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Breathless5.9

Breathless5.9

Member
Posts
24
Location
Rutland, UK
Not exactly a build thread as it’s practically finished now but a photo of the bare bones nonetheless. Built as a workhorse for towing and as a mobile workshop for the farm, onboard compressor and air tanks with airline fittings, air suspension in rear for self levelling, 24/12v jump start capable and a mountain of torque! Been fully stripped to a bare chassis and any weak/corroded parts cut out and welded up, poly bushes, new ball joints etc. A lot of time spent but not that expensive to build really.
 

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Unfortunately the phone I used to take the pics of the rebuild is knackered but I have got a few..
This is essentially the air suspension. P38 rear bags with axle and chassis mounts modified to fit. These are connected to a lorry trailer levelling valve so it self levels. I've hinged the levelling valve on a bracket which is connected to a lever on the tunnel so I can lower the rear to hitch trailers without the jockey wheel.
 

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I thought the chassis was in reasonable condition but as it turned out it wasn't as good as I thought. Any sign of rust was cut out and new steel put in, nothing was simply plated over even had to remove radius arm mounts to get to the bits under them
 

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The engine is a non turbo 5.9 Cummins, still 130bhp and more torque at tickover than the 200tdi had flat out. I rebuilt it completely as it was from an overheated horsebox. The gearbox is a 5 speed ZF from a daf lorry mated to the lt230 transfer box with 1.003:1 ratios in high range. 1800rpm at 70mph in 5th.
 

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marjon said:
Cracking stuff:).
Leave body it looks fine:).




The red adapter plate on the gearbox? Can I ask where from.

J
Click to expand...
It actually came from a guy called Reece Myers. I had designed my own from plywood and was going to make a steel version but Reece only charges £100 for it and he was supplying the billet input gear to join the boxes so I got one from here... Incidentally it's identical to my plywood template so I must have got it right lol
 
kermit_rr said:
Cracking project, curious why you didn't put airbags all round..
Click to expand...
The front is pretty heavy, on the official axle limit in fact. I wasn't convinced that any airbag that would fit in the space of the spring was up to the task long term. Also it would probably mean a move to an electronic control system rather than my bombproof all mechanical on on the rear. I only really need the rear to self level for different loads so a lot of work for little gain. Front springs are HD 90 rears.
 
Breathless5.9 said:
The front is pretty heavy, on the official axle limit in fact. I wasn't convinced that any airbag that would fit in the space of the spring was up to the task long term. Also it would probably mean a move to an electronic control system rather than my bombproof all mechanical on on the rear. I only really need the rear to self level for different loads so a lot of work for little gain. Front springs are HD 90 rears.
Click to expand...
It's a fair and valid point, you can end up going down a never ending rabbithole
 
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