D90 Rebuild......

[LandyAndy]

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.

[HeadDamage]

What bender are you using?

[LandyAndy]

What bender are you using?

JD2 Mk3 with a 6.5"CLR die & Bendtech Pro V6 for design.

[ANDYD]

Its looking great Andy, thanks for sharing the build ... when do you expect to "launch" her?

[LandyAndy]

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:

[LandyAndy]

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

Spare is held up nice & high, leaving access to the rear winch & tow hitch.
http://i946.photobucket.com/albums/ad30 ... C05526.jpg

Will mount a 3rd brake light into the middle of the carrier frame.
http://i946.photobucket.com/albums/ad30 ... C05527.jpg

Made it easy to load too, the darn thing is rather heavy to lift.... or I'm just getting old !
http://i946.photobucket.com/albums/ad30 ... C05528.jpg

[Dave_F]

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:

[LandyAndy]

or a toilet...with a little modification :lol: :lol: :lol: :lol:

Umm.... reminds me of the Top Gear bumper dumper :mi7:

[skeena river rover]

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

[e.prevost94]

Looking great! Are you planning on making the rear "Defender Like" for lack of better words?

[LandyAndy]

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.

[LandyAndy]

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:

http://i946.photobucket.com/albums/ad30 ... e4607c.jpg

http://i946.photobucket.com/albums/ad30 ... 8ed842.jpg

http://i946.photobucket.com/albums/ad30 ... b1e9b6.jpg

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

http://i946.photobucket.com/albums/ad30 ... fcdfc6.jpg

[LandyAndy]

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

Hydro assist & harness mounts kits

http://i946.photobucket.com/albums/ad30 ... 3c65b3.jpg

http://i946.photobucket.com/albums/ad30 ... 82a9d3.jpg

http://i946.photobucket.com/albums/ad30 ... fee5e8.jpg

Rear shock & bump stop mounts made

http://i946.photobucket.com/albums/ad30 ... 99edcb.jpg

http://i946.photobucket.com/albums/ad30 ... 5b526a.jpg

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

http://i946.photobucket.com/albums/ad30 ... 0facaa.jpg

New front lower shock mounts and bump stop mounts made

http://i946.photobucket.com/albums/ad30 ... 5a951c.jpg

http://i946.photobucket.com/albums/ad30 ... f52ec7.jpg

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

[LandyAndy]

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

http://i946.photobucket.com/albums/ad30 ... 1f10d3.jpg

Passenger side mounted up

http://i946.photobucket.com/albums/ad30 ... c2119d.jpg

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

http://i946.photobucket.com/albums/ad30 ... 1c473d.jpg

[LandyAndy]

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 :)

http://i946.photobucket.com/albums/ad30 ... 920188.jpg

http://i946.photobucket.com/albums/ad30 ... aff417.jpg

http://i946.photobucket.com/albums/ad30 ... b2dc9e.jpg

http://i946.photobucket.com/albums/ad30 ... ad04df.jpg

[Strange Rover]

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:

[LandyAndy]

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.

http://i946.photobucket.com/albums/ad30 ... 4b38d2.jpg

http://i946.photobucket.com/albums/ad30 ... 679188.jpg

http://i946.photobucket.com/albums/ad30 ... bbe99d.jpg

[LandyAndy]

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:

http://i946.photobucket.com/albums/ad30 ... fbf190.jpg

http://i946.photobucket.com/albums/ad30 ... d8c611.jpg

http://i946.photobucket.com/albums/ad30 ... 0db163.jpg

http://i946.photobucket.com/albums/ad30 ... 2a8cc4.jpg

[franko]

Man she is looking great!

[LandyAndy]

Rear mudflaps finished :D

http://i946.photobucket.com/albums/ad30 ... 73c99c.jpg

http://i946.photobucket.com/albums/ad30 ... f2ac30.jpg

[Dave_F]

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?

[LandyAndy]

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

[LandyAndy]

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.

http://i946.photobucket.com/albums/ad30 ... f3107d.jpg

http://i946.photobucket.com/albums/ad30 ... 1bfbae.jpg

[99Disco2]

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

[LandyAndy]

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.