The Rover-Landers of BC

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....

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

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:

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... 40x316.jpg

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... 40x386.jpg

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

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!

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:

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.

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

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.

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.

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:

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:

http://i946.photobucket.com/albums/ad30 ... 4link1.jpg

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

http://i946.photobucket.com/albums/ad30 ... 4link2.jpg

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

http://i946.photobucket.com/albums/ad30 ... x480-1.jpg

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

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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.

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

Made some new mounts for the rear 4 link setup

http://i946.photobucket.com/albums/ad30 ... 60x480.jpg

Cleaned up & painted the bulkhead

http://i946.photobucket.com/albums/ad30 ... 60x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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.

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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.

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

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

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... 60x480.jpg

Cab back together :D

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

http://i946.photobucket.com/albums/ad30 ... 40x480.jpg

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

http://i946.photobucket.com/albums/ad30 ... /ECU-1.jpg

Till the next time.... happy rovering !

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

Matt

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

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

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....

http://i946.photobucket.com/albums/ad30 ... 76x768.jpg

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

http://i946.photobucket.com/albums/ad30 ... 76x768.jpg

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

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:

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 :)

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

Front will get some tubular 'challenge' style wings made next.

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

Bulkhead bracket & inner tube.
http://i946.photobucket.com/albums/ad30 ... 76x768.jpg

Outer tube being trimmed to size, front will get cross bracing across the slam panel. Wings will be skinned with diamond plate on top.
http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

Can you guess what this'll be :wink:
http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

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

Bulkhead bracket & inner tube.
http://i946.photobucket.com/albums/ad30 ... 76x768.jpg

Outer tube being trimmed to size, front will get cross bracing across the slam panel. Wings will be skinned with diamond plate on top.
http://i946.photobucket.com/albums/ad30 ... 24x768.jpg

Can you guess what this'll be :wink:
[img]http://i946.photobu

Hmmm...rear-mounted turret, a-la Batmobile!? :lol:

Link fixed :wink:

Spare tire mount?

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

DBrands wrote:Spare tire mount?

Yup... :)

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.

What bender are you using?

HeadDamage wrote:What bender are you using?

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

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

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:

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

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:

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

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

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

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

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.

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

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

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

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

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:

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

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

Man she is looking great!

Rear mudflaps finished :D

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

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

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?

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

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

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

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.

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

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:

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

Wow!! Amazing! Build!

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

Thanks for sharing!!

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 ;)

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

http://i946.photobucket.com/albums/ad30 ... 86eb55.jpg

http://i946.photobucket.com/albums/ad30 ... 82437d.jpg

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.

http://i946.photobucket.com/albums/ad30 ... 1fc0db.jpg

http://i946.photobucket.com/albums/ad30 ... 5fd8ab.jpg

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:

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.

http://i946.photobucket.com/albums/ad30 ... 92947f.jpg

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.

http://i946.photobucket.com/albums/ad30 ... db61c5.jpg

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

http://i946.photobucket.com/albums/ad30 ... 9de362.jpg

http://i946.photobucket.com/albums/ad30 ... 02047b.jpg

http://i946.photobucket.com/albums/ad30 ... aaa78a.jpg

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.

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

LED lights for the rear cargo area.
http://i946.photobucket.com/albums/ad30 ... 219e1b.jpg

LED lights to see where I'm going :D
http://i946.photobucket.com/albums/ad30 ... 5f0bb5.jpg

Limb riser tabs & couple more brackets for LED ditch lights.
http://i946.photobucket.com/albums/ad30 ... 0de12e.jpg

Got a bought a pair of new seats in the sales.
http://i946.photobucket.com/albums/ad30 ... 075398.jpg

Will use the Qt f/g seat mount.
http://i946.photobucket.com/albums/ad30 ... 21ae66.jpg

With some adaptor brackets to make them easy removable.
http://i946.photobucket.com/albums/ad30 ... e9a61e.jpg

Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
http://i946.photobucket.com/albums/ad30 ... 6a41e1.jpg

And in it's place will be.... :D
http://i946.photobucket.com/albums/ad30 ... f28a78.jpg

And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
http://i946.photobucket.com/albums/ad30 ... 5a3a5a.jpg

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:

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

http://i946.photobucket.com/albums/ad30 ... b6fcba.jpg

http://i946.photobucket.com/albums/ad30 ... 1ae7b4.jpg

http://i946.photobucket.com/albums/ad30 ... 3b0813.jpg

http://i946.photobucket.com/albums/ad30 ... 62e346.jpg

http://i946.photobucket.com/albums/ad30 ... b04ad1.jpg

And that's about it so far....

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

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

I doubt it'll be finished for then... lol

[quote="LandyAndy"]Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
http://i946.photobucket.com/albums/ad30 ... 6a41e1.jpg

And in it's place will be.... :D
http://i946.photobucket.com/albums/ad30 ... f28a78.jpg

And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
http://i946.photobucket.com/albums/ad30 ... 5a3a5a.jpg

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.

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.

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.

A few updated pics.....

Drive line assembled with the crawler box.
http://i946.photobucket.com/albums/ad30 ... fac8nw.jpg

Trial fit of the Goat Build PAS pump & Alt relocation brackets.
http://i946.photobucket.com/albums/ad30 ... bapmsp.jpg

Hi/Lo lever flipped round for easier cable shift hook up with the crawler box.
http://i946.photobucket.com/albums/ad30 ... zuckr0.jpg

Added the TD5 clutch pedal.
http://i946.photobucket.com/albums/ad30 ... 6xibrx.jpg

Trial fit of the Vortec to check water pump clearance to the Allisport rad.
http://i946.photobucket.com/albums/ad30 ... ppless.jpg

Might need to swap the oil pan out for a Camaro one if clearance at full bump is an issue.
http://i946.photobucket.com/albums/ad30 ... amlbk5.jpg

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.

I forget, have you lengthened the wheel base?

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.

Major milestone reached.....

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

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

http://i946.photobucket.com/albums/ad30 ... otei1r.jpg

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

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

Well pleased :grin

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

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

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

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

http://i946.photobucket.com/albums/ad30 ... u4i6cm.jpg

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

http://i946.photobucket.com/albums/ad30 ... vre1h7.jpg

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

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

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

http://i946.photobucket.com/albums/ad30 ... izsd6m.jpg

Custom schedule 40 exhaust manifolds being made

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

Engine harness all finished

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

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

http://i946.photobucket.com/albums/ad30 ... s7hfyb.jpg

Heater fully plumbed & installed

http://i946.photobucket.com/albums/ad30 ... iu6l8e.jpg

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

http://i946.photobucket.com/albums/ad30 ... h49oz8.jpg

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

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

http://i946.photobucket.com/albums/ad30 ... 6l3kmw.jpg

And finally the exo cage is all powder coated & fitted

http://i946.photobucket.com/albums/ad30 ... 7mn5cz.jpg

http://i946.photobucket.com/albums/ad30 ... tjitj2.jpg

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 !

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

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!

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.... :(

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.

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

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:

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

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

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

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

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.

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

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....

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.

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

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

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

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.

Deleted

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

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

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

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

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

ANDYD wrote: Sun Feb 19, 2023 10:03 pm 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 !

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

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.

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

Belly skid all ready for install, next job once I complete the tub trailer for its new owner.