Series King Cab

[Dr_evil]

Think mine may be louder than yours by the time it's going

 

[Dr_evil]

Parts purchased for box, sides and axle mods

 

[Dr_evil]

New crossmember made up for the middle where I have to chop out the old box in order for the LT230 to fit in.
IIRC is 120x100x5mm box and then I used 6mm plate for the ends, simple enough, chop the box 12mm too small then the 6mm plate makes up the difference

Also started making up the gearbox adaptor as I've been a bit busy til now, looking good so far and I'll get a pic up later tonight as I've left it in the boot of my car

 

[Dr_evil]

Discovery to defender gearbox convertor, simple enough if you have a lathe. This is it about 50% complete, two of the three lips are turned and then it needs a hole drilling and tapping along with a 5/8th hole in either end with a 3/4" solid in the to separate them

Started life as a 50mm bar and turned to the correct diameter

I'll make a separate thread detailing it incase anyone needs to search in the future but I used some pinched designs (essentially going to compound the info)

 

[Dr_evil]

Got a shift on again today, body off and started to look at the best place to move the cab back to!

Thinking 1/3rd into the pickup bed leaving a decent amount of space and giving a good amount of extra room inside

So heres the pics (didn't get any in situ ones)

Floor out as well as checker plate bench pieces and crossmember cover (britpart sticker was still on that crossmember)

Tub off

Central slat missing as the fixing was corroded so going to put some angle onto the sides, rivet it in and rivet the slat to that for support

Bottom of the cab off too as the ****ing bastard had welded it to the galv capping :doh: total ####wit given that theres bolt holes there………

Held together with pigeon **** too :doh: and sealant!

Guy welded about 1/4 of it in random spots and used sealant for the rest!

New crossmember fits

Gearbox wrapped up

Looking a bit bare doors tied together in order to support the roof too

Wrapped up now as its gonna rain………

 

[Dr_evil]

Measured up a 90 tub today off an 89 IIRC, seems to be 10mm wider and one inch longer so that and the matching sides + seatbox

Going to flatpack it as best I can the rivet back together once I've trimmed the king cab sides then weld an S extension onto the x-member

 

[Dr_evil]

sides collected

 

[Dr_evil]

Todays work, started about 11 and finished packing away at 4 cos of rain

Heres the pics of how to do it anyway

Long bolt is from this hole

Short bolt holes

With those three removed then take off the cover plate to get access to number four

Remove the selector housing

Selector shaft exposed

5mm allen key and a suitable driver to get some purchase on there

Remove the screw

Other grub screw you'll need

This is the selector rail adaptor

Gear selector quadrant

You need to push the shaft into third in order to get enough space to remove the disco selector and get the defender selector mechanism on there

This is the old mechanism

Apply loctite to the screws

Pointed one goes onto the shaft that slides into the selector

Tighten this mutha####a up! And I mean tighten!

Long grub screw now

Apply loctite again

Again torque the bastard!

You don't want them coming undone!


Step back and take a break

Remove the LT77 selector from your chosen storage space

Apply a good bead of sealant and begin assembly

Locate it on dowel and remember where your bolts came from

Begin with the long bolt

After this just tighten the buggers up, I found out I cant select the bottom set of gears too easily which on inspection looks to be the bias plate that needs some fettling so I'll sort that at a later date


So I did some more work after this as the sun was still out

Roof off

New crossmember in (had to grind a chamfer and remove some old welds from the previous owner) Needs welding in but its not going anywhere as I had to fit it with a No.1 engineers tool

Removed old crossmember (it had a hole in it and had water inside but was fairly solid)

My cutting disc ran out about half way in so had to use a hacksaw, cold chisel and a large hammer to roughly remove the rest, rain then stopped play before I could put the transfer box on so I tucked him in and set about tidying up

Brought the winch inside after this and began to strip it

 

[Dr_evil]

Rock/tree sliders made, roof purchased and some ally angle procured

 

[Dr_evil]

So today I got a bit of a move on again, sorted out transfer box and linkages, put body back on and started tidying it up ready for the new innards


In removing the final parts of the old crossmember I smashed my thumb open :doh:

Anyway after this I moved onto getting the transfer box in

Removed selector in order to free it up

After this I hooked it up again and sorted out the linkages, now goes into high, neutral and low. Gearbox also selects all gears now that I've removed the T-Piece and plunger switch from the housing

Roof delivered and packed away (Cheers Egg )

LT95 arrived too

One man removal is simple with some planks, just lift up the pallet by hand and slide them under before using them as a ramp to slide it down

Rear tub back on (turtled it over then used planks to slide it on properly)

Sorted out the drivers side seatbox with some aluminium angle after this

Looking more series like again!

Packed up under a tarp again

Gonna get some more aluminium to sort out the floor and then make a start on the gearbox mounts, its getting there! Pace has picked up now and the to do list is rapidly shrinking

 

[200tdi ayre]

That's not an injury ! Haha

 

[Dr_evil]

I know cos I was holding the chisel properly so that when I hit my thumb by mistake it slid off rather than getting smashed to bits!


Still hurts though!

 

[200tdi ayre]

Bonus, the other week I dropped a heavy piece if steel on my finger split it right to the bone and blackened the nail, wrapped it up in steristrips and a plaster and removed my RR gearbox

 

[Dr_evil]

I just went with TCP soaked bandage and some elastoplast tape


Not crushed any bones yet just seems to be flesh wounds, had a deep cut on my hand when I removed the overdrive and no idea how I got it! Only realised when I saw the overdrive had started turning red

 

[Dr_evil]

Found the missing pic

 

[discomark10]

Looking good... think I.may just have my one running befor you

 

[Dr_evil]

Cheers


I'm tempted to try and fire it up this weekend if my new engine mounts are in the shop tomorrow

However that being said I still need to work out how I'm going to do this stupid prop shaft, been quoted £90 for a 30* wide angle prop shaft which isn't bad at all! But it limits my rear axle travel to 110mm down from 200mm which isn't so bad when you think about it for greenlaning but I'm half tempted to try and increase it back towards 200 with some fancy fabrication

 

[Dr_evil]

I've still got a decent amount of work left anyway, making up the roof for the king cab and need to make up a custom floor and possibly custom seat box too! Defo need a custom tunnel

 

[Pikey]

WTF happened to almost finished?????

 

[Dr_evil]

WTF happened to almost finished?????

I ripped it apart again……….


Wings need to go on, floor needs to go in, prop shafts need making, roof and sides want bolting together plus final riveting on roof and I've opted for new engine mounts in order to raise the sump away from the axle.
Tunnel I can knock up in a couple of hours, could have used old floor but decided I may as well do it properly instead of use the piece of **** floor that came with it


Basically adding more jobs to it that I didn't need to do but may as well in order to make it better