Cookie Monsters Puma D90 Build

[cookie monster]

Hi all,

Thought id share with you the build up of my new 2015 D90. Bought in February this year(2015) with the view to kitting it out for outback touring.
This may seem a strange choice, especially as I sold our much loved(but often hated!) & well kitted out 99 Nissan Patrol 4.2td to fund the purchase of BEN(you will see the reasoning for the name with the first photo !), but there are only the 2 of us now our daughter has grown up, so why not !
A couple of images attached of BEN on his first outing and when i figure out drop box, ill post some threads on the following projects:
Aluminium Drawer System
Bullbar & Winch Fitment
Accessory Switch Panel

Cheers Cookie

[Toxic_Avenger]

Nice 90. I'm partial to them myself :cool:
What colour is yours?

[cookie monster]

Thanks Toxic.
The colour is Corris Grey Metallic.
Cheers Cookie

[Toxic_Avenger]

Mine is Orkney grey, looks like yours is a shade darker though.

We need more pics!
My defender is in getting some repairs, so I need to live vicariously through others!

[cookie monster]

Ok, so here is the start of the drawer system build. I have basically copied the commercially available design of a single 750mm wide x 1000 deep x 220 high drawer. I used 2mm aluminium for both the frame and the drawer and had a friend fold and weld them up.

First up though I wanted to make the rear a little more dust proof, so run a bead of silicone along the sides of the rear floor area where the floor is riveted to the wheel arches.
I had found that wisps of dust had already started to show themselves, even after some very light gravel road use !

http://i827.photobucket.com/albums/zz198/neilcook/002%204_zpsa1hkld0l.jpg (http://s827.photobucket.com/user/neilcook/media/002%204_zpsa1hkld0l.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/08/476.jpg (http://s827.photobucket.com/user/neilcook/media/003%204_zpsqcgcm250.jpg.html)

First job was to attach the 220kg rated full extension runners to the frame. The holes were marked onto the frame and 5mm dia holes drilled through.

https://www.aulro.com/afvb/images/imported/2015/08/477.jpg (http://s827.photobucket.com/user/neilcook/media/002206_zpsgzvmlmw4.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/478.jpg (http://s827.photobucket.com/user/neilcook/media/003205_zpskmhpi93c.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/479.jpg (http://s827.photobucket.com/user/neilcook/media/004204_zpsfhdhhigy.jpg.html)

The same was then done on the drawer, allowing for clearance both top and bottom. I had a diagonal 'set' folded into the base of the drawer to strengthen it, as 750 x 1000 is a large area for 2mm aluminium and I didn't want to use a plywood base in the drawer to strengthen it.

https://www.aulro.com/afvb/images/imported/2015/08/480.jpg (http://s827.photobucket.com/user/neilcook/media/002207_zpsyj6cppgp.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/481.jpg (http://s827.photobucket.com/user/neilcook/media/001207_zpsnxllzcvp.jpg.html)

Once the runners had been fitted, I then transferred the positions of the rear seat locating holes and the tie down mount positions on the passenger side of the car onto the frame. The seat mounts & tie down mounts would secure the frame onto the floor and the side of the wheel arch.

A packer was made from the 17mm ply that I had bought for the shelf, to space the frame out slightly so that the drawer would clear the rear door frame.

https://www.aulro.com/afvb/images/imported/2015/08/482.jpg (http://s827.photobucket.com/user/neilcook/media/001%208_zps921imth4_1.jpg.html)

Floor and side mounting holes for the rear seats
https://www.aulro.com/afvb/images/imported/2015/08/483.jpg (http://s827.photobucket.com/user/neilcook/media/001%206_zpsczg7it8c.jpg.html)

Trial fitting of the assembled frame & drawer
https://www.aulro.com/afvb/images/imported/2015/08/484.jpg (http://s827.photobucket.com/user/neilcook/media/007%202_zpsgpeivlsf.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/485.jpg (http://s827.photobucket.com/user/neilcook/media/008%202_zps4unrmqpz.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/486.jpg (http://s827.photobucket.com/user/neilcook/media/005%203_zpsb2idtepm.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/08/487.jpg (http://s827.photobucket.com/user/neilcook/media/006%202_zpsmn5ocmpa.jpg.html)

Cheers Cookie

[cookie monster]

Hi all,

Just a plug for my build thread over in the Projects and Tutorials Section

Hope this link works:

http://www.aulro.com/afvb/projects-tutorials/223880-cookie-monsters-puma-d90-build.html

Ill be covering the build up of my D90 as a touring vehicle. Items ill be fitting include:
Aluminium drawer system
ARB bullbar and Warn magnum 10k fitment
On board compressor
Custom switch panel
Custom drinks bottle holder
Fixing up a second hand roof rack
Dual battery install
IPF LED Spots

and plenty more along the way...

Hope you can pop in and say gday.

Cheers Cookie

[Tombie]

Looking good mate. Look forward to seeing it at Melrose next year...

[cookie monster]

Looking good mate. Look forward to seeing it at Melrose next year...

Thanks Tombie , yes we should be there as it was s great weekend this year. We are also members of the SA Register now, so hoping to get a bit more involved involved.
Cheers Cookie

[YOLO110]

Mate, it looks great! Very impressed... a hard act to follow!

So, what are the plans for the 90? Sounds like a 'lap' may be brewing?

Cheers, Pete :>)

[cookie monster]

Mate, it looks great! Very impressed... a hard act to follow!

So, what are the plans for the 90? Sounds like a 'lap' may be brewing?

Cheers, Pete :>)

Thanks Pete, I'll try get the next phase of the drawer build up early next week week.
Unfortunately a big lap is not on the cards at present, but we will be heading up to the Kimberley next year and then Cape York in 2018.
I'll be looking to put some airbags in the rear and also beef up the front springs to compensate for the 15mm reduction in height from the fitment of the bar and winch.

Does anyone know if 110 springs are stiffer than the 90?

Cheers Cookie

[cookie monster]

Ok,

Next job on the drawer system build was to get the timber shelf made and fixed in place. I couldn't get the sheet into the car cut to the full width, so had to settle for using 3 pieces.
There are 2 long sections which straddle the width of the car, so they both sit on the drivers side wheel arch. A single piece was then cut to fill the remaining area on top of the wheel arch.

Sheets being positioned
https://www.aulro.com/afvb/images/imported/2015/08/220.jpg (http://s827.photobucket.com/user/neilcook/media/009_zps3d58l5vz.jpg.html)


I used the seat mounting points as anchors and drilled out the D hooks to accept the 10mm bolt. Our fridge sits perfectly between the D hooks and nestles into the trim cutout.

https://www.aulro.com/afvb/images/imported/2015/08/221.jpg (http://s827.photobucket.com/user/neilcook/media/010_zpsd9cakkt6.jpg.html)


https://www.aulro.com/afvb/images/imported/2015/08/222.jpg (http://s827.photobucket.com/user/neilcook/media/007_zpsjytjc4e7.jpg.html)


Boring the recess for the D hooks
https://www.aulro.com/afvb/images/imported/2015/08/223.jpg (http://s827.photobucket.com/user/neilcook/media/011_zpsvtvxswhw.jpg.html)


3rd trim piece being shaped and holes bored for the D hook mounts
https://www.aulro.com/afvb/images/imported/2015/08/224.jpg (http://s827.photobucket.com/user/neilcook/media/003202_zpsm2xlpvc7.jpg.html)


Timber was shaped to clear the speaker trim and also left ~10mm off the side panel to allow for cables to be run to the rear
https://www.aulro.com/afvb/images/imported/2015/08/225.jpg (http://s827.photobucket.com/user/neilcook/media/002%205_zpsvkxzxz7o.jpg.html)


Its a crap shot, but this shows the packers that were cut to take up the gap between the wheel arch step down and the timber shelf, same were put on the passenger side, with the D hook bolts running through the middle of them.
https://www.aulro.com/afvb/images/imported/2015/08/226.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0157_zpsf02ivk9b.jpg.html)

The 3rd piece was fixed to the wheel arch using existing mounts to the rear of the car and new holes drilled toward the front of the car.

That's it for now, next time Ill cover the carpeting of the shelf etc.

cheers Cookie

[cookie monster]

Next job was to carpet the shelf and the drawers with marine carpet. We chose the short pile version, as with previous drawer systems id found that the longer pile carpet tended to pull out a bit and leave strands of carpet around.
Quick set contact adhesive was used to glue the carpet to the timber and the aluminium.


My wife Linda applying the glue:
https://www.aulro.com/afvb/images/imported/2015/08/136.jpg (http://s827.photobucket.com/user/neilcook/media/017_zps3yovrsga.jpg.html)


Marking out for the inside of the drawer:
https://www.aulro.com/afvb/images/imported/2015/08/137.jpg (http://s827.photobucket.com/user/neilcook/media/014_zpsd8hc5don.jpg.html)


Drawer lining trial fitment:
https://www.aulro.com/afvb/images/imported/2015/08/138.jpg (http://s827.photobucket.com/user/neilcook/media/016_zps2flexwnv.jpg.html)


Finished product:
https://www.aulro.com/afvb/images/imported/2015/08/139.jpg (http://s827.photobucket.com/user/neilcook/media/002_zpskib0utbn.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/08/140.jpg (http://s827.photobucket.com/user/neilcook/media/001_zps0jarozkj.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/08/141.jpg (http://s827.photobucket.com/user/neilcook/media/9004bace-475b-4a13-be02-a1100269c780_zpstkc4rfam.jpg.html)
First trip away with makeshift dividers in place !:
https://www.aulro.com/afvb/images/imported/2015/08/142.jpg (http://s827.photobucket.com/user/neilcook/media/003_zpspn4p27hg.jpg.html)


After a couple of trips away with the single drawer, we are looking to make another couple that will be stacked on top of the existing drawer. We will also put the gulwing door on both sides to access the fridge on the drivers side and the cooking gear on the passenger side. The new drawers will end up the same height as the fridge and I will use mesh to stop items stored on the shelf from ending up on our lap or on top of the fridge.
That's all a little while away though.


Cheers Cookie

[cookie monster]

All,


Below is the info on the telescopic drawer runners I used. They lock in both the closed and open positions, so are great for this type of application.

1 x
LOCKING SLIDE 1016mm - 227kg Rated
RDF1016XLH - $157.08

Freight Adelaide to Adelaide $6.60
Total $163.68



ELRACO DISTRIBUTORS Pty Ltd
ABN 70968547655
45 Jacobsen Crescent
Holden Hill. S.A.
p 618 82618499
f 618 82618599

http://elraco.com.au (http://elraco.com.au/)


Below is the sketch of the drawer and the frame that was used to fabricate both parts - apologies for the quality.
https://www.aulro.com/afvb/images/imported/2015/08/135.jpg (http://s827.photobucket.com/user/neilcook/media/DSC_0159_zpscrrl8nlr.jpg.html)


Cheers Cookie

[cookie monster]

Another little mod we wanted to do was to make some decent drink bottle holders, as the factory holder on the front of the cubby box is a bit impractical.
When you have standard 750ml drinks bottles in there, they foul on the gear lever and generally get in the way.
I also wanted to use the space where the factory drink bottle holders are, for a switch panel to house all the auxiliary switches I would be using(more to come on that later).

The new bottle holder fits were the factory sub woofer is installed at the rear of the cubby box.

I had my sheet metal mate knock up the holder and then assembled it up :

https://www.aulro.com/afvb/images/imported/2015/09/718.jpg (http://s827.photobucket.com/user/neilcook/media/001203_zpszmjcggyt.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/09/719.jpg (http://s827.photobucket.com/user/neilcook/media/002203_zpswle8lpug.jpg.html)

The centre divider was riveted in place and the holes drilled for the existing speaker mounting holes (150mm x 150mm):
https://www.aulro.com/afvb/images/imported/2015/09/720.jpg (http://s827.photobucket.com/user/neilcook/media/003203_zpsgdr4tggd.jpg.html)

The internal faces were then trimmed with some left over marine carpet:
https://www.aulro.com/afvb/images/imported/2015/09/721.jpg (http://s827.photobucket.com/user/neilcook/media/012_zpsqxxzi2jd.jpg.html)

The holder fits 2 1.5L SIGG water bottles:
https://www.aulro.com/afvb/images/imported/2015/09/722.jpg (http://s827.photobucket.com/user/neilcook/media/013_zpsd8crxcua.jpg.html)

Ill post up a pic of the installed holder and the drawing shortly.

Cheers Cookie

[Toxic_Avenger]

Great idea, my Sigg 1L model has been banished to inside the cubby box, which will invariably leak all thru it one day.

Biggest gripe about those bottles is how any change in air pressure / elevation leads to them leaking all over your lap when you open them. No matter how careful I am, it gets me every time!

[cookie monster]

Thanks Toxic.


Whilst we made the holder to fit the 1.5L sigg bottles, we do tend to use regular 750ml sports bottles, as they are easier to open whilst driving. We keep the sigg bottles in the back for top ups.


I was considering making another holder that was as wide as the gap between the seats, which would then be able to hold the 2x sigg and 2x 750ml sports bottles - still undecided though.


Drawing for the holder below:


https://www.aulro.com/afvb/images/imported/2015/09/713.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0201_zpsejxftjsz.jpg.html)


Cheers Cookie

[cookie monster]

Holder installed using existing speaker mounting holes:

https://www.aulro.com/afvb/images/imported/2015/09/292.jpg[/img][/IMG]

Cheers Cookie

[cookie monster]

Next little job was to finish off the switch plate that I had folded up, that sits where the original drinks holders were in the centre console.

The switch positions were marked onto the panel and then stitch drilled around the circumference of the rectangle and the centre cut out with tin snips.
https://www.aulro.com/afvb/images/imported/2015/10/147.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0131_zpslykohweh.jpg.html)

Then the rectangle was filed out to size.
https://www.aulro.com/afvb/images/imported/2015/10/148.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0132_zpskogdeu1f.jpg.html)

More rectangles filed to size.
https://www.aulro.com/afvb/images/imported/2015/10/149.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0133_zps24jk8xcg.jpg.html)

All the apatures finished, ready to accept the switch's.
https://www.aulro.com/afvb/images/imported/2015/10/150.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0135_zps6htlffdy.jpg.html)

Switch's mounted.
https://www.aulro.com/afvb/images/imported/2015/10/151.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0136_zpszjdrprsy.jpg.html)

Cable was then run from the battery box to the switch panel and the switch's wired up.
https://www.aulro.com/afvb/images/imported/2015/10/152.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0141_zpsoemdbhcm.jpg.html)

I'll post a pick of the installed panel when I get back from a work trip.
Cheers Cookie

[cookie monster]

As we are setting the 90 up for touring, we decided to add a couple more drawers in the rear to carry food, cooking gear etc. I have put all my tools and recovery gear in the original lower drawer, so it keeps the weight nice and low.

New twin drawer frame, in 3mm Ali :https://www.aulro.com/afvb/images/imported/2015/11/138.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0970_zpsg4o69lfa.jpg.html)

Timber top being positioned :https://www.aulro.com/afvb/images/imported/2015/11/139.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0971_zpsaoowigsd.jpg.html)

Finished product all carpeted up:https://www.aulro.com/afvb/images/imported/2015/11/140.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0972_zpst6jc3hau.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/11/141.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0973_zpsucnyenxj.jpg.html)

Thought we'd test out the new drawers with a weekend in the SA riverland :
https://www.aulro.com/afvb/images/imported/2015/11/142.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0974_zpsagrtiusy.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/11/143.jpg (http://s827.photobucket.com/user/neilcook/media/Mobile%20Uploads/DSC_0980_zpsidpwizin.jpg.html)

Cheers Cookie