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rijidij
28th November 2010, 09:30 PM
As some of you may remember, I’ve had these spare wheel carriers on my drawing board for quite some time. One of the main hold ups was the need for a Puma in my workshop to do a pre-fitting so I could finalise the design and make any small adjustments if needed. Thankfully another member on AULRO generously made two trips down from Melbourne to my place near Geelong so I could finally see the end product on the back of a Defender. I’m happy with the result so far.

To give some sort of idea how much work is involved in getting to the finished item, there are approximately 163 individual components that go into a carrier. I wont bore you all with the details of the design process.

https://www.aulro.com/afvb/images/imported/2010/11/59.jpg


There are a number of things I wanted to achieve with the design……..
: Opens automatically with the door.
: Locks automatically in the open position.
: Easy to use.
: Robust and strong enough to handle all conditions.
: Minimum vibration and movement of the tyre/wheel/carrier.
: Use existing holes to mount the hardware where possible.
: Hopefully as good or better than commercially available products.
: Cheaper than comparable retail products (not hard to achieve that :eek:)
: Laser cut components for accuracy and professional appearance.
: Has to look good too ;).


It all mounts up to existing holes, except for two points……
One 12mm hole needs to be drilled in the bottom of the chassis (not pictured) for a brace to bolt to. This hole already exists on older models like County’s, but not on the Puma. As it’s out of sight, it’s not a big issue.
The only modification needed on the vehicle is to cut a slot in the steel trim under the door. Again, on older models, this trim isn’t there so a gap already exists. I think this trim might have been added to Defender models from 2002 when the one piece door was also introduced.
The slot is approximately 60mm x 10mm to allow a brace to go through to an angled section of the chassis and bolt to an existing hole. I’d prefer not to have to drill or cut anything, but the slot can be done neatly with a drill and a die grinder and really isn’t too noticeable. You could probably get away without the top brace if you only want to carry a standard spare, but I think it’s worth cutting the slot for the extra strength it adds. On my own carrier I have a steel wheel with a 33’ tyre, as well as a 20 litre jerry can of water, so that’s a fair bit of weight.

These pics show the slot, the bracket and the bracket in place…..

https://www.aulro.com/afvb/images/imported/2014/03/879.jpg

https://www.aulro.com/afvb/images/imported/2010/11/60.jpg

https://www.aulro.com/afvb/images/imported/2010/11/61.jpg


The backing plate for the main chassis mount assembly, I’ve made so it wraps around the back of the top and bottom of the chassis to make use of the strength of the horizontal plate, rather than just sandwiching the vertical faces.

https://www.aulro.com/afvb/images/imported/2010/11/62.jpg


Also, the chassis mount assembly is the full height of the chassis member. I’ve seen similar commercially built carriers that don’t cover the full height of the chassis, therefore making it more vulnerable to crushing or fatigue caused by ‘oil canning’ the vertical face of the chassis.

https://www.aulro.com/afvb/images/imported/2010/11/63.jpg


The main beam is welded to a machined hub and fitted with tapered wheel bearings, an oil/grease seal and a dust cap (not pictured).

https://www.aulro.com/afvb/images/imported/2011/11/248.jpg

https://www.aulro.com/afvb/images/imported/2010/11/64.jpg

https://www.aulro.com/afvb/images/imported/2010/11/65.jpg


The bottom locator which bears some of the weight in the closed position is bolted on the front of the tow bar face plate using the top two bolts. This Defender has the factory type tow bar.

https://www.aulro.com/afvb/images/imported/2010/11/66.jpg

https://www.aulro.com/afvb/images/imported/2011/03/873.jpg


The door plate replaces the original spare wheel mount and this allows the carrier to attach to the door with the pivot arm. The door plate is attached to the door using the original bolts. The pivot arm is fitted with nylon bushes…..no need for grease which would just attract dust.

https://www.aulro.com/afvb/images/imported/2010/11/67.jpg

https://www.aulro.com/afvb/images/imported/2010/11/68.jpg

https://www.aulro.com/afvb/images/imported/2010/11/69.jpg

https://www.aulro.com/afvb/images/imported/2010/11/70.jpg


In the closed position, the pivot arm presses firmly against a rubber buffer, as does the bottom locator (pictured above). This eliminates any unnecessary movement.

https://www.aulro.com/afvb/images/imported/2010/11/71.jpg

The tension of the pivot arm pressing on the rubber buffer can be adjusted by adding or removing washers.

https://www.aulro.com/afvb/images/imported/2010/11/72.jpg


To further reduce movement and vibration, the wheel mount is adjustable to allow the side wall of the tyre to rest firmly against the front of the carrier.

https://www.aulro.com/afvb/images/imported/2010/11/73.jpg

https://www.aulro.com/afvb/images/imported/2010/11/74.jpg


The lever for the locking pin is oval section aluminium and the pin is hardened steel. It’s spring loaded so it automatically locks in position when the door is open just over 90*.
The pin slides on a piece of bearing grade nylon which is riveted to the chassis mount with stainless steel rivets (pictured above).

https://www.aulro.com/afvb/images/imported/2010/11/75.jpg

https://www.aulro.com/afvb/images/imported/2010/11/76.jpg


This particular Defender just happened to have some ‘Mulgo’ bumperettes fitted. Luckily the chassis mount cleared the bumperette by a few millimetres.

https://www.aulro.com/afvb/images/imported/2013/10/906.jpg


The finished project. I’m happy to say, the carrier really suits the Puma. The satin black powder coat is a pretty close match to the chassis. Colour coding to the colour of the paint would also be an option.

https://www.aulro.com/afvb/images/imported/2010/11/77.jpg


I should point out that metal fabrication is just a hobby of mine that seems to have got a little out of control (since owning Landys :D) With the sometimes over the top retail prices of accessories, I love being able to make my own.
Now that I have the finalised design (for the Puma anyway), I intend to go ahead and make some more carriers shortly. I don’t run a business and selling through the forum is not allowed, other than in the markets section, so anyone who wants more info other than general discussion on the thread, please PM me.

Cheers, Murray
stig0000
28th November 2010, 09:55 PM
looks good, so its a 2 hand job to open it, and ones its unlatched and the door is open,, is it realy easy to open close,, iv seen alot of carryers that are realy stiff to open,
rijidij
28th November 2010, 10:29 PM
looks good, so its a 2 hand job to open it, and ones its unlatched and the door is open,, is it realy easy to open close,, iv seen alot of carryers that are realy stiff to open,

You don't need two hands. Just open the door as you normally would. Remember, the bulk of the weight of the spare is now supported on the chassis, so you're just 'pushing' the carrier open with the door rather than carrying the whole weight of the spare on the door.

Cheers, Murray
Sideroad
29th November 2010, 10:58 AM
Very slick. I am impressed by your attention to detail and use of original mounting points. Great work!
alittlebitconcerned
29th November 2010, 11:41 AM
I have one fitted and have done so for at least 6 months. I like it and it works well. It very strong and easy to operate. Along the way I've had to make a few minor adjustments to remove a squeak here or there; but that is very easy to do. Keep the pivot point for the levered arm clean and lubricated and all will work as it should. The powder coat finish is the equal or better than some of the main brands offerings and the fact it is also zinc plated underneath the powder coating puts this carrier ahead of much of the competition. Highly recommended for its durability and ease of use. Looks good too.

I'm in Sydney. If anyone wants to see one installed on a defender, just PM me.
rijidij
1st December 2010, 01:28 PM
There's a good chance I'll have a 2002 Td5 Defender (one piece back door) in my workshop on the weekend, so I'll be able to check if the carrier works on that model, without the need for changes hopefully.

Cheers, Murray
rijidij
5th December 2010, 05:15 PM
There's a good chance I'll have a 2002 Td5 Defender (one piece back door) in my workshop on the weekend, so I'll be able to check if the carrier works on that model, without the need for changes hopefully.

Cheers, Murray

Well, we fitted a carrier up to the 2002 Td5 Defender today, and I'm happy to say it's the same setup as the Puma with no need for any changes.

I imagine the only difference with the early Td5 and the Tdi models will be the size of the door plate. I have a rear door here off an early Td5 so I should be able to measure that up ok, and I'm guessing the Tdi door plate will be the same as a County, which I have here also.


Cheers Murray
rijidij
11th December 2010, 11:09 PM
Can anyone give me the dimensions of the door plate on the rear door of a Tdi Defender.
The picture below is the door plate on an early Td5 Defender '99 - ~'02 with the older style two piece door.
I'm pretty sure the Tdi will have a smaller plate the same size as a County, but I'd like to confirm this.
Any help would be appreciated.

Cheers, Murray

https://www.aulro.com/afvb/images/imported/2010/12/1247.jpg
LowRanger
12th December 2010, 09:05 AM
Can anyone give me the dimensions of the door plate on the rear door of a Tdi Defender.
The picture below is the door plate on an early Td5 Defender '99 - ~'02 with the older style two piece door.
I'm pretty sure the Tdi will have a smaller plate the same size as a County, but I'd like to confirm this.
Any help would be appreciated.

Cheers, Murray

https://www.aulro.com/afvb/images/imported/2010/12/1247.jpg

Hi Murray

I just went out and measured the plate on the rear of my 94 Tdi and the plate is the same as the plate in the photo above 190H x 270W.
The only reason I haven't replied earlier in this thread is that I thought that the Rear wheel carrier for the Tdi would be different to what you would be making at the moment.But if it looks like they will fit,Santa needs to leave me another present,so please keep me in mind.

Wayne
rijidij
12th December 2010, 10:55 PM
Hi Murray

I just went out and measured the plate on the rear of my 94 Tdi and the plate is the same as the plate in the photo above 190H x 270W.
The only reason I haven't replied earlier in this thread is that I thought that the Rear wheel carrier for the Tdi would be different to what you would be making at the moment.But if it looks like they will fit,Santa needs to leave me another present,so please keep me in mind.

Wayne

Thanks for that Wayne. That's interesting, I thought the Tdi's would have the smaller plate, but that's good because the more common components I have between models the easier it is to make them.

Cheers, Murray
LowRanger
27th February 2011, 08:22 PM
Just fitted my wheel carrier to the rear of my 94 Defender

All fitted up nicely without any problems.And it really is a nice bit of kit

Sorry for the poor quality pic,but it was getting dark and starting to rain


Thanks again Murray
rijidij
27th February 2011, 09:08 PM
Thanks for posting the pic Wayne,
It's been very satisfying to see the carriers finally fitted to vehicles, and with some welcome feedback.

I had a couple of minor issues with the carriers, which were actually more to do with minor differences between vehicles than anything else, but the AULRO member's, and other's who have purchased them, have been most patient and helpful in sorting things out. Thanks guy's, I really appreciate it.

Cheers, Murray
grover7488
27th February 2011, 09:23 PM
although i dont have one of these carriers - yet :p i have to say that Murray's attention to detail is second to none. Really impressive workmanship, well thought out and a great quality unit :cool:
LowRanger
27th February 2011, 09:43 PM
although i dont have one of these carriers - yet :p i have to say that Murray's attention to detail is second to none. Really impressive workmanship, well thought out and a great quality unit :cool:


Yes,that is why I held off for so long,until I saw something come on the market,that met my needs and expectations.And Murrays' product does that.I needed a product that would carry my 35" tyres and steel wheels without causing major stress areas at the mounting points.And I wanted something that didn't look like it was homemade in someones bathroom.And now having seen the product 1st hand,and fitted it,I have no problem recommending to anyone else that may be thinking about it.Don't think about it.......do it,the product is that good.And the communication from Murray has been exceptional.

Wayne
LowRanger
8th March 2011, 06:15 PM
Just a pic with the 35" spare fitted

Handles the weight of the 35 without any problem,and is secure and no rattles......probably one of the few things on the truck that don't rattle.And I have better access to the rear door handle than I had with 265's fitted to the standard mount on the rear door.

Wayne
pommy
8th March 2011, 06:23 PM
Couldn't agree more with lowranger Murray fitted carrier for me about a month ago on my 99 defender and its a good piece of kit . Mine holding a 35 " as well . Great to deal with and well priced .
kelvo
3rd April 2011, 01:06 AM
That looks a realy good job rijidij. Should remove all the strain from the rear door when its closed.

Next you need to work on a twin wheel carrier!
rijidij
3rd April 2011, 09:14 AM
That looks a realy good job rijidij. Should remove all the strain from the rear door when its closed.

Next you need to work on a twin wheel carrier!

Thanks Kelvo,
Twin wheel carriers seem to be popular at the moment, and I have got some ideas, but that will have to be a future project.

Cheers, Murray
p38arover
5th April 2011, 07:03 AM
This is a project thread. No selling nor requests to purchase one allowed. Posts deleted.

If you want to make and sell them, become a Vendor and advertise them via the Verandah.

Thread locked.