Grommet becomes a Utility, Gone the days of a hard top

[sclarke]

Well i was thinking about making this part of the Members rides, but there is so much to do so it gets pride in the projects area....

So what have we and what are we trying to achieve?

We have a 1994 Landrover Defender Hardtop, 300Tdi R380 with about 320k on the clock.

We are trying to achive a conversion from the Hardtop to a Utility, Not a Tray, but a Tub. Simple really, i just need $$$$$$

Along the way i will be buying stuff and selling stuff, when i get a good deal i'll tell you where i got it from and how much. When i get ripped off i say nothing................

So far i have this..................
https://www.aulro.com/afvb/images/imported/2007/04/302.jpg

And i want it to become this
https://www.aulro.com/afvb/images/imported/2007/02/264.jpg

Well not exactly, i will keep mine White and i will have my own touches.
Alot of idea's i have have been tried and tested on Camila (old Fender)
https://www.aulro.com/afvb/images/imported/2008/12/1189.jpg

Sliders, rear bar and other internal car will be the same......
I miss Camila, But Grommet will be far more fun and turn heads.

So here is what i will be doing over the next 3-1000 months (money permitting)
Convert to a Single Cab ute like the Green one.
Sliders and rear protection bars
Doors may become Series 3 doors due to rust in the Defender doors, but i'll try to fix the defender ones 1st.
Suspension will remain OEM, 130 coils in the front and the rear will remain 110, Shocks will be Koni as i have some in the shed.
Tyres............ for the bush 35" Simex, Street will be 235/85/16 BFG AT's
Rear ARB Diff lock with 130 housing (allready have it) i'll put my Maxi shafts from Grommets Std diff into it.
Endless air and tank from the existing AC compressor
Water tank into the rear, Stainless tank.
And all the normal stuff, GPS, UHF, RFDS radio ect....
Ohh and one day when it becomes avail at the right price... Warn 8274 Himount Winch.
Rear Tailgate will be a custom made swing door, like a Defender and not a Series.


OK, so apart from all the jabbering i have just done. Here is what i have found and started on.

RUST
Grommet has not had a nice time in the anti corrosion stakes.... due to poor design and living near the ocean, grommet has suffered from "Rooted Under Some Tar" Yep good old fashioned Rust. I spotted most of it when i bought him, and knew it would be bad, but like most things you dont know untill you poke around.
I took the Drivers door trim off 1st to try to fix a broken weld on the door frame to find Rust and a bit of it.... Not as bad as the Pass door, its ****ed.
Pix of the Broken frame and Rust...
https://www.aulro.com/afvb/images/imported/2007/02/265.jpg
https://www.aulro.com/afvb/images/imported/2007/02/266.jpg

I will weld this up today and then finish treating the rust (with disrespect)
https://www.aulro.com/afvb/images/imported/2007/02/267.jpg
https://www.aulro.com/afvb/images/imported/2007/04/305.jpg
https://www.aulro.com/afvb/images/imported/2007/02/268.jpg
https://www.aulro.com/afvb/images/imported/2007/02/269.jpg
https://www.aulro.com/afvb/images/imported/2007/02/270.jpg

What did it look like with the door trim on i hear you ask?????? OK, looked not that bad. If your door has some small bubbles on the outside and you look underneith the door and can see some rust...... Dont pull the trim off you will freak.....

they rust here from 2 reasons...... water gets in when it rains and it then starts electrolosis. The frame is steel and the skin is alloy..... 1 big battery with water and acid......
To stop this, well slow it down i have drilled 5x 10mm holes in the bottom of each door, helping with the drains

I then poked around the Firewall/bulkhead
https://www.aulro.com/afvb/images/imported/2007/02/271.jpg
https://www.aulro.com/afvb/images/imported/2007/02/272.jpg

More rust...... that will have to be treated and cut out when i put the Ute roof on it and pull the screen out.

Ok, so i'll keep you all updated on the rust fixing process......

What else have i done.....
I washed it.......

And i bought a Single Cab utility Roof and Rear panel with Glass.

Rear panel with glass is from a Series 3, why??? Stronger than a Defender and a better style of sliding Window.
I have pulled all the glass and runners out and its getting stripped back as the paint is stuffed and someone painted it in hammertone with no preperation...... Grrrr

https://www.aulro.com/afvb/images/imported/2007/02/273.jpg
https://www.aulro.com/afvb/images/imported/2007/02/274.jpg

So when the roof turns up i'll show you pix of it then i can start stripping Grommet.

[ladas]

Love the Pussy, is she / he the QC manager

[sclarke]

Jaguar is more than QC, he is the brains of the whole company..........:o

[D110V8D]

Love the Pussy, is she / he the QC manager

:D Yeah, if that cat can get out of the car when the doors are shut the gaps are up to standard!:D :D

[sclarke]

I welded the door up yesterday and finished treating the rust on the RH Door, then fitted the trim and the window winder from the pass side as the drivers side was routed.
I then pulled the pass door apart and pulled the door skin off to the 1/2 way mark and scrapped all the sand and rust out and then knocked the dints out, the dints i did not get to flash as alloy stretches and it was a beast to get even half ok.
I then cleaned the rust up and treated it and drowned it in wax stuff.....

Today i will pull the dash out to fix the wiper spindle......
YAY.....

[sclarke]

Today i completed the following, Replaced the Windscreen wiper Box and the wiper arm (broken)

Then tackled the Master Cylinder for the Clutch, not an easy job, but took only 1 hour, then 10 mins to bleed it.

Then replaced some missing bolts and thats about it....

[sclarke]

Sunday was a slack day of me researching many other options to what i want and can afford.....

But with the help of others i have found this..................

Ex Aust Army 110 Full canvas........
I need to get it modified to become a 3/4 canvas, but thats no problems. Its more a stop gap until i work out exactly what i want......

https://www.aulro.com/afvb/images/imported/2007/02/207.jpg
https://www.aulro.com/afvb/images/imported/2007/02/208.jpg

I also scored some hoops for the canopy, i could only get center ones, but that is ok, i will cut 2 of them and make them longer to make the front a rear ones...

So i'm starting to get the bits i need.....
All i need now is more $$$$$

Ohh and i finished the Wipers also.
https://www.aulro.com/afvb/images/imported/2007/02/209.jpg
https://www.aulro.com/afvb/images/imported/2007/02/210.jpg

Clarkie

[sclarke]

Today i picked up my Rear Cab panel from the Bead blasters.........

Damn it looks good....
The Alloy has very little pitting and the Gal looks sooooooooooo Sexy... i'm tempted not to paint it.... Just clear coat it.....

Hey..... there is an idea...... Clear coat all of Grommet.......

https://www.aulro.com/afvb/images/imported/2007/02/188.jpg
https://www.aulro.com/afvb/images/imported/2007/02/189.jpg
https://www.aulro.com/afvb/images/imported/2007/02/190.jpg

That is my other QC manager......Rocco.......

I'll get some Etch primer on it this week, or weekend...... mmmm soon i hope........

Who did it i hear you ask??????????????

Vision Speciality Blasting, 68 Parkhurst Drv, Knoxfield, Victoria
03 98010733

They Sand Blast, Bead blast and cater for all kinds of metals and plastics... While i was there they were doing a Budda Statue and a HK Monaro and a Vespa.

What did it cost i hear you ask????
$50............ Yes $50....
How in hell can you strip any panel with sand paper or chemicals for $50???

I asked what a complete car would cost...... $1400 That is damn cheap, that is not the outer panels either.... Engine bay and Boot...

Clarkie

[D110V8D]

Tidy......Very ****in tidy! *In best Pando(2 hands) impersonation I can do*:D :D :D

[sclarke]

Saturday morning i got very excited............
LRH was coming down to take posession of the Roof and the roof rack was going for a Trip to Sydney also.

So out with the 10mm and 13mm sockets and ring spanners.

3/4 hour later i had the roof unbolted.

Barney turned up just in time to give me a lift.

Now it looks like this..............

https://www.aulro.com/afvb/images/imported/2007/02/102.jpg
https://www.aulro.com/afvb/images/imported/2007/02/103.jpg
https://www.aulro.com/afvb/images/imported/2007/02/104.jpg
https://www.aulro.com/afvb/images/imported/2007/02/105.jpg

I'm going to go out now and see if its cooled down enough to paint the Rear cab panel in etch.

Updated 2 hours later

I went out and etch primed the rear cab. then thought what the hell and primed it at the same time. i need to fix a few things on the cab, and i will reprime those area's later. Here is the finished cab and i fitted it just to make it look more like a Ute.

https://www.aulro.com/afvb/images/imported/2007/02/106.jpg
https://www.aulro.com/afvb/images/imported/2007/02/107.jpg
https://www.aulro.com/afvb/images/imported/2007/02/108.jpg
https://www.aulro.com/afvb/images/imported/2007/02/109.jpg

Clarkie

[sclarke]

Roof turned up today, So i fitted it to see if all lines up.

Well it does and now it is a UTE.......... YAY.....

Paint time now

https://www.aulro.com/afvb/images/imported/2007/02/80.jpg

Roof in the Box it was packed in..... Thank you for looking after my roof.

https://www.aulro.com/afvb/images/imported/2007/02/81.jpg
https://www.aulro.com/afvb/images/imported/2007/02/82.jpg
https://www.aulro.com/afvb/images/imported/2007/02/79.jpghttps://www.aulro.com/afvb/images/imported/2007/02/78.jpg
https://www.aulro.com/afvb/images/imported/2007/02/83.jpg
https://www.aulro.com/afvb/images/imported/2007/02/84.jpg

Bring on the weekend

Clarkie

[ciapek]

Keep it coming Clarkie, this would have to be one of the more exciting threads that I have read for quite some time.....A 4x4 Ute is Born....Oz Style........Good On Ya ..........

I'm getting some deep inspiration here to start something of my own.....:eek:

[easo]

So is it a series back?

[BigJon]

Looking good. You are giving me inspiration to convert one of my Series LRs from traytop to ute back.

[MacMan]

Effin outstanding!

[sclarke]

Shanks.....

paint this weekend if all goes well...... might paint the roof also, its a bit ratty

[wardy1]

Now that he's somewhat 'abbreviated'...... do we call him a her?

GROMMETTE?

:wasntme:

Great work Clarkie

[sclarke]

This weekend i got excited and pulled Grommet apart again. He is not a ute anymore......

So i pulled the Windscreen out and started the rust repairs on the Bulkhead and i polished the roof..... wow.....

I cut the rust out of the bulkhead, welded a new plate in, Ground it back, added some filler for good measure, then primed the panel and a quick sand and top coat......

Now.... one problem... the Defender did not have a paint code so i went to the paint mob and he Guessed the colour......lol

Its close.... NOT.... but will do, you wont pic the colour diffence when its covered in mud.....

https://www.aulro.com/afvb/images/imported/2007/04/304.jpg
https://www.aulro.com/afvb/images/imported/2007/02/33.jpg
https://www.aulro.com/afvb/images/imported/2007/02/34.jpg
https://www.aulro.com/afvb/images/imported/2007/02/35.jpg
https://www.aulro.com/afvb/images/imported/2007/02/36.jpg
https://www.aulro.com/afvb/images/imported/2007/02/37.jpg

The pix make the while look really out, but its so close a polish might make the difference.

[hiline]

what paint code you after ???

if its chawton maybe i could help :D ;)

[sclarke]

Got the new colour and painted it Thurs night. Alpine white
i'm assembling it this weekend so more pix to come

[sclarke]

OK,
Due to the rush to get it on the road i have been spending more time on Grommet than any woman would like.......

Then i had to go to Morwell last night for a party, got home today at about 1pm and got back into it.

So.....
last week i repainted the firewall/bulkhead and the rear cab.

https://www.aulro.com/afvb/images/imported/2007/03/270.jpg
https://www.aulro.com/afvb/images/imported/2007/03/271.jpg
https://www.aulro.com/afvb/images/imported/2007/03/272.jpg

Then yesterday i fixed the rust that was on the Gal runners on the tub top, or waist height for those with a wagon.
Then i painted it also.
https://www.aulro.com/afvb/images/imported/2007/03/273.jpg

Then today i re-assembled the whole thing.
Screen back in, Rear cab on and glass and new slides and trim fitted, then the roof and all the seals.
i needed to adjust a few things with a big hammer to make it look right.
The 4 brakets that hold the rear cab to the rear bulkhead came up spanky.....
https://www.aulro.com/afvb/images/imported/2007/03/274.jpg
https://www.aulro.com/afvb/images/imported/2007/03/275.jpg

So now it looks like this.............. 90% complete. Needs the tailgate sorted and the corner glass fitted.
https://www.aulro.com/afvb/images/imported/2007/03/269.jpg
https://www.aulro.com/afvb/images/imported/2007/03/267.jpg
https://www.aulro.com/afvb/images/imported/2007/03/268.jpg

Now the Negative to a ute conversion......... NO ROOM.
the series back kills an extra inch of room so the seat is not as far back as i would like. time will tell if this is going to crap me off. if it does i will replace the rear cab with a Defender 110 or 130 one.
https://www.aulro.com/afvb/images/imported/2007/03/276.jpg

1 week until its registered............. YAY

[rangieman]

it,s realy looking great mate:D

[incisor]

great job mate....

[JDNSW]

Looking good! What are you doing about the upper seat belt mounts? There were several different solutions to this in the Series cabs?

John

[sclarke]

Ahhhhhhh the old "seat belt mounting trick"
I have the original Hardtop ones, well a set from a hard top, well would you believe a boy scout with a pocket knife.
I have cut them and rewelded the brackets to suit the cab. i'll post pix tommorow when i take some pix.

Tailgate has me thinking, Drop down or swing out???
or get a drop down and make it swing to look retro??? then i can use the std fender catch.

[LRHybrid100]

Looks good mate,

the tailgate show be a swing away conversion I recon.

LRH

[sclarke]

ok Seat belt mounts as requested.........

not a detailed pic, but an idea on what i did.....
https://www.aulro.com/afvb/images/imported/2007/03/262.jpg

then i put the glass in today and pulled the bull bar off and put the STD bumper on with the tow eyes.
https://www.aulro.com/afvb/images/imported/2007/03/263.jpg

https://www.aulro.com/afvb/images/imported/2007/03/264.jpg
https://www.aulro.com/afvb/images/imported/2007/04/308.jpg

Next is the clean up and then the tail gate.

[sclarke]

Today i picked up my tailgate.
i was going to cut down a Wagon door, but then the handel would be in the wrong spot for the right look.
So i opted for the Series 2/3 tailgate.

Its grown on me, i like the look of it.

But do i hinge it like std and have it folding down??? or do i go the Mod look and have it swing out???

if i go swing out, i can use the Std lock and cut it down so it has no outer handle or keylock (i have a spare as i sold the one from Grommet).
Or do i use the pin style the Series had and have it only on the LH side??

https://www.aulro.com/afvb/images/imported/2007/03/257.jpg

i have it mounted for now with the lower hinges from a Series 3 chassis, i cut the old cross member up and have used them as bolt on for now. this is only to get an idea on what i want.

https://www.aulro.com/afvb/images/imported/2007/03/259.jpg
https://www.aulro.com/afvb/images/imported/2007/03/258.jpg

So fold down or Swing out???

[rangieman]

fold down then you can use it as a table plus if you get a long load the tail gate just folds down a bit hard for a swing door to stay open

[MacMan]

I reckon fold down would look better, but unless you can drop it all the way down you'll get the sheets with it reaching over it to put things in the back or remove them once the canvas is on.

Love your work!

[Phoenix]

another vote for fold down, 90% of the time it is more usefull, and much easier to drive with it open for long loads, unlike the swinging door, and it also can't swing closed and hit you.

[sclarke]

Today i fitted the Galvenised Lock plates for the top and then i fitted the tailgate and welded the hinge brackets on.

bummer i painted the top gal strip last week... now i have shiny pop rivets......

https://www.aulro.com/afvb/images/imported/2007/03/249.jpg

Special weld...... ohh my Mig is my friend....

https://www.aulro.com/afvb/images/imported/2007/03/250.jpg

[sclarke]

Well its finished....... Kind of.... need to get it on the road and then start to make it tough....

Last night i painted the tailgate and painted the rear cross member.
https://www.aulro.com/afvb/images/imported/2007/03/234.jpg
https://www.aulro.com/afvb/images/imported/2007/03/235.jpg

Then i fitted the Tail gate
https://www.aulro.com/afvb/images/imported/2007/03/236.jpg
https://www.aulro.com/afvb/images/imported/2007/04/356.jpg

I was worried there would be too much Galvenised parts on the back, but by painting the Gall top strip on the tail gate it made it look right, blends in and the catch's and hinges look right. Not to much gal in my opinion. if i painted them it would look funny i think....

Then i cleaned her up and drove up the road to the local park and took some full pix.....
I'm very happy with the result....

https://www.aulro.com/afvb/images/imported/2007/04/303.jpg
https://www.aulro.com/afvb/images/imported/2007/03/231.jpg
https://www.aulro.com/afvb/images/imported/2007/03/232.jpg
https://www.aulro.com/afvb/images/imported/2007/03/233.jpg
https://www.aulro.com/afvb/images/imported/2007/03/210.jpg

So thats it for this thread.... next one will be the Mods on Grommet.....
Thanks for watching and your idea's...

Clarkie

[sclarke]

As requested by my fellow Viewers, Where i got all my parts and costing and time frame.....

OK
You need the following.........

Defender, County or Stage 1 or series....... if its not a hardtop 3 door then you will have to find a hard top rear tub....

Then you need to find a roof that suits that model... i have a Defender so i sourced a 2nd hand Defender 110 Single cab roof from "British Off Road" in QLD. Ph 07 54451094

Rear Truck cab is from a Series LR, i sourced it from "Fred Smith Automotive" in Bayswater, Vic

Then you will need all the rubbers, and trim and brackets.... get the brackets from the guys you get the roof and rear cab from.

New rubbers, window runners, and misc new parts i got from "Fred Smith Automotive"

Tailgate and fittings from "Fred Smith"

Now the cost for the parts......
Roof $350
Rear cab $150, Bead Blasting $50
Tailgate $70
Rubbers, Runners and misc parts $400-600
Paint............. i can do my own so it cost about $300 if you paid someone else about $1000-$1500
Labour...... roughly 250 hours....... @$50 per hour $12,500

So if you pay someone else to do the conversion for you it could cost as much as $15k...........

if anyone wants me to convert there County or Defender into a ute and to make it nice i will do it for $5k.

If i was to sell grommet today i would ask over $12k, if i got it that would be another case......

The people i bought parts from were very helpfull and i only had one PITA, that person i wont mention. But i highly recommend British Off Road for parts in QLD and Fred Smith in Vic.

There you go, you can convert your Fender into a Ute in 6 weeks.

Clarkie

[gj]

Hi clarkie it has turned out a great job. Grommet must be pleased. Do you mind if I ask where you bought the roof and rear panel you have the prices but not where from. I was thinking of doing the same to my 110 . Thanks and once again it is great job
Cheers
Jamey

[sclarke]

Yep, its all in the above post....

I sourced a 2nd hand Defender 110 Single cab roof from "British Off Road" in QLD. Ph 07 54451094

Rear Truck cab is from a Series LR, i sourced it from "Fred Smith Automotive" in Bayswater, Vic

The Series cab is stronger than the Defender one, but you loose some backwards movement in the cab. Next time i would go a Defender rear cab.

Regards
Steve

[Dave110HardTop]

Hey Steve,

Noticed in later photos you are now running simexs?
What size? any modes required? Any rubbing?

I think the Hardtops came with firmer springs as standard.

Definately like the ute conversion.. but not this year :-)
Damn tempting though.

Thanks

Dave

[sclarke]

Hey Steve,

Noticed in later photos you are now running simexs?
What size? any modes required? Any rubbing?

I think the Hardtops came with firmer springs as standard.

Definately like the ute conversion.. but not this year :-)
Damn tempting though.

Thanks

Dave

The Simex are 32" but roll out at About 33.5"
No rubbing, no mods needed
Hardtop springs are the same as 110 wagons.

I have Std Rear and 130 front coils

[LRHybrid100]

Hey Clarkie,

What are the specs on the D130 springs?

Also whats your bump stop distance with the D130 spings / bar / winch?

THX

LRH

[sclarke]

Hey Clarkie,

What are the specs on the D130 springs?

Also whats your bump stop distance with the D130 spings / bar / winch?

THX

LRH

Let me measure this weekend.
Springs are the Genuine LR HD 110 or 130 springs, part number is 9877 or sumthing like that....

[WOLLAPIT85]

And look at it now.....:blink:
Black and white and all muddy...

[paulthepilot_5]

Hi Sclark, How did you modify the seatbelt mounts to fit the Ute Cab, I am converting Yellow Pezza into a Ute and I am was going to use the hard top mounts as well, but they don't quite fit, Looks like there is some re-fabrication involved? :(

Cheers
Paul

[sclarke]

Hi Sclark, How did you modify the seatbelt mounts to fit the Ute Cab, I am converting Yellow Pezza into a Ute and I am was going to use the hard top mounts as well, but they don't quite fit, Looks like there is some re-fabrication involved? :(

Cheers
Paul

Yeah, i just cut and remade them to suit the Single Cab ute..... not a hard job, easier than the whole conversion really.....

i cant remember which part i cut.... the top or vertical part......

[paulthepilot_5]

Ok cool, I'll muck around with it a bit and see how i can cut the least amount of meat off it.

[VladTepes]

Great thread Clarkie.

I am planning to do it slightly differently and convert my ute to a ute.

(It's currently a tray top)

All I need (I think) is the 110 tub.....


anyone ?