Defender Sliders. Home made and Cost effective

[sclarke]

After pricing some sliders from different places i decided to make my own.

I copied the design from Camel Mark, His Defender has a nice strong set made from 100x50x3mm RHS.

Mine are the same dimensions, but i mounted mine in a different fashion.

I wont bore you will all the details on how long it takes and problems as the 1st set you make are the hardest.
But i will tell you how i did it.

I 1st removed the original sills and took the measurment of them. 1860mm from memory
i then cut my RHS 6mm shorter than this to allow the endcap steel to be welded on and it should then be the same size. I cut the RHS on the same angle as the original sills and then 60mm down i cut it back at a 45deg angle. This makes it neater and slide over things better. I then welded plates on the ends and cleaned up the welds.
Sliders complete.............. nearly

Mounting..........
Well here is the part some will go different ways about.
I looked at the bearmac and others and they only have a front tag to the front outrigger bolt plus the rear mount. Strong enough, but i wanted to make sure i could jack off mine.
So i used a 40mm Angle at the front and cut it flush with the body, at a later stage if the sliders move i can plate the bottom of this to the outrigger.
Then i used 80mm wide offcuts of the RHS and cut them to the correct body length. middle one was 38mm, rear 72mm and the RHS was 15mm difference.
How do they mass produce these??? when there is such a difference in dimensions?
I bolted both on with 2 bolts each in 10mm and used Nylocs to stop them undoing. Bolts are High tensile.
I then used the hoist i was working on to hold the sliders on the body and i G-clamped the slider to the mounts and then checked again the measurements.

Out came the Mig and i Tack welded the Slider onto the mounts. I then released the G-clamps and the hoist.
I then unbolted the mounts and slid it off the Defender.
Then i fully welded all the mounts and cleaned up the welds and cleaned off burs ect of the holes.
Then the part we all dred.... will it fit again.
YES Perfect. Very tight fit.

Now all i have to do is paint them.
I'm chosing Flat black at this stage but long term might paint them a different colour.

The only thing i have to do is drill a hole in each end for the flare to mount. But im toying with differnt ways as i have a master plan for that large capacity of RHS......

AIRTANK. Both sides are Airtight to my knowledge. so i'm going to weld some fittings on and when i install the compresser it can use them and tanks.

As for the cost involved. Materials about $120-$140 and labour was about 14 hours unpainted.
Next set i think i could do in about 8 hours.
So if you have to pay someone else to do them then $500 is a cheap set.

Hear are some pix. More to come and the lot are in my gallery.
http://www.aulro.com/modules.php'set_album...=view_album.php (http://www.aulro.com/modules.php'set_albumName=album329&op=modload&name=gallery&file=index&include=view_album.php)

http://www.aulro.com/albums/album329/Defender110slider1.jpg
http://www.aulro.com/albums/album329/Defender110slider_end.jpg
http://www.aulro.com/albums/album329/Defender110slider_mounted.jpg
http://www.aulro.com/albums/album329/Defender110slider_frontoutrigger.jpg
http://www.aulro.com/albums/album329/Defender110slider_mounts1.jpg

[cols110]

Very nice mate, with the cost of a new set I don`t know why more people dont make their own, over here in the UK you can pick up a set for $250-300.

[Ace]

Very nice steve, this is on my to do list now i have a welder. Matt

[LandyAndy]

Very nice job.Now to battle test them 8) 8) 8) 8) 8)
Then ask for orders :idea: :idea: :idea:
Andrew

[discowhite]

engineering marvel there steve!
the defenders are so simple to make, dont know why more people
dont make there own!

the disco ones are a bit more tricky, Ace will
see what im talking about when he tackels his!

phil

[RoverOne]

Great job, good pics, just the inspiration I need to get moving on mine.

When I sell the County steps off mine I should break even on the cost.

Cheers
Bryce

[sclarke]

And the Painted Pix. See working all those different jobs over the years paid off......
Now what new skills do i need.............
Next weekend i'll bolt them on.

With painting that good i should sell these buggers and build a new set....

http://www.aulro.com/albums/album329/Defender110slider_painted1.jpg
http://www.aulro.com/albums/album329/Defender110slider_painted_end1.jpg
http://www.aulro.com/albums/album329/Defender110slider_painted_end.jpg

Steve

[George130]

Paint work looks good. The entire package looks good actually.

[DEFENDERZOOK]

<span style="color:blue">you need to weld a bit of pipe through them to fit the standard defender jack......

then i will bring lurch and fit them up......




now.....to get a LITTLE bit serious.....these $99 arc welders available around the place....are they any good for anything .....or do i need to spend big bucks to buy a proper welder to make bits and pieces....?</span>

[sclarke]

I have a ARC and a Mig i borrow. Arc is good for heavy stuff

Spend the $800 and get a Mig

[DaveS3]

They will do the job, but only have a smally duty cycle (around 10%)

Thats what I built mine with (my computer is playing up, so I can post pictures :? )

That being said, I am now looking for a Mig.

All depends on what you already know how to use and can afford. If you can arc well very well - you will master mig easily 8)

Looks good Steve - BTW dropped into HC4x4 today to see what they did (Didn't even know they were there :oops: ) seemed like nice guys.

Dave.

[sclarke]

Originally posted by DaveS3
They will do the job, but only have a smally duty cycle (around 10%)

Thats what I built mine with (my computer is playing up, so I can post pictures :? )

That being said, I am now looking for a Mig.

All depends on what you already know how to use and can afford. If you can arc well very well - you will master mig easily 8)

Looks good Steve - BTW dropped into HC4x4 today to see what they did (Didn't even know they were there :oops: ) seemed like nice guys.

Dave.

Ahh you asked about a 110 Salisbury Diff for a Hybrid project.....

"I Know Nothing............"

[abaddonxi]

Now all you need to do is scan in some drawings with measurements on them and shift this thread to projects and we can all copy your hard work.

Looks great.

Simon

[DaveS3]

Originally posted by sclarke

Ahh you asked about a 110 Salisbury Diff for a Hybrid project.....

"I Know Nothing............"

Yah...Saw one under the undercoat Rangie :wink:

Thought I"d ask.

Interesting about the 110 in QLD :wink: He should buy it.

Dave

[hiline]

Steve when you going to build mine style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif as promised :evil: :evil:

[sclarke]

Ray,
Wait until mine are on then we will look to see if you want the same....

[JohnE]

Lurch's dad, for what its worth I bought on one those $99 GMC welders a couple of years ago, surprisingly it was made in italy proably a rebadged SIP. I was a bit worried about the duty cycle as it isn't fan cooled, however i have used it on heavy stuff and light stuff ,it performs really well on the 2.5mm satincraft rods.and has only cut out once , but then it was about 40degC that day. I did a welding course in sydney before i moved up here to gods country and we had a demo one night on an inverter welder, very impressive. There is a welding supply place in Bankstown just off the bypass road from the Hume Hwy to Rookwood rd opposite the water tower. They had really good prices on welders especially MIGs. They would be worth a look. i can't remember there name, only how to get there.

john

[BMac]

I've had a moderna 150 as shown here http://www.thetoolshed.co.nz/products/area...eas/welder.htm# (http://www.thetoolshed.co.nz/products/areas/welder.htm#) for about 6 years and it's been great and I use it a lot. The low duty cycle and light weight ( easy on the back ) is due to the use of an aluminium coil. As long as you weld a bit, grind a bit, cut a bit , weld a bit etc etc, it'll be fine. My Dad has had one longer than me and it has had to work pretty hard - he's building a 26 foot steel ketch.

Bruce.

[DEFENDERZOOK]

Originally posted by JohnE
Lurch's dad, for what its worth I bought on one those $99 GMC welders a couple of years ago, surprisingly it was made in italy proably a rebadged SIP. I was a bit worried about the duty cycle as it isn't fan cooled, however i have used it on heavy stuff and light stuff ,it performs really well on the 2.5mm satincraft rods.and has only cut out once , but then it was about 40degC that day. I did a welding course in sydney before i moved up here to gods country and we had a demo one night on an inverter welder, very impressive. There is a welding supply place in Bankstown just off the bypass road from the Hume Hwy to Rookwood rd opposite the water tower. They had really good prices on welders especially MIGs. They would be worth a look. i can't remember there name, only how to get there.

john





<span style="color:green">i know where that is.....i will have a look when i have the cash and time....


no good buying a welder and not having cash to buy materials.....
to make up a set of those sliders would a $99 arc do the job.....?
i wont be using it everyday.......</span>

[sclarke]

Yes it will.
the RHS i'm using is 3mm wall.

Arc can weld 1.6mm upwards

The trick with ARC welding is to keep the work area Warm. Keep the Welding rods in a tin box in a warm area and to get a better weld preheat them for 1/2 hour in an oven. this gets the moisture out.

A mig would be better, but you will get a good result with an Arc. Buy a cheap one and give it a go. find some scrap and make a nice garden scupture out of offcuts..... That will give you some ideas on what works and what does not work.

Then take on the big job.....

Ray if your serious about a set let me know and we can see what we can come up with....

[hiline]

<div class='quotetop'>QUOTE</div><div class='quotemain'>Ray if your serious about a set let me know and we can see what we can come up with....
[/b][/quote]

letting you know style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

[sclarke]

PM Me....

i'm working out a Price.... as i need to make them at Hardcore 4x4 and he needs his kick back for me using his tools.

I'd need your rig for a day, Sat or sunday then a weeks later you can fit them as i like the paint to dry for a week to make sure its hard....

I'm not sure on Powder coating costs, it would be better but expensive

To make it worthwhile custom made for your rig about $500 thats neg if you help out and help drink Beer or Bourbon with us.....

Let me know. Wait until you see mine on Sunday....

[hiline]

ok, i'll check yours out first


i'm a fussy bugger, when its comes to my car 8O 8O :wink:

[sclarke]

Smart Move.
wait until you see mine then you can work out if you want it different.

[hiline]

i might look big and dumb 8O 8O

but sometimes i do turn the brain on style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif :wink:

[sclarke]

Originally posted by hiline
i might look big and dumb 8O 8O

but sometimes i do turn the brain on :lol: :lol: :wink:

Nope you look big and smart and you remove the brain when you go bush....lol...

I look simple and quiet and i DO TAKE MY BRAIN OUT......

[hiline]

see you sunday style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

[sclarke]

That you will.....

Ohhh i might not be in the Fender thou... bugger.. i'll come visit you if i dont take it.....

[hiline]

if i'm lucky i'll get to take the rangie as well style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

[JohnE]

As Sclarkey said practice makes perfect.
When i did my evening course, they asked us to bring in a project, I needed a new floor and spring hangers and so on for my trailer so that was it. A whole new learning curve, I did all of it with a MIG , very good machines. I borrowed one of a mate to finish the floor at home.
That place at Bankstown were selling a SIP Mig for $700 gas/gassless. (they may be more now)The same one I used at the course. At the end of the day, an ARc was a better proposition and cheaper. I have fiddled and practiced with it, plus talked to a few people locally and the main thing I found was using the right rods i had a bit of trouble with the pink ones not the right setting sticking and so on. The satincraft 2.5mm were suggested and thats all I use now. I have done two repairs on the broken window lift arms on the disco using it.
As my welding teacher said, if your not sure how good the weld is hit it hard with a hammer if it breaks grind it and do it again.
Keep your eyes open Bunnings and the like have good sales on every now and then and you can get one of those GMC at a good price(less than a tank of fuel) They sell the telwins too.
If you can borrow one, get someoen to show you how and practice before you buy.

john

[sclarke]

Finished.......

See the pix....

http://www.aulro.com/albums/album329/defender_slider_finished1.sized.jpg
http://www.aulro.com/albums/album329/defender_slider_finished2.sized.jpg
http://www.aulro.com/albums/album329/defender_slider_finished_hardcore.sized.jpg
http://www.aulro.com/albums/album329/defender_slider_finished_frontmount.sized.jpg
http://www.aulro.com/albums/album329/defender_slider_finished_rearmount.sized.jpg
http://www.aulro.com/albums/album329/defender_slider_finished5.sized.jpg


And i have started the rear bar.... see new post...

[hiline]

nice job mate style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

[MacMan]

Dead sexy. I want to make some for the Disco... Still puzzling over how to bend RHS to follow the curve though.

[sclarke]

Originally posted by MacMan
Dead sexy. I want to make some for the Disco... Still puzzling over how to bend RHS to follow the curve though.

There is a bloke selling them in Melb. he advertises in the LROCV magazine....

About $450 i think....

Either way its cheap. just buy his....

As much as i'm a tight ass. some things i buy. its going to be to hard to make it, then i buy it....

you dont have to bend the Disco ones, but they look better bent...

Ask Roverland, i think he knows of a guy making them.

[MacMan]

I am catching the tightarse bug and I enjoy metal fab work too much also. Still, $450 frees up two weekends to go hunting or wheeling...