My Cummins 110 CSW build

[Lockey]

Hey lads, some of ye might be aware (Sitec), ive decided to swap the 200tdi out for a Cummins 6bt lump. so seeing as i have been using sitec build a lot to help me i said it was only fair that i filled ye in on the progress so far :)

So first on the to do list was to pick up a Daf45 and strip it! :

https://www.aulro.com/afvb/images/imported/2014/07/364.jpg (http://s1042.photobucket.com/user/clocke08/media/photo4_zps24e2f853.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/365.jpg (http://s1042.photobucket.com/user/clocke08/media/photo3_zps3b5087e5.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/366.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0768_zps966e2f53.jpg.html)

Once that was out and brought home, the next step was to strip the 110, i knew it needed a bit of chassis work so the plan was to strip it back to bare chassis and build from the ground up:

https://www.aulro.com/afvb/images/imported/2014/07/367.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0848_zpse619f44a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/368.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0850_zpsf111e4ff.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/369.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0851_zpse7d95e97.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/370.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0852_zps62eea982.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/371.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0855_zps05a16003.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/372.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0856_zpsb85fa8e2.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/373.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0895_zps9ce985f8.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/374.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0899_zpsef90d01d.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/375.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0926_zps75843bb8.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/376.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0928_zpsbdeaec23.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/377.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0935_zps35bff2ec.jpg.html)

And then the rot needed to be assessed :( :

https://www.aulro.com/afvb/images/imported/2014/07/378.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1001_zps474e340a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/379.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1002_zps80e4862a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/380.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1003_zps7c4d6bdd.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/381.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1006_zpscef67176.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/382.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1005_zps81fca972.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/383.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1007_zps3097da6f.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/384.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1008_zpsd0be46f4.jpg.html)

The budget wont allow for a shiny new chassis so ive had to work with what i have so heres a look at the repairs so far:

https://www.aulro.com/afvb/images/imported/2014/07/385.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1053_zps6107b4cc.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/386.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1065_zps397d084a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/387.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1066_zpse5707ee3.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/388.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1014_zps43493385.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/389.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1015_zps96d92c0c.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/390.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1018_zps074ad88e.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/391.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1020_zpsfbddacca.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/392.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0925_zps87d7b2cf.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/393.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0924_zps475c97ba.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/394.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0923_zps5dc895e8.jpg.html)

Bought a 12v started and alternator with a vacuum pump (cummins doesnt have one):

https://www.aulro.com/afvb/images/imported/2014/07/395.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1033_zpsb2d44052.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/396.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0990_zps0a3c924e.jpg.html)

I was getting a bit disheartened by the amount of welding i needed to do so took a break from it and decided to fit the engine to the chassis for a look :) :

https://www.aulro.com/afvb/images/imported/2014/07/397.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1079_zpsd670a9df.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/398.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1081_zpsc8565b83.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/399.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1082_zpsd280f394.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/400.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1084_zpsb5a8d374.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/401.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1107_zps55fa2932.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/402.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1106_zpsf7b27cc8.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/403.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1095_zps7e8aeff6.jpg.html)

Once in i started lining up where the transfer box was going to sit (obviously under the crossmember but was trying to see how close to the chassis rail it'd sit) :

https://www.aulro.com/afvb/images/imported/2014/07/404.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1104_zpsbc255b62.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/405.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1102_zps16c9d994.jpg.html)

Clearance around the axle looks ok so far :) :

https://www.aulro.com/afvb/images/imported/2014/07/406.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1109_zps59abd03f.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/407.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1110_zpseeab6ad1.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/408.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1111_zps38b5283f.jpg.html)

Whole lot sits about an inch and a half from the front crossmember (tight fit!!) :

https://www.aulro.com/afvb/images/imported/2014/07/409.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1108_zps914c25e8.jpg.html)

Then today, i had a go at fitting the bulkhead, a wing and the bonnet to see will it all squeeze closed, it did, JUST!! :

https://www.aulro.com/afvb/images/imported/2014/07/410.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0162_zps4bcb2755.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/411.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0163_zps1afeda9f.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/412.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0164_zps6b849af8.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/413.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0165_zps4f915d19.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/414.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0166_zpsf10243a6.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/415.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0167_zpsb65fdea7.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/416.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0168_zps0ad89a78.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/417.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0169_zps3c59ca09.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/418.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0170_zpsb31004fc.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/419.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0171_zps2d00a5cc.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/420.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0172_zpsa8bec9fe.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/07/421.jpg (http://s1042.photobucket.com/user/clocke08/media/GOPR0173_zps01af8d6b.jpg.html)

Thats all for now lads!

Next on the to do list is finish the chassis, and once im happy i have all the brackets and bits welded on that i need, ill send it to be galvanised.

Let me know what ye think!

[Sitec]

Hi Lockey! Yeah, I'd been watching the progress over on Book Face. Looking good so far!! Have to say, I don't miss the rust caused by salted roads!!! Cork used to b home for me as a kid! Keep up the good work, and there will be a huge smile the first time you drive it!! :)

[Lockey]

Hi Lockey! Yeah, I'd been watching the progress over on Book Face. Looking good so far!! Have to say, I don't miss the rust caused by salted roads!!! Cork used to b home for me as a kid! Keep up the good work, and there will be a huge smile the first time you drive it!! :)

Lots done, more to do Simon, im sure youre aware of that all ready though :D jesus really? small world haha! yeah the coastal cities batter the chassis' really but mine came in from the UK, they salt the roads there during winter rather than grit them like here in Ireland, so the poor untreated defender chassis' suffer badly over there :mad: its getting there though, the worst of the rot is mostly cut out and replaced, im taking my time with it though, want to get it right!!

[jakeslouw]

Bleeding heck that is a big lump of an engine.

Aircleaner going to be on the LHS?

[Lockey]

Bleeding heck that is a big lump of an engine.

Aircleaner going to be on the LHS?

Im hoping it'll fit somewhere on the D/S but it is huuuuge!! would prefer to use a proper air cleaner housing rather than a cone filter because i'd like it to be piped into the snorkle :)

[67hardtop]

make sure u don't twist the chassis with all that welding...:o

Cheers Rod:wasntme:

[Lockey]

make sure u don't twist the chassis with all that welding...:o

Cheers Rod:wasntme:

thought did cross my ming, but im doing it face by face so at all times it should be more than capable of ceeping its shape as only one section is being done at a time, im also stitching it first so as not to head up one side too much and warp it.

Im more worried abbout the engine warping the chassis under load though if im honest :D

[isuzurover]

nice work. Make sure you brace the front axle. They bend even with a 4bd1 (4BT) if you go offroad.

Not sure about the engine mounts though... what happends if those welds crack...?

Here is the bracing I added to my front axle:
https://www.aulro.com/afvb/images/imported/2014/07/294.jpg

8mm thick butt weld pipe cap to replace the diff pan.
https://www.aulro.com/afvb/images/imported/2014/07/295.jpg

[Lockey]

nice work. Make sure you brace the front axle. They bend even with a 4bd1 (4BT) if you go offroad.

Not sure about the engine mounts though... what happends if those welds crack...?

Here is the bracing I added to my front axle:
https://www.aulro.com/afvb/images/imported/2014/07/294.jpg

8mm thick butt weld pipe cap to replace the diff pan.
https://www.aulro.com/afvb/images/imported/2014/07/295.jpg

will definitely be bracing the axle as you have done (although this build is to facilitate towing an off roader around so its exposure to rough terrain should be minimal!) as for the chassis, im planning to add spreaders to the mounts to spread the load a bit more on the chassis.

[Lockey]

Transfer box is now bolted to the gearbox, so im getting somewhere!! handbrake drum is quite close to the crossmember so ive to decide what to do with that yet. the options are to get an x/brake or to trim the crossmember a bit, not decided which is the way i want to go yet!
Its also touching the O/S chassis rail at the moment as the engine is sitting a bit askew, so i must redrill one of the engine mounts :)

https://www.aulro.com/afvb/images/imported/2014/08/1082.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1151_zpsf66fe63a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1083.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1152_zps16bdb348.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1084.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1154_zps1bd8fbaa.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1085.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1158_zpsb0a1b698.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1086.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1157_zps40c13aa0.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1087.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1156_zps296bbbbc.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/08/1088.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1155_zpsf1acfc5e.jpg.html)

[Ancient Mariner]

I shifted the crossmember back 150mm used some 3x5/16"flat bar welded at an angle on the front edge then bent perpendicular to pick up the body and seat belt points worked out well .Gives enough room to remove TC

AM

[Sitec]

Make the x member boltable, and do away with that earlier clutch slave. The later one is a lot slimmer and does not have that 'lump' sticking out! You will also have to upgrade you're clutch master from the std 3/4" cyl to 1". Ser 3 Brake Cyl is the go!

[slug_burner]

I take it there are plenty of those DAF trucks to get the Cummins from.

[brettphillips43]

Outstanding effort cobber! Is going to be an absolute monster when she's done!

Sent from my GT-I9300 using AULRO mobile app

[Lockey]

Ok lads, heres a look at the last few weeks worth of work!!

so the chassis went from this:

https://www.aulro.com/afvb/images/imported/2014/09/1276.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1209_zpscc2053a9.jpg.html)

To this!!!:

https://www.aulro.com/afvb/images/imported/2014/09/1277.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1229_zps998d8ee4.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1278.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1228_zpse0de510f.jpg.html)

Really happy with the result and definitely worth the effort and time that went in to repairing it!

Also got a delivery the same day o got the chassis back (was like christmas!!)

https://www.aulro.com/afvb/images/imported/2014/09/1279.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1224_zps4835319c.jpg.html)

So that evening the axles went under it:

https://www.aulro.com/afvb/images/imported/2014/09/1280.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1232_zpsc4ffc6c1.jpg.html)

Next day i spotted the crack in the gearbox so that tore the arse out of putting the engine and gearbox in that day, so gearbox went in this morning after a bit of welding, along with the t/box (temporarily):

https://www.aulro.com/afvb/images/imported/2014/09/1281.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1265_zpsfa80b781.jpg.html)

Then cleaned the gearbox, shock turrets, tank and a few other bits up and gave em a lick of paint!:

https://www.aulro.com/afvb/images/imported/2014/09/1282.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1276_zps858f86fb.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1283.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1275_zps176fa8d7.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1284.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1274_zps5ba1eb80.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1285.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1273_zps7458fc5a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1286.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1272_zpsbd412b3e.jpg.html)

Amazing what a lick of paint does!

Heres a look at the clearance for the handbrake drum, not ideal for removal, but if it becomes an issue ill look at getting an x/brake or making something similar!:

https://www.aulro.com/afvb/images/imported/2014/09/1287.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1268_zps79cdbde8.jpg.html)

Thats all for now! forgot to take pictures of the paint i bought for it, tempted to keep it a surprise though :P

[Lockey]

Got the rear wiring done today and all tidied away in ducting pulled off the truck, made a neat job of it :) :

https://www.aulro.com/afvb/images/imported/2014/09/1037.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1281_zps6d213077.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1038.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1282_zps2fd6de37.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/1039.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1283_zpsc781d467.jpg.html)

And heres a look at the colour :) :

https://www.aulro.com/afvb/images/imported/2014/09/1040.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1285_zps06bdb9a9.jpg.html)

[Sitec]

Lookin gud!!! That's a nice colour too!!!! Work well with silver chassis. Silver Compomotive Alloys would look the part too... The wide rare ones!!

[Lockey]

Lookin gud!!! That's a nice colour too!!!! Work well with silver chassis. Silver Compomotive Alloys would look the part too... The wide rare ones!!

cheers dude! think ill stick with the not rare 15"x10" modulars for now though, the money is starting to run out :D




Anyways lads heres a look at the work this weeks work!

First up was to do the brake lines:

https://www.aulro.com/afvb/images/imported/2014/09/921.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1292_zps37b57a29.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/922.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1293_zps02448657.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/923.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1294_zpseb3e0594.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/924.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1295_zpsffd6562e.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/925.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1296_zps9ab13116.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/926.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1297_zpsfb03daaa.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/927.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1298_zpsf1f0215a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/928.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1300_zpsd9922d05.jpg.html)

Then had a look at the intercooler and rad setup, going to be tight, but it'll work!:

https://www.aulro.com/afvb/images/imported/2014/09/929.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1310_zpsfc672686.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/930.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1305_zps17be5ac2.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/931.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1302_zpsabf0f08e.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/932.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1311_zps3934ffc5.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/933.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1312_zps593d739f.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/934.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1307_zps5ec913ee.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/935.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1304_zps925bd00d.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/936.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1308_zps72e78e8b.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/09/937.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1314_zps87b54ac8.jpg.html)

I must confess, im overly excited about how well the fans fit the rad :D

[67hardtop]

Looking good. Keep up the good work.

Cheers Rod:wasntme:

[Wicks89]

The scale of this build is Mental. You are mental. That rig will be mental. It is a crime not to take that bad boy off road. I am dead set sitting in my computer chair basking in the glory of that 110.

You, sir are creating one of the greatest frankensteins monsters Ive seen on this forum. Cant wait to read more!

[Lockey]

The scale of this build is Mental. You are mental. That rig will be mental. It is a crime not to take that bad boy off road. I am dead set sitting in my computer chair basking in the glory of that 110.

You, sir are creating one of the greatest frankensteins monsters Ive seen on this forum. Cant wait to read more!


hahahaha, cheers dude, awesome to hear others like it :) i may call it frankensteins monster actually:D

[Nick S]

Call it "Frankenrover"

[isuzurover]

Call it "Frankenrover"


That name is taken by a us d90 with extended wheelbase and unimog axles.

EDIT to add some pics:
http://www.pirate4x4.com/forum/attachments/land-rover/626721d1318810514-interesting-frankenrover-picts-image-2-.jpg
https://www.aulro.com/afvb/images/imported/2014/10/1152.jpg

http://www.pirate4x4.com/forum/attachments/land-rover/626722d1318810530-interesting-frankenrover-picts-image-1-.jpg
https://www.aulro.com/afvb/images/imported/2014/10/1153.jpg

Photos courtesy of:

D. Pro Photography
Littleton Colorado
303-884-3946
dpro_photo@live.com
dpro-photo.smugmug.com

[Nick S]

OK "Frankenrover UK" then

[Lockey]

OK "Frankenrover UK" then

Frankenrover IRL ;)

[Lockey]

Ok so heres a look at what has to be done with the input gear so as to connect drive from the gearbox to the input of the transfer box. This has to be a bespoke setup as there is nothing off the shelf that'll do :(

SO!! heres a look at the LT230 input gear (right) and the ZF S5-42 (gearbox) output flange:

https://www.aulro.com/afvb/images/imported/2014/10/799.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1344_zps460882a0.jpg.html)

The plan is to turn down the output flange until its a stub and weld it to the end of the LT230 input gear like this:

http://www.aulro.com/afvb/attachments/projects-tutorials/67252d1382138451-zf-s5-42-lt-230-image.jpg

http://www.aulro.com/afvb/attachments/projects-tutorials/72722d1392096143-zf-s5-42-lt-230-image.jpg

Now, ideally i would be using a 1:1.003 LT230 from a 3speed auto RRC (torqueflight box) as this would give the perfect ratio for daily driving, but im having trouble finding one, but seeing as i havent, ive settled for the 28d 1.22 RRC box i currently have. It has the correct internals so that i can, at a later date, rebuild it as a 1.003 box (waiting for ashcroft to have em back in stock), alternatively its possible to get 2.83 ring and pinion gear sets for the diffs, but that would require swapping the back axle for a 90 axle, not the end of the world but not ideal either! either way, the 1.22 box will suit fine for the meantime (to be honest it will most likely be grand all together but the 1.003 ratio would be a more refined/comfortable ratio )

Anyway, the gear is gone out to the engineer to be made up, just been to busy to chase him about it!

So, besides the input gear ive been busy welding up the bulkhead (had some holes in it and had to be modified to get around the mahoosive gearbox ;) ) :

https://www.aulro.com/afvb/images/imported/2014/10/800.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1349_zps4dbd0a68.jpg.html)

Also had to sort out an issue with the oil filter fouling on the steering box, managed to source a shorter filter:

https://www.aulro.com/afvb/images/imported/2014/10/801.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1364_zps4685ab5c.jpg.html)

Oh and ive been sanding, filling, priming and painting like a mad thing, decided to do it panel by panel as i dont have a shed big enough to do it all in one go, and i wanted to do as close to a factory paint job as i could. its taking a savage amount of time though!!! :

https://www.aulro.com/afvb/images/imported/2014/10/802.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1384_zpsa6c9c6c1.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/10/803.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1387_zpsa3e63e7e.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/10/804.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1386_zps9beb0d82.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/10/805.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1385_zpse460faab.jpg.html)

Heres what ill tackle today/tomorrow:

https://www.aulro.com/afvb/images/imported/2014/10/806.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1388_zpsdfc2787f.jpg.html)

So all thats left to paint is the rear tub, roof and a few bits and bobs, just waiting for good weather to do the big bits. no way of getting them indoors :/

Let me know what ye think!! cheers

[Dougal]

The thrust bearing setup in the lt230R isn't good enough for high torque. My one behind my isuzu has worn the intermediate shaft and thrust washers.
The best option is a 1.003:1 lt230t from ashcroft.

[reachjatt]

I have been recently asked, if one can put tank engine into series landy !! .. My resposne was sure you can. Get in touch with this guy:D "My Cummins 110 CSW build".

Your thread is bit overwhelming for me.. Hats off great enthusiasm!! keep up the good work.

[Lockey]

I have been recently asked, if one can put tank engine into series landy !! .. My resposne was sure you can. Get in touch with this guy:D "My Cummins 110 CSW build".

Your thread is bit overwhelming for me.. Hats off great enthusiasm!! keep up the good work.

hahahaaha, a tank engine?!!? yeah that sounds like something stupid enough for me to try :D

but then, my mantra is, if an idea is stupid and it works, its not stupid ;)

[Sitec]

Hmmmm... That drawing and welded gear look familiar... Can't picture from where tho...... ;). Have not seen the Gear for 12000kms now!!! :D

[rangieman]

hahahaaha, a tank engine?!!? yeah that sounds like something stupid enough for me to try :D

but then, my mantra is, if an idea is stupid and it works, its not stupid ;)

Its not a Irish joke:wasntme:;):angel:

[Lockey]

Hmmmm... That drawing and welded gear look familiar... Can't picture from where tho...... ;). Have not seen the Gear for 12000kms now!!! :D

Hahaha :D totally original drawing, i swear!! :P thats a good sign that you havent seen it in 12000kms though ;) hopefully i will have the same complaint!! what rods were used to weld yours do you know??

[Sitec]

Hahaha :D totally original drawing, i swear!! :P thats a good sign that you havent seen it in 12000kms though ;) hopefully i will have the same complaint!! what rods were used to weld yours do you know??

No idea sorry. I've been contemplating getting a spare made tho as our travel is getting more remote with each trip we do. That was the only bit I paid a guy to do as I knew it had to be right. Will try and find out. :)

[Lockey]

Bits are finally going back on :)

https://www.aulro.com/afvb/images/imported/2014/10/678.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1390_zps4d3014a8.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/10/679.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_1389_zps0cfda5d8.jpg.html)

Getting excited now!!

[Lockey]

Lots has happened since my last post, so ill backdate it eventually, but heres a look at todays effort ;) https://www.youtube.com/watch?v=HJklKuwI9WA&feature=youtu.be

[Toxic_Avenger]

Needs moar footage rollin' coal with some daylight!
Sounds mean.

[Lockey]

https://www.youtube.com/watch?v=gmWx2iX3cg0&feature=youtu.be

[BadCo.]

That thing just sounds awesome, nice work.

[LR V8]

I want one [thumbsupbig]

[Lockey]

Got the Gear Selector finished today (all sealed and finetuned after the pics were taken):

https://www.aulro.com/afvb/images/imported/2014/12/583.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0079_zps4923ca08.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/12/584.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0077_zps5ef316e3.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/12/585.jpg (http://s1042.photobucket.com/user/clocke08/media/IMG_0078_zpsb0fdcf7d.jpg.html)

And heres a vid of it operating!

https://www.youtube.com/watch?v=u_OWKbwGqXc&list=UUdIaHUn6HVMmMjkOUu1GM-g

[Lockey]

Went for a spin today!

https://www.youtube.com/watch?v=gJX06cjjOaw&feature=youtu.be

[Dinty]

It's now coming together for you and it looks the ducks guts, waiting patiently for you to finish and take it for a run on the road, cheers mate Dennis

[67hardtop]

Sounds mean and awesome. sounds like you could climb up walls with all that power:D:D:D

Cheers Rod :wasntme:

[MLD]

Any updates?

MLD

[nrs91]

Lockey is too busy enjoying the beast :P