Rattler's 90 Chassis Swap

Then we cut the chassis up

Then we got the tub back in for son to replace the side cappings but forgot to take pic's of stripping them off

Then i made some plates up ready for when we fit the tub back on

And here is the new chassis

Fitting the axles to the chassis, i struggled a bit fitting the rear axle as with the suspension being + 2" there was loads of tension on the trailing arms so i had to resort to using two ratchet straps one to hold the axle to the chassis ( kept rolling away when i let go ) and the other to pull the chassis down one side at a time to compress the springs to locat the trailing arms into the poly bushes in the chassis but i got there in the end

then i painted a few brackets ready for fitting them on monday just gone

then on monday me and son fitted the painted brackets, A frame to chassis, the new Terrafirma + 5" rear shocks and re-location cones, extended brake pipes, + 2" bump stops and power steer box, then we fitted the tub and called it a day

We also fitted a couple of new front of tub to chassis brackets aswell then we fitted the tub and called it a day

Awesome

Monday i started the day by pushing the landy out a bit so i could have a good sweep up then i got started on fitting the fuel tank bracket in place after painting it, then i fitted the new tank in place and fitted everything to it inc new filler pipe, breather pipe, sender unit, aswell as all new gaskets.
the tank ( BP ) was slightly shallower than the original tank so i had to cut the return stack pipe down to suit, just hope the new tank is the same size fuel wise as i gave the old tank to the scrap man with the chassis so i couldn't compair

Then i fitted the painted link arm to the chassis and connected the panhard rod

Yesterday me, son and his g/friend fitted the engine and bulkhead in place then son made up a couple of brake master cylinder to compensator valve pipes and one of the front brake pipes, still got to make the N/S/F and the front to rear brake pipes yet and whilst he was doing them his g/griend wired in the new L.E.D. ( coloured ) rear lights, then before they are fitted we will paint where the lights are going then after the 90 is back on the road and the weather gets better we will give it another re-paint in the same colour, anyway some more pic's of the engine and bulkhesd fitted

these are of the the brake pipes that have been made and fitted

And these are of the rear L.E.D.'s being wired in

Looking good mate, you sure are cracking on with it.

Flying along. It's almost done!!

Cheer's guys, yeh its mainly because its not a full nut and bolt rebuild and also the fact we don't have the use of a jetwash which would have been great for cleaning everything off from past off roading as our drive is on a slight slope towards the garage and there is muddy grass between the drive and the garage which we need to sort, mite just hardcore it for now then decide wether to stone it or concrete it later not decided yet, where as the series rebuilld will be more of a nut and bolt rebuild which will be stripped pretty quick then slowly rebuilt but yeh its coming along great

Painted the bulkhead to tub supports bars today as the galv has all rusted at the tub end then removed the seized screws in the drivers door bottom hinge as when i replaced the hinges a few months ago i couldn't do this one till i armed myself with new clips and screws which i ordered a few weeks ago and have now replaced all the front door screws and clips and copper slipped aswell, then i decided i wasn't happy with the intercooler pipes ( steel ) so i removed them and painted them in gloss black and left them to dry to re-fit tomorrow with the bulkhead to tub bars

Some more bits went back on today inc tub to bulkhead support bars, rock slider's, painted the intercooler steel pipes, fitted 2 of the 3 rear door hinges to the tub inc new s/steel cap head screws then cleaned up and painted the gearbox mounting brackets ready for when we get the gearbox done as we have to wait till he is back from his 6 weeks hols starting from just before xmas till the end of January

Sorry i didn't get chance to come on yesterday but on Saturday i fitted a few more bits n bobs to the 90 inc the newly painted g/box mounting brackets, bolted the g/box x member in place, fitted a new accelorator cable and tried fitting a new power steer pipe but found that one of the fittings won't fit the pump ( male nut fitted instead of a female nut ) i do have a spare banjo fitting that came with the new pump but need another fitting to fit between the two to connect the pipe to the pump which i will have to get at a later date