Defender Tray back - The build

[Graz]

My turn at show and tell. Started this project 2 months ago to replace the tub on the Defender. It isnt 100% complete but i will post further progression.

http://img84.imageshack.us/img84/1820/dscf1601pb5.jpg
Materials were a bit heavy than what i would have liked, but it was all that was on offer. U channels (5mm), Angle iron (2.5mm), Checkerplate (2mm).

http://img167.imageshack.us/img167/6599/dscf1602mr4.jpg
More of the same.

http://img150.imageshack.us/img150/4827/dscf1624gg0.jpg
On underside: Several coats of primer then gap filler. Then, Later a gloss black finish.

http://img329.imageshack.us/img329/9058/dscf1627gd5.jpg
Frontal veiw

http://img507.imageshack.us/img507/5108/dscf1653ko7.jpg
Fabricated Chassis attach points. 5mm wall thickness channel and Stainless steel fasteners.

http://img379.imageshack.us/img379/7199/dscf1656bx6.jpg
The Basic Tray attached to the chassis mount points. Still alot more work to do.


Signed Ben (for Graz) - The Household nerd

[long stroke]

Love it keep us posted!

CHEERS TIM.

[Graz]

http://img135.imageshack.us/img135/2015/dscf1660es2.jpg
A bit more progress

http://img135.imageshack.us/img135/5458/dscf1659na6.jpg
Got me foxed though, how to sort out the fuel tank filler.

[LandyAndy]

Looging good Graz
Andrew

[Outlaw]

Very nice tray... looks strong :D

[Graz]

Finally got the fuel filler sussed. A bit more work on the tray mounting and its finished. Need to have another crack with the spray gun and try and get a better gloss finish.
Next the pod for the 110 Waeco and camping gear then the mount for the trail bike.
Thinking of mounting the spare onto the bonnet as well.

Then ....one power ball so I can go and enjoy it.:tease::beer::clap2:

[LandyAndy]

Hi Graham
LOVE THE ROPE MAN:p:p:p:p:p:p
If you want GOOD(Hafele)roll out drawer slides for the WAECO,I got a price of $113/Pair for 700mm extension,good for 120kg/pair.Getting a price on 550mm tomorrow.
Andrew

[Graz]

At least I used green rope:eek:

[The ho har's]

Is that a celebratory drink for a job well done sitting on the back of the tray:p


Mrs ho har:angel:

[Graz]

Is that a celebratory drink for a job well done sitting on the back of the tray:p


Mrs ho har:angel:

Certainly was. A rather egreeable Cab Sav:D

[cucinadio]

nice job mate ........:twobeers:

[Graz]

30/9/08

[Graz]

The next step of the project : The Camping pod.

http://img402.imageshack.us/img402/8774/dscf1674px6.jpg
Beginning frame fabrication using the lightest possible metal 50X50X3, welding where it touches. :p

http://img509.imageshack.us/img509/2023/dscf1676oy8.jpg
As 3mm ally sheets are being bonded on the outside all welds had to be internal. Dont you just love the new ultra slim angle grinder cutting discs?

http://img72.imageshack.us/img72/7377/dscf1713qd2.jpg
Heavy frame at the back to support 2 Spare wheels, roofrack bar and gantry to lift trail bike on and off.

http://img410.imageshack.us/img410/738/dscf1715jc6.jpg
Shelves to keep SWAMBO happy.

http://img215.imageshack.us/img215/9353/dscf1718zj4.jpg
Didnt have the time nor money to put the ally sheets on, Cost ~$600 and one more sleep until Kalbarri.

[agrojnr]

Just give me a bell when you want the ali done Gaz I might be able to help


Adam

[Graz]

I am currently preparing the ally sheets for the skins on the pod. I intend to bond the ally to the steel frame and only using a few fasteners in each panel to hold them in place while the goop cures.
Interested in anyones opinion as to what goop to use. The aviation glues and sealants I know of are too expensive.
Something like liquid nails is dirt cheap though I dont know if it woiuld be any good. The steel is primed and the mating face of the ally sheets will be etch primed.
Thanks in advance.

[Blknight.aus]

sikaflex....

and we've had the locktite boys out again for a restock and they left us a sample bottle of something new in the metal glue range that allegedly goes on like treacle and will stick almost any metal to almost any other metal and is bragged to be stronger than welding....

I'll check the steel/ally numbers and get the goop number for you along with a cost... (Im guessing not cheap)

[Olive Drab]

love the recessed fuel filler and the recessed guards reallllly cool

[Graz]

More progress for the Toad. Click images for bigger image.

http://www.aulro.com/app/uploads/8953/DSCF1834.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1037.jpg (http://www.aulro.com/app/showphoto.php/photo/12178)

Pod access doors, 3 mm aluminium with a light steel 3 qtr square tubing frame to take torsional loads. Bonded using sicaflex 252 structural adhesive. Preparing to mount gas struts, need more structure as it is bending at the strut mounts. Inherent problems with a production run of one.

http://www.aulro.com/app/uploads/8953/DSCF1835.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1038.jpg (http://www.aulro.com/app/showphoto.php/photo/12179)

The RHS will end up being storage for the camper trailer bits and peices, mid shelf a pantry and lower shelf for tools and recovery gear.

http://www.aulro.com/app/uploads/8953/DSCF1836.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1039.jpg (http://www.aulro.com/app/showphoto.php/photo/12180)

Still got the spare wheel attachement (X2) and the motorbike hoist and mounting to come. (WIP)

http://www.aulro.com/app/uploads/8953/DSCF1838.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1040.jpg (http://www.aulro.com/app/showphoto.php/photo/12181)

Somewhere to keep the beer cool. Will end up holding outbourd motor and camping chairs aswell.

http://www.aulro.com/app/uploads/8953/DSCF1839.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1041.jpg (http://www.aulro.com/app/showphoto.php/photo/12182)

Finally completed the bull bar ex-Wrecker after a head-on. In hindsight it should have been scrapped, as it was a real pain to get straight and fitting the chassis. At the 4x4 show recently, the lightforce rep advised HID upgrade kits will be available for these lights soon. The winch which i aquired from a local (turned out to be a POS) the motor is intermittent and the clutch disengages after one turn. China needs to go into receivership for dumping so much junk on the market.

http://www.aulro.com/app/uploads/8953/DSCF1840.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1042.jpg (http://www.aulro.com/app/showphoto.php/photo/12183)

Installed the Headlight wiring upgrade kit with the additional spotlight relay and wiring. Stuck to the advised LHS guard in the instructions.

http://www.aulro.com/app/uploads/8953/DSCF1841.JPGhttps://www.aulro.com/afvb/images/imported/2008/12/1043.jpg (http://www.aulro.com/app/showphoto.php/photo/12184)

Close-up of the mounting. Was rivetted to braket using monel rivetts, if these work loose we will replace with bolts.

[Sly]

Looks great and well made. All it needs now is some red dust inside.