindle... gotta love 1.5” 35 spline shafts :D

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'85 ex-MOD D100 with 5.3 GenIII power.

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