D90 Rebuild......

[LandyAndy]

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

http://i946.photobucket.com/albums/ad30 ... ozl2ll.jpg

Working out the rad hoses...

http://i946.photobucket.com/albums/ad30 ... vxs4j9.jpg

http://i946.photobucket.com/albums/ad30 ... udyv87.jpg

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

http://i946.photobucket.com/albums/ad30 ... zqc8xt.jpg

http://i946.photobucket.com/albums/ad30 ... uaqlr6.jpg

Back to the gardening.... :(

[LandyAndy]

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.

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

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

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

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:

http://i946.photobucket.com/albums/ad30 ... n7nh6h.jpg

http://i946.photobucket.com/albums/ad30 ... eqvz20.jpg

Next to finish the rest of the chassis loom and start to get it installed.

[LandyAndy]

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.

http://i946.photobucket.com/albums/ad30 ... ogjf87.jpg

[LandyAndy]

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:

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

http://i946.photobucket.com/albums/ad30 ... qi3wz7.jpg

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.

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

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

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

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

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

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

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

[LandyAndy]

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

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

http://i946.photobucket.com/albums/ad30 ... ft2ptw.jpg

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.

http://i946.photobucket.com/albums/ad30 ... e4c1su.jpg

[LandyAndy]

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

http://i946.photobucket.com/albums/ad306/Landy_Andy/NV4500%20-%20Vortec%20Install/th_Engine%20video_zpsmmp312fu.mp4

[LandyAndy]

Chipping away at those little jobs...

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

http://i946.photobucket.com/albums/ad30 ... 1q6rjh.jpg

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

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

[LandyAndy]

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

http://i946.photobucket.com/albums/ad30 ... 5jjqn6.jpg

Got to work on the 5052 skins.

http://i946.photobucket.com/albums/ad30 ... p2k1fy.jpg

http://i946.photobucket.com/albums/ad30 ... np7k5g.jpg

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

[LandyAndy]

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

Custom triple sticks for the LT230 & crawler box

https://oi946.photobucket.com/albums/ad ... 3o1nzq.jpg

https://oi946.photobucket.com/albums/ad ... 8rsbd5.jpg

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

https://oi946.photobucket.com/albums/ad ... 3deaua.jpg

Now to finish the trans tunnel mods & put the rest of the cab back together.

[ANDYD]

Looking Great Andy, so close to finishing now......you should be out on the road this summer!

[LandyAndy]

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

https://i946.photobucket.com/albums/ad3 ... s5f9l2.jpg

https://i946.photobucket.com/albums/ad3 ... mfzykq.jpg

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

[LandyAndy]

Nibbling away at the little things....

http://i946.photobucket.com/albums/ad30 ... yyxn66.jpg

http://i946.photobucket.com/albums/ad30 ... ohah46.jpg

Batteries wired & the jerrycans mounted up.

[LandyAndy]

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.

http://i946.photobucket.com/albums/ad30 ... cjit2z.jpg

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

[bclandrover]

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

Don

[LandyAndy]

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

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

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.

http://i946.photobucket.com/albums/ad30 ... k7kuvb.jpg

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.

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

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

http://i946.photobucket.com/albums/ad30 ... 7jijet.jpg

[LandyAndy]

Finally have it ready for a VI next week…. Going to be really weird driving stick again and with my right hand shifting, last time was 12yrs ago back in the UK :shock:

https://hosting.photobucket.com/images/ ... 01(64).JPG

Dash worked out well and the new transmission tunnel too….

https://hosting.photobucket.com/images/ ... 01(59).JPG

https://hosting.photobucket.com/images/ ... 01(60).JPG

Rear axle is about complete, just needs a 3rd member and another axle shaft.

https://hosting.photobucket.com/images/ ... 01(33).JPG

Front is waiting on drive flanges, inner axle shafts and a 3rd member.

https://hosting.photobucket.com/images/ ... 01(66).JPG

Have made a new x-member and adapters for the front 3 link so it’s all bolt in for a easy swap.

https://hosting.photobucket.com/images/ ... 01(67).JPG

https://hosting.photobucket.com/images/ ... 001(4).jpg

This’ll give me better numbers than the old 3 link setup for anti-dive.

[LandyAndy]

Deleted

[franko]

Theres an error in your link. But good to hear you are still getting on it. Such a cool rig.

[LandyAndy]

Figured it out… here are some recent pic’s of the new axles installed, 1350 rear drive shaft & hydro boost brake conversion.

[LandyAndy]

And for this trailer queen, her new trailer…. Just need to get the lights installed & the wiring finished off now.

[ANDYD]

Very nice! Good to see the project is still moving along.

Looks like the sun is shining again in the Frozen back country 8)

[LandyAndy]

Very nice! Good to see the project is still moving along.

Looks like the sun is shining again in the Frozen back country 8)

Thanks & nope… we’re feet deep under the snow & have a 10-15cm snowfall warning for tonight. I doubt I’ll see my lawn until May !

[LandyAndy]

Thought we’d add a rear sway bar, should be able to squeeze it in with some custom mounts.

[LandyAndy]

Got to load up the trailer once the snow was clearing. Just love the beefy 609’s…. Now I need to get a set of 37’s.

[LandyAndy]

Thought I’d add a full belly skid plate, maybe it’ll be finished one day :D