BennehBoy's D2 adventure

Car's been blowing some smoke so decided to give the induction system a clean. Also had some overheat problems so wanted to check the rad out...

Pulled the front grill off to find this on the intercooler:



Thought I'd popped the intercooler but it turns out it's just oil blown out of the outlet where the hose wasn't on tight enough.

Flushed all the pipes and the IC with white spirit/paraffin. Used an exhaust expander to get the IC inlet/outlet nice and round and put it all back together.

Also fitted a new filter to my provent - I'd been running without one following the cylinder head replacement.

This is what came out of the radiator fins when I jet washed it:



No wonder it wasn't cooling as well as it could!

I've also got rid of my 8 inch spotlamps to see if that improves airflow into the IC/rad. Will maybe put some LED ones or 4/5 inch spots back on at some point.



Next job is the re-chassis, gbox/tbox replacement (with the refurbed ones sat in the shed), and getting the bumpers and sliders re powder coated.

Some BFG AT KO2's will finish it off nicely.

Few updates...

Decided the car needed some TLC....

Jetwashed...
Hand washed with a posh car shampoo
Jetwashed again
Clayed head to toe with Meguiars Clay Bar System
Machine polished with a light cutting colour enhancing polish
Hand waxed with Meguiars Tech Wax 2.0
Steel wheels cleaned with Wonder Wheels Hot Wheels
Tyres & plastics dressed with Turtle Wax Wet n Black (still the best!)



Doesn't look too shabby to say it gets used properly. Who says you can't polish a turd!

Next, it shot oil out the dipstick tube and covered the engine bay.

Turns out the provent filter was completely blocked.

The last one I bought wasn't MANN branded and has turned out to be ****. Replaced it with a genuine item (50 bloody quid!) and it's right as rain again.



I've been on the lookout for a good used chassis for a while but these are basically like hens teeth. So I've bitten the bullet and bought a brand new chassis from Richards in Mexborough. Spanner Monkeys up in Washington are going to do the swap out, I just don't have time or the facilities.

I've my rebuilt R380 & LT230 to drop in during the Chassis swap, that will give me HD cross pin, sleeved case, extended sump, and a V8 5th gear.

Chassis is getting acid etched and painted black before fitting - goes up mid July to get done. Can't wait!

Anyhow because it's getting a nice new chassis I'm getting the sliders, bumpers, & receiver hitch shotblasted and recoated. Axles, traling arms and anything else I can get done will follow on later in the year.

Sliders & receiver hitch are off:

What looks like rust on the sills is just trapped dirt - I'll clear silicon along the top when refitting.


The hitch has really been hit hard by road salting.


Rear bumper off - revealing tatty chassis!


Winch off - needs a tart up.


Front bumper off - car sitting about 3 inches higher lol:

Wow! Just read this thread from start to finish! It took a while Very nice.

What brand bumper is the front one? Looks good.

Cheers, glad you enjoyed it!

The front bumper is from these guys in Keighley -> Torque Performance 4×4 | Innovation in Steel

Is that where you got your Rock Sliders too?

All the bits at the blasters:

TrilloThrillo110 said:

Is that where you got your Rock Sliders too?

Click to expand...

No the sliders were bought as part of a group deal on the d2bc forum. They are good but took way too long to arrive (months & months).

So do those rock sliders mounts to the chassis or body?

They mount to the sills.

Bought this Raptor pod at Ripley Show.



Got some fake chinese carling switches coming for the winch, and future locker, but want to fit my zada-tech display into the CB slot of the facia...



That's the display for a digital gauge which measures EGT, Boost pressure, & Coolant temp.



There's a bit of a gap so I'm going to trim it up with som car interior edge trim, then just glue gun it all in - unless someone has a brigher idea?

Also trying to find some carling style USB sockets but I can only find expensive ones (£60 for carling ones ffs!), or ones with naff blue led back lighting. Not fussed for illumination but would go with green to match the car trim if absolutely need to.

Anyone seen any kicking about?

Got the bits back from the coaters this lunchtime.

All the bits look great, finish has a few bumps where some dust must've got in under the coat, but it's an offroader and it was cheap as chips

Got the rear bumper back on:



Rest will get done tonight, back to work for now.

Got 5 10 mins to mount the front bumper - left the winch out for now since this will come off again when it goes up to spannermonkeys for the chassis doing in 2 weeks...



Might leave the A-bar off for now too.

Bodged up the Zada-Tech display into thr Raptor pod, it'll do for now.

Like the bumpers! Looks much better than a couple pages back

TrilloThrillo110 said:

Like the bumpers! Looks much better than a couple pages back

Click to expand...

Yeah they've come up a treat, just the rest of the car to sort now

Decided to give the sills a bit of TLC before fitting the rock/tree sliders back on...

Put some of that Kurust stuff on that's been sat in the shed for a year... conclusion.... it's crap.


I reckon it only works if it's really light surface rust.

Anyhow gave it a bit of what for with a light bronze brush to get rid of most the rust then put some supposed rust proofing paint on. If nothing else it should help starve the rust of water/oxygen.


Couple more coats then I'll bang the sliders back on.

Shiny black sliders back on.

Ran some clear sealant beads down between the stitch welds on the sliders, bit crap that they're not welded all along really. If I ever get them recoated I'll get the welds extended because this is where the rust seems to creep in. Hopefully the sealant should help keep moisture out.

My new Richards chassis, half way through being painted after acid etch

Couple pics of the chassis....





Also replaced the terrafirma shocks n springs with new OME ones.