Cummins powered 90 (Well nearly)

vegari said:

Just interested in how well it all goes, build looks great!

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Ah, fair enough, Cheers

trax said:

seen the other cummins thread? http://www.landyzone.co.uk/lz/f7/cummins-110-csw-build-262286.html .

funny cos his is now a blue 110 and yours is a blue 90.. done at the same time.

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Yep, seen it, been speaking to the lad loads on the dreaded facebook most of the way through my build and all the way though his build.
'tis funny the blue on his is actually more like the colour I wanted to begin with, but happy with mine now it's done and well, it's too late now anyway :crazy:

looks awesome and a good non bodgy job.

So the adapter, another piece of the puzzle that I was scared of!
As I said earlier I eventually found someone who would design and make the adapter.
So he came and picked the gearbox up and off he went.
He has his own cummins landrover in the shape of a 140, so was full of confidence that the job would be done right.
It took a while as he went on holiday halfway through, but was sent these pics during the process.

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So the day of reconing arrived about a month later and so did a bag of goodies.

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Basically the gear is made up of the old zf prop flange and the LT230 input gear.
zf prop flange turned down and welded to the input gear.

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And the adapter plate, which was laser cut out of 25mm steel plate.

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And has a pocket milled out of the back for the zf.

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This is what the back of the gearbox looks like before we started and what we had to contend with.

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Plate bolts to the gearbox.

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Screw the drawbar onto the gearbox output shaft.

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And put the new gear on.
So this is effectively what you have but with the gear inside the transfer box usually.

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Or if you look at it the other way, put it in the transfer box and the excess pushes onto the gearbox output shaft.

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I decided to do a test run with it on the floor as opposed to struggling with it in the vehicle.
So stick the draw bar on the end of the gearbox, new input gear in the transfer box and slot the box on.

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Then the original zf prop flange nut put on to hold all the gubbins together.

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Both boxes are very close, but the reason being is to get the transfer box as low as possible to improve prop angles.
Needed more so on the 90 as the rear prop ends up quite short.

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And that was that sorted, Just to fit now.

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Other than that, the price was very reasonable I thought and seems a good piece of kit.
If anyone is doing or thinking of a conversion and don't know which way to go, get in touch and I can put you in contact with who did mine.
As I know he has made quite a few now for people who have seen mine.
Think he said he lost count at 7 so more are getting out their and quite a few conversions on the go!

So continuing from where I left off, the next job was to get the gearbox in.
It's a bit heavier than an lr gearbox

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Then stuck the transfer box on so I could make some mounts for it.
But being on a galv chassis meant I didn't want to weld to it.
So I bolted a piece of 6mm plate to the chassis and welded the original mounts to that.

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And then moved onto the passenger side, which was a little more difficult, as usually the mount would be bolted to the gearbox, which obviously isn't an option for me.

So I did the same with the chassis mount on the N/S.

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I then made a mount that bolted to the adapter plate and also bolted directly to the gearbox to try and tie everything together.

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Cleaned and painted both mounts and final fitted and that was another job off the list

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With that done and out of the way I carried on with the intercooler plumbing.

This being the passenger side.

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And this the drivers side.
Both of which have to go through the wings next to the headlights.

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Fantastic work. I would love to live nest door to you! It's a shame as my neighbours are all sound as; several of us love tinkering with our motors, few mechanics live on the street and there is always the sound of a grinder from somewhere! I felt comfortable pressure washing a series 3 gearbox and transfer box on the pavement outside my house, which counts for a lot in any good neighborhood.
Good luck on your build and with those who have too much time on their hands in your street.

looks excellent!!

the zf is light!! lift themm every day at work, as they attached to the cummins in our road sweepers..
shame about the neighbpours..just dont make noise after 9 and their is feck all they can do really..

PLEASE edit your pics to remove reg number, as i know where you live.(dont really, cos i dont want to know, but its one phone call away to find out,,plus your door number in pic).and if i can find out so can theiving barstards..new chassis, 2 90's etc..
yes i know i am a pain, but i know the value TO YOU of your babies, as mine are too me..

what you gonna do about gearing?? as you will have a 45mph top speed as is???

trax said:

looks awesome and a good non bodgy job.

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Cheers

ronsealdeath said:

Fantastic work. I would love to live nest door to you! It's a shame as my neighbours are all sound as; several of us love tinkering with our motors, few mechanics live on the street and there is always the sound of a grinder from somewhere! I felt comfortable pressure washing a series 3 gearbox and transfer box on the pavement outside my house, which counts for a lot in any good neighborhood.
Good luck on your build and with those who have too much time on their hands in your street.

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Thanks That's how it should be with neighbours, helping each other out instead of ****ing a whining.
I think they think what I do is not good enough for the street and basically stick their nose up at me.
It does actually make me feel uncomfortable to be honest, but why should I let them stop me.
The only other option for me would be to rent a unit somewhere, but again why should it cost me money just because they don't like it.

zen said:

looks excellent!!

Cheers

the zf is light!! lift themm every day at work, as they attached to the cummins in our road sweepers..

Aye, not much more than an lr box really, but when you're 9st (ish) and built like a racing snake it aint easy

shame about the neighbpours..just dont make noise after 9 and their is feck all they can do really..

Yep, twunts!
But yeah, It's rare I'm out past 6 never mind 9.
They just don't want it done at any hour

PLEASE edit your pics to remove reg number, as i know where you live.(dont really, cos i dont want to know, but its one phone call away to find out,,plus your door number in pic).and if i can find out so can theiving barstards..new chassis, 2 90's etc..
yes i know i am a pain, but i know the value TO YOU of your babies, as mine are too me..

what you gonna do about gearing?? as you will have a 45mph top speed as is???

As for gearing, it wont be quite that bad, more like 75mph at full chat and be f*cking deafening no doubt.
My next post was going to be about gearing and I'll post the ratio charts up if I can find them.
The ideal would have been 1.003 transfer box, but with adapter made it's a little late to change, well it isn't but means having the gear remade.
So I've bought a set of KAM 2.83 crown wheels and pinions.
Gives the same kind of difference actually, That should be better but if it isn't I guess it's big tyres

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Gearing, this caused me much headache about what to do.
When having the adapter made I gave the guy the 1.2 input gear and never thought any more about it.
It wasn't until it was made that I realized the gearing wouldn't be very good.
Now the 1.003 transfer box is the ideal, but with the input gears not being interchangeable it meant having the adapter remade with a new gear, costing yet more money.
That coupled with the lack of 1.003 boxes on the market made me think of other routes.
So one of the other options was, big tyres, which if I'm honest I want to avoid as that means I'll have to lift it etc. and will also make the prop angle worse on an already short(ish) rear prop.

So option two was KAM 2.83 crown wheels and pinions.
Again it wasn't an option I was keen on as again they're not made anymore and if I was to break one I'd be buggered.
Plus the fact that this way also alters the low range gearing.

Anyway, hear is a few gear charts showing the difference.

This is as standard with 1.2 transfer box and 3.54 diffs.
As seen, not ideal and an engine that only revs to 3000rpm would be revving it's knackers off all the time.

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This is with 1.003 transfer box and 3.54 diffs.
Much better and lower revs at cruising speeds.

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And this is with 1.2 transfer box and 2.83 diffs.
Not far off the above really and still a massive improvement.

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I umm'ed and ah'ed about this for a very long time and really didn't know what to do for the best and every option their wasn't exactly cheap.

In the end I decided on the KAM 2.83 diffs.
Why? probably because it's the least hassle and gives reasonable results.
Which I bought off Nigel at Megasquirt, still new, along with pegged casing.
Top service and very happy.

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awesome ……

oh and sod the neighbours

Great build mate and shame about the idiots I your street should be live and let live nosey bustards

Chris W said:

awesome ……

oh and sod the neighbours

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Thanks
And I say sod the neighbours too now

v8geoff said:

Great build mate and shame about the idiots I your street should be live and let live nosey bustards

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Exactly mate, nothing better to do, oh and thanks

I think you need a cherry bomb exhaust. The neighbours will move out

So after a somewhat terrible year, what with working no more than 6 months of the year, I've sold most of what I own, including spares I'd have liked to have kept.
All in the name of trying to finish this project and I'm still at it.
If I'm honest I've struggled for money throughout the build and every thing I had has gone into it.
So this is where I was at about 3 months ago and I've not touched it since

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She also runs (hopefully the link will work )
As I said earlier in the thread, 24volt starting, 12volt running via a series parallel relay.
https://www.facebook.com/video.php?v=792151884168674&set=vb.100001216082627&type=3&theater

So what's left to do?
Custom length props (I was originally going to do them myself but decided I don't trust myself not to f*ck 'em up and get them not running true) So need to find someone for that.
Exhaust. I have the bits, or some of them at least, but I need the propshafts first to make sure their is no interference.
Transfer box selectors, High/Low and diff lock.
Make a gear stick.
Change front springs for something that will cope with the weight as it's nose diving at the mo.
And fit some shocks as that's one job I never did during the main build as I couldn't decide what to get.
Other than that, just general tarting up and checking stuff.

The reality is the amount left is miniscule compared to what's been done.
But seems so close yet so far

If anyone is interested in a more detailed write up then have a look at my build thread as theirs loads more info and pics in their.
Or ask if you want more info

http://www.landyzone.co.uk/lz/f7/aarons-90-rebuild-round-2-a-247956.html

Well,what a fantastic thread,very envious of that,well done bud,a great credit to you.Oh yes feck the neighbours.

gemsdad said:

Well,what a fantastic thread,very envious of that,well done bud,a great credit to you.Oh yes feck the neighbours.

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Thanks for the kind comments bud
And the neighbours go without saying

aaronmorris said:

Thanks for the kind comments bud
And the neighbours go without saying

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that really is a great build,very well done.raise:

cracking build aaron ,attention to detail is fantastic

aaronmorris said:

So after a somewhat terrible year, what with working no more than 6 months of the year, I've sold most of what I own, including spares I'd have liked to have kept.
All in the name of trying to finish this project and I'm still at it.
If I'm honest I've struggled for money throughout the build and every thing I had has gone into it.
So this is where I was at about 3 months ago and I've not touched it since

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She also runs (hopefully the link will work )
As I said earlier in the thread, 24volt starting, 12volt running via a series parallel relay.
https://www.facebook.com/video.php?v=792151884168674&set=vb.100001216082627&type=3&theater

So what's left to do?
Custom length props (I was originally going to do them myself but decided I don't trust myself not to f*ck 'em up and get them not running true) So need to find someone for that.
Exhaust. I have the bits, or some of them at least, but I need the propshafts first to make sure their is no interference.
Transfer box selectors, High/Low and diff lock.
Make a gear stick.
Change front springs for something that will cope with the weight as it's nose diving at the mo.
And fit some shocks as that's one job I never did during the main build as I couldn't decide what to get.
Other than that, just general tarting up and checking stuff.

The reality is the amount left is miniscule compared to what's been done.
But seems so close yet so far

If anyone is interested in a more detailed write up then have a look at my build thread as theirs loads more info and pics in their.
Or ask if you want more info

http://www.landyzone.co.uk/lz/f7/aarons-90-rebuild-round-2-a-247956.html

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Hi Aaron,
I admire your effort and work and I thought I might be able to cheer you up a little as it is coming up to the season of good will, as I work for Cummins, I spoke to the lads at the training school about your engine and they have given me some books on the engine so if you want I will send them up to you for free so PM me your address.

gemsdad said:

that really is a great build,very well done.raise:

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Cheers again, much appreciate bud

THEengineer said:

cracking build aaron ,attention to detail is fantastic

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Thanks I try me best, doesn't always workout mind.

busakaz said:

Hi Aaron,
I admire your effort and work and I thought I might be able to cheer you up a little as it is coming up to the season of good will, as I work for Cummins, I spoke to the lads at the training school about your engine and they have given me some books on the engine so if you want I will send them up to you for free so PM me your address.

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Hello mate, thanks, what a very nice offer
I will send you a pm shortly
Theirs another lad on here who works for Cummins too, but he's at the Darlington plant I believe.
He's another nutter fitting a 6.7 in his 110.
He's talked of going to the anniversary next year with the few Cummins lr's their is out there, which would be interesting if it happens and mine is on the road

aaronmorris said:

So what's left to do?
Custom length props (I was originally going to do them myself but decided I don't trust myself not to f*ck 'em up and get them not running true) So need to find someone for that.

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Give these lot a bell.

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