Rear Wheel Carrier for Defender/County

[rijidij]

There’s a lot of different wheel carriers on the market. Everyone seems to have their own ideas of where and how they should mount. Some open with the door and some have to be unlatched and swung out of the way before the door can open. Many are not adjustable for different size tyres. Some use bearings in the main pivot points and some use nylon bushes. Some mount on the vehicle using existing holes and some require drilling some new holes.
I decided to make a new wheel carrier using a combination of the ideas that work best (in my opinion anyway) This is how I went about it………….

I wanted a carrier that mounted using existing holes, and that also opened automatically with the door. I also want it to be strong enough to take a bigger tyre than standard and possibly other equipment as well.
First I measured everything accurately on the back of the vehicle…..in this case, my ’99 Defender and my ’88 County, then drew up a full scale drawing to see how everything would work and order some materials for the job.

https://www.aulro.com/afvb/images/imported/2009/02/1369.jpg https://www.aulro.com/afvb/images/imported/2009/02/1052.jpg

The main mounting bracket is the first part to fabricate.

https://www.aulro.com/afvb/images/imported/2009/02/1370.jpg https://www.aulro.com/afvb/images/imported/2009/02/1371.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1372.jpg https://www.aulro.com/afvb/images/imported/2009/02/1373.jpg

I made sure the main mounting bracket covered the chassis rail right to the top and bottom edges where it’s strongest. The jacking tube is also behind the bracket, so it adds a bit of strength too.

https://www.aulro.com/afvb/images/imported/2009/02/1374.jpg https://www.aulro.com/afvb/images/imported/2009/02/1375.jpg

The main bracket has a couple of smaller brackets that extend under and over the chassis. Probably not totally necessary, but a bit of added strength wont hurt. Defenders with the one piece rear door wouldn’t be able to use the top bracket as the gap between the chassis and door is filled in.

https://www.aulro.com/afvb/images/imported/2009/02/1376.jpg

I used a stub axle at the main pivot point because it’s strong and operates very smoothly, and importantly, doesn’t allow any movement with the use of tapered roller bearings.
https://www.aulro.com/afvb/images/imported/2009/02/1377.jpg https://www.aulro.com/afvb/images/imported/2009/02/1378.jpg

Even though the main bearing point is quite capable of taking the load of the whole carrier, I’ve mounted a small steel bracket on the tow bar bolts to take some of the vertical load. This will prevent any minor vertical movement from being exerted on the door mount. The holes in the bracket are slotted so it can be finely adjusted to the correct height and allow the door to close smoothly.

https://www.aulro.com/afvb/images/imported/2009/02/1379.jpg https://www.aulro.com/afvb/images/imported/2009/02/1380.jpg

Wheel carriers appear fairly simple when you look at them on a vehicle, but there’s actually quite a lot of components that go into making one. I’m just making these in my home workshop, so there’s a bit of time involved with some of the ‘fiddly’ bits.


https://www.aulro.com/afvb/images/imported/2009/02/1381.jpg https://www.aulro.com/afvb/images/imported/2009/02/1382.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1383.jpg https://www.aulro.com/afvb/images/imported/2009/02/1384.jpg

After fabricating all the components, I finally got to the stage where I could start welding things together.

https://www.aulro.com/afvb/images/imported/2009/02/1385.jpg https://www.aulro.com/afvb/images/imported/2009/02/1386.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1387.jpg https://www.aulro.com/afvb/images/imported/2009/02/1388.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1389.jpg https://www.aulro.com/afvb/images/imported/2009/02/1390.jpg

This is the mechanism that allows the carrier to open with the door, shown here in the open and closed positions. In the closed position the swing arm will press firmly against the rubber buffer on the door plate. I think one of the most important things with a wheel carrier is to make sure there is no movement so it can’t rattle or vibrate. The firmness of the buffer can be adjusted by adding or removing washers behind it.

https://www.aulro.com/afvb/images/imported/2009/02/1391.jpg https://www.aulro.com/afvb/images/imported/2009/02/1392.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1393.jpg https://www.aulro.com/afvb/images/imported/2009/02/1394.jpg

The pivot bracket on the door plate is adjustable to allow for slight variations in the door position.

https://www.aulro.com/afvb/images/imported/2009/02/1395.jpg


I’ve made the wheel mounting plate adjustable to allow for different size wheels and tyres. This also allows the wall of the tyre to rest firmly against the vertical section of the carrier, eliminating any movement…….again, I think this is very important. Some carriers have the wheel and tyre sort of hanging in mid air, and if you grab them, you can actually move them by hand, so imagine what’s happening on those giant outback corrugations.

https://www.aulro.com/afvb/images/imported/2009/02/1396.jpg https://www.aulro.com/afvb/images/imported/2009/02/1397.jpg

After trial fitting the carrier to the Defender for the first time, I found I will have to make a slight adjustment as my bigger tyre (255/85/16) nearly hits the tail light in the fully open position. It doesn’t actually hit, but it’s too close for my liking, so I’ll extend the next carrier by about 60mm.

https://www.aulro.com/afvb/images/imported/2009/04/857.jpg https://www.aulro.com/afvb/images/imported/2009/02/1398.jpg

I made it so the center of the wheel was in the same position as the original door mount, but if I extend it by 60mm it wont really affect anything. There will still be plenty of room to grab the door handle without having to squeeze your hand in and the height will remain the same, so you wont lose any rear vision.
Below is a 235/85/16 tyre (same diameter as 750/16…31”) and a 255/85/16 (33”)

https://www.aulro.com/afvb/images/imported/2009/02/1399.jpg https://www.aulro.com/afvb/images/imported/2009/02/1400.jpg



That’s as far as I’ve got for now. I’ll post more pics as the project continues.

Cheers, Murray

[Chucaro]

Great job mate, just in case that you are going into production put my name in your list.
Defender 110 1994 ;)
Cheers

[isuzubob]

Again, top job. Will a Hi-lift with adaptor still fit into the chassis jacking point? Also, it looks like with the 235 the rack might just clear, but not the 255. If, as you say you move it out 60 mm it looks like it wont be a problem.

http://img145.imageshack.us/img145/2475/hilift003ep0.jpg

http://img88.imageshack.us/img88/3051/hilift004ay0.jpg

[long stroke]

Very well thought out Murray:)
Great job:thumbsup:
P.S hope you don't mind us copying that design:whistling:

CHEERS TIM.

[Redback]

I wonder if this could be adapted to fit a Disco:confused:

Exellent job mate

Baz

[Outlaw]

very nice... great tute :D

[weeds]

noice

[rijidij]

Again, top job. Will a Hi-lift with adaptor still fit into the chassis jacking point? Also, it looks like with the 235 the rack might just clear, but not the 255. If, as you say you move it out 60 mm it looks like it wont be a problem.

I haven't tried my jack adapter yet, but I don't see why it wouldn't work.

There is actually enough room between the body and the 255 for a high lift jack to be mounted as it is in the pic. I've been considering this already. I just have to make sure the jack doesn't break the blinker lens when in the open position.
As for using a high lift with the door closed, I will double check the clearance with the 255 on, but I'm pretty sure it will need to be moved the 60mm as you suggest. Thanks for bringing that to my attention.

Cheers, Murray

[Trippo]

top job
I bought a stub axle & hub in November to do the same.
Like the design - might find a similar looking one around soon
Got to finish the off-road camper first. (current project)
Chris

[rijidij]

top job
I bought a stub axle & hub in November to do the same.
Like the design - might find a similar looking one around soon
Got to finish the off-road camper first. (current project)
Chris

Mate, I've got so many 'Current Projects' on the go, I'm surprised I got time over the holidays to do the wheel carrier :D

[sclarke]

Murray, your very talented...

How did you work out the length of the pivot arm for the door?? and its exact positioning?

[rijidij]

How did you work out the length of the pivot arm for the door?? and its exact positioning?

G'day Clarkie,
Basically, on my full scale drawing, I measured the position of the door hinges in relation to the main pivot of the carrier, in the open and closed positions, and how far it 'threw out' the carrier. I could then work out how short I could make the little pivot arm. The most important thing is to make sure the pivot arm, in the closed position, is angled out away from the door so the door pushes it away when opened.

Cheers, Murray

https://www.aulro.com/afvb/images/imported/2009/02/1052.jpg

[rijidij]

Over the weekend I got some paint work done.
Any bare metal was first treated with POR Metal Ready. This eliminates any minor surface rust that may have started to form, and it also coats the metal with Zinc Phosphate to prepare it for painting, including gal and also works on aluminium.
Next, a coat of primer.
And a coat of Anti Chip.
And a couple of coats of auto spray enamel to finish it off.

I'll be fitting it all to the County shortly to see how it all works. Hope I've worked out the angles corectly (fingers crossed) :D

https://www.aulro.com/afvb/images/imported/2009/02/1050.jpg https://www.aulro.com/afvb/images/imported/2009/02/1051.jpg

[LandieMan]

Nice job.:thumbsup:

I'm well impressed with both the engineering and the effort you've taken to document and share it.

Thanks very much.

Cheers, Iain

[rijidij]

I'll be fitting it all to the County shortly .........

Well, the prototype is now fitted on my County. I'm happy to say it all seems to work well.
I'll have my County at the Vic 4WD Show this weekend if anyone is interested in having a look at the wheel carrier. I'll be working some of the time, but you can give me a call on 0438661046 and see what I'm up to.


Cheers, Murray

https://www.aulro.com/afvb/images/imported/2009/04/858.jpg https://www.aulro.com/afvb/images/imported/2009/02/463.jpg

https://www.aulro.com/afvb/images/imported/2009/02/464.jpg

[long stroke]

Lookin swweet:cool:

[County4.4]

Great job
Can I ask where you sourced the hub from ?
Also with the little swing arm on the door are they bushes inside the two metal sleeves and where did you get these if they are?
Thanks

[isuzurover]

Great job Murray. Your fabrication is far neater and more detailed than I would ever have paitience for.

I have never liked that type of spare wheel carrier - all the ones I have seen rattle like anything - but your design looks good.

I also MUCH prefer bushes over bearings (for the main pivot(s)), but that seems to just be me these days...

[rijidij]

Can someone please tell me the diameter of the bolts that hold the spare wheel bracket to the back door of a Puma.

Murray

https://www.aulro.com/afvb/images/imported/2009/05/315.jpg

[dmdigital]

Pretty sure they are M8. They go through to a nylock (non-captive) nut on the inside of the door.

[rijidij]

Pretty sure they are M8. They go through to a nylock (non-captive) nut on the inside of the door.

Thanks Derek,
I thought they would be M8's, but I don't have a spare Puma lying around to check. I'm making up a door plate to suit the Puma for the wheel carrier.

Murray

[rijidij]

Well I've managed to get some more work done on the wheel carriers.
I found out that on Defenders from ~02 have a metal trim which blocks off the gap between the chassis and the body, so this prevents the use of the top bracket.
I've fabricated a new mounting bracket which goes on the inside face of the chassis, but there are no crush tubes at this point, so I've made the bracket in a way that it spreads the load as well as 'gripping' the top and bottom of the chassis. The big door plate is to suit Defenders ~02 to Puma with the pressed steel wheel mount on the one piece door.
https://www.aulro.com/afvb/images/imported/2009/06/1062.jpg https://www.aulro.com/afvb/images/imported/2009/06/1063.jpg

I've made some other changes from what I first made up. I've extended the whole carrier 60mm to the left so there is more clearance between the tyre and indicator lense when it's in the open position, and I've used a heavier tube for the pivot arm.
https://www.aulro.com/afvb/images/imported/2009/06/1064.jpg https://www.aulro.com/afvb/images/imported/2009/06/1065.jpg

Another thing I wanted to achieve was a system where the carrier automatically locked in the open position and was then easy to close again.......I mean easy enough that it doesn't seem like a hassle to close the door. I tried a couple of different things, but this is what I came up with in the end. It's a spring loaded lever with a vertical 12mm pin which locates in a hole in the open position. To close the door, you simply push the lever down. I've never liked those fiddly little pins dangling on a tiny cable. I'll also be using a piece of high density polyethylene on top of the mounting bracket where the pin rubs to prevent it rubbing through the powdercoat/paint.
https://www.aulro.com/afvb/images/imported/2009/06/1066.jpg https://www.aulro.com/afvb/images/imported/2009/06/1067.jpg

https://www.aulro.com/afvb/images/imported/2009/06/1068.jpg https://www.aulro.com/afvb/images/imported/2009/06/1069.jpg

I hope to get one to the powdercoaters in the next couple of days, so we'll see how it comes up.

Murray

[carjunkieanon]

Brilliant. You've had a far more productive day than me.

How much does it all weigh?

[rijidij]

You've had a far more productive day than me.

How much does it all weigh?

Yeah !!!!..........I did bugger all yesterday though :D We all need a day off now and then.

I haven't weighed it yet, but I will when I get a chance. I think it probably looks heavier than it is.

Murray

[dullbird]

mate that looks like one very nicely built robust unit...I only wish you made these earlier before we fitted ours I would of brought one off you for sure:(

[sclarke]

Stupid question...
What is the price your selling them for???

I have a Bearmac one, but wont fit it if yours is a good price...

its to suit a County...

[Dave_S]

Looks great! Nice & strong. Keep me on the list (also a County):BigThumb:

[rijidij]

Looks great! Nice & strong. Keep me on the list (also a County):BigThumb:

I haven't forgotten you Dave ;)


Stupid question...
What is the price your selling them for???

I have a Bearmac one, but wont fit it if yours is a good price...

its to suit a County...

I'm actually in the process of working out what I should charge for them at the moment. I haven't come up with a final figure yet, but I can say they will be $600+.
Anyone who's had a go at making one knows how much work there is in it, and considering the cost of something like a K**mar is $1048 + $170 fitting, you're looking at not much over half price, and for something better IMHO :angel::p

Having said all that, at the moment I have a completed prototype, one finished carrier to suit a Puma which is spoken for, and three more partly completed carriers which can be made to fit County or Defender. One will be going on my County, one has Dave_S's name on it and the other is spare for now.
I am quite busy at the moment with other things which 'should' get priority, but if there is firm interest in these carriers, I might be able to sneak out to the workshop while my wife's asleep (she's a gem really) and finish them off.
If I get good feedback on these first ones I would probably make some more, but it wouldn't be for a while as I really do have other stuff to do.

Cheers, Murray

[troppojon]

put me down for one.
I wouldnt mind one for my 98 defender.
would $600 be powder coated and painted?

[rovercare]

Murray, you work is fantastic, yet again:)

[rijidij]

put me down for one.
I wouldnt mind one for my 98 defender.
would $600 be powder coated and painted?

I'm still costing it out, but powdercoat will probably be $60-$80 extra. Still getting prices, but I'm hoping to get the first one to the powdercoaters tomorrow. It's going on a SVX Puma and the owner has requested black powdercoat.
I'll just be painting the one going on my County, for three reasons......I already have paint, much cheaper than powder, and, although I do like powdercoat, the wheel carrier is pretty well protected from chipping etc being on the back of the vehicle. As long as you don't skimp on primers etc, paint can be pretty durable. I usually treat bare metal with 'POR5 Metal Ready', and I have etch primers if needed too.
I'm going to paint mine in a slightly textured silver grey, just to be different from black, and grey is a sort of neutral colour, so it should go with anything and hopefully look classy........we'll see anyway.

I wasn't happy with the middle striker plate I had, so this is what I came up with. This is for Defenders with the H/R tow bar. I've still gotta work something out for Countys with the vertical tow bar as there's not as much room to play with.

https://www.aulro.com/afvb/images/imported/2009/06/740.jpg https://www.aulro.com/afvb/images/imported/2009/06/741.jpg


I got some of the components zinc plated for some extra rust prevention.
https://www.aulro.com/afvb/images/imported/2009/06/742.jpg

[EchiDna]

tempting Murray, damn tempting... maybe for the second batch :)

[rijidij]

Well, after a lot of work, the first wheel carrier is finally finished and ready to be shipped off to it's new owner........a shiny new SVX Defender.
I've changed the lock pin release lever to anodised aluminium with a black grip, and with black gloss powder coat, it should really suit the SVX.
Anyway, I'm really happy with the finished product and look forward to some feedback from the new owner. Hopefully it all fits up well.

Cheers, Murray

https://www.aulro.com/afvb/images/imported/2009/06/384.jpg

https://www.aulro.com/afvb/images/imported/2009/06/385.jpg https://www.aulro.com/afvb/images/imported/2009/06/386.jpg

https://www.aulro.com/afvb/images/imported/2009/06/387.jpg https://www.aulro.com/afvb/images/imported/2009/06/388.jpg

https://www.aulro.com/afvb/images/imported/2009/06/389.jpg https://www.aulro.com/afvb/images/imported/2010/03/79.jpg

[Dave_S]

Looks fantastic Murray. :BigThumb:

[carjunkieanon]

Looks absolutely brilliant, wish I was that skilled. Your attention to detail is amazing.

Two questions.

Could one be made by running a single bar from the hinge point diagonally to the middle of the door (rather than a horizontal across and vertical up)? You'd lose the strength of the horizontal bar fitting into the striker plate, but it would be a distinctive approach?

How strong is the hub axle?

[rijidij]

Looks absolutely brilliant, wish I was that skilled. Your attention to detail is amazing.

Two questions.

Could one be made by running a single bar from the hinge point diagonally to the middle of the door (rather than a horizontal across and vertical up)? You'd lose the strength of the horizontal bar fitting into the striker plate, but it would be a distinctive approach?

How strong is the hub axle?

G'day,
There's no reason that you couldn't run a single bar on an angle, but, as you obviously noticed, the horizontal bar allows the use of a striker plate in the middle of the chassis to share the load in the closed position.
I did actually consider an angled or curved single bar, but the main point of a wheel carrier on the back of a Defender/County is to save the back door, and reduce the chance of fatigue, so spreading the load was what I worked on in this case.
The stub axle is pretty strong being the same dimension as you would find on a trailer axle. An un-braked trailer can be up to 750kg, so I'd guess one stub axle would be rated to a minimum of ~400kg, not that you'd ever get anywhere near that weight on a wheel carrier. I think the chassis would be the weakest link.

Murray

[rijidij]

Here's the first carrier finally fitted to a Landy.......a shiny new SVX actually.
We've had a couple of minor issues with the position of the door bracket, but we're sorting that out.

https://www.aulro.com/afvb/images/imported/2010/04/644.jpg https://www.aulro.com/afvb/images/imported/2009/06/19.jpg

https://www.aulro.com/afvb/images/imported/2009/06/20.jpg

[EchiDna]

good to see the panels are nice and straight on the SVX! crikey that shiney paint makes em look shockin... unlike the wheel carrier which looks schmick!

[rijidij]

I finally got time to finish off the carrier for the back of my County.
The following video shows how the pivot arm, striker and locking pin work.
The striker and pivot arm both hit against rubber buffers, and the tyre rests firmly on the bottom of the main vertical section, so in the closed position, there is virtually no movement. I've got a couple of trips coming up, so I'll see how it goes.

Cheers, Murray

YouTube - Land Rover Wheel Carrier

[weeds]

top job mate

[dullbird]

very nicely done.....looks like a well engineered piece of kit top job

[justinc]

Well done Murray, detail and finish is fantastic!

You are one very patient and meticulous craftsman, Keep at it!

JC

[Cap]

Just saw this thread... like others have said, fantastic work, very professional and great design idea to boot. :cool:

[Grockle]

spot on mate quality job

[Rudolf]

Stunning, very well done!!!

[prith]

Fantastic work Murray, Just saw your thread, much better than the Mantec ones. Do you have one for a 1990 Defender 110 station wagaon. Planning on using 35 x 10.5 x 15" on my Landy. Do you ship internationally?

[rijidij]

Fantastic work Murray, Just saw your thread, much better than the Mantec ones. Do you have one for a 1990 Defender 110 station wagaon. Planning on using 35 x 10.5 x 15" on my Landy. Do you ship internationally?

I have several components ready to construct some more carriers, but I need to find the time to put them together....I'm just too busy at the moment. I'm hoping to get on to them not long after christmas ????????
I don't see any problem with shipping internationally. I packaged one up and sent it to Sydney, so it's really no different from my end.
When I do manage to get some more ready, I'll post it on here.

Cheers, Murray

[Drover]

Best ever Murray.

Nothing comes close. I am deffiently keen to buy one as soon as they are ready.

What is price for black powder coated version ?

Thanks Grant

[saiken]

I'm interested in one as well!

I love the design of yours, its heaps better than both the beermach and kaymar ones.

Can't wait to see a price and know when your ready to make some.

[Ranga]

Very nice work! Put me down for one on my 95 Defender as soon as they're ready.

[spudboy]

Nice ideas Murray. Looks like you've got yourself a new business venture!

[rijidij]

Thanks for all the positive comments guys. I can't believe that I started this project a year ago.

I have made some minor improvements to the design, and I'm just about to get some components laser cut.........to improve quality and appearance, and to save me a :censored: load of fiddly work and time.

I'm hoping to get some carriers made over the next several weeks. It's a busy time of year, but I'll try to fit them in around everything else.

And just to punish myself even more..........I have just drawn up plans for a wheel carrier to go on the back of a 130 crew cab. As far as I know, there are no carriers available for the 130, so I'm keen to come up with something.

Cheers, Murray

[prith]

Murray,
Waiting for your reply. Do you have one for a Defender 110 1990 CSW?

[big harold]

Watching intently for the 130 spare wheel carrier as mine has just broken for the third time.

[Skiboy]

Congrats on a great bit of gear and a well documented build
SKiboy

[alittlebitconcerned]

I want... no, need one! Much respect. Elegant design and beautifully executed.
So how do I get on the list for one?

[rijidij]

I'm hoping to get some carriers made over the next several weeks. It's a busy time of year, but I'll try to fit them in around everything else.

My appologies for not keeping up to date with this thread, but as I suggested above, time is not something I have enough of at the moment............

Turning this............
https://www.aulro.com/afvb/images/imported/2010/04/643.jpg

Into this, is taking longer than I had hoped.............
https://www.aulro.com/afvb/images/imported/2010/04/644.jpg

And this doesn't help either........not serious, but enough to slow things down for 2 or 3 weeks. :(
https://www.aulro.com/afvb/images/imported/2010/04/645.jpg

Having said all that, I have managed to get one new carrier finished for a Puma, and just freighted it last week. This is the first one including the changes I made to the design, so I’m looking forward to feedback from the owner after it’s fitted so I can confidently build some more.

Price wise, it’s looking like $850 including powdercoat, plus freight.

So, as soon as my thumb is mobile again I should be able to get some work done.



Murray,
Waiting for your reply. Do you have one for a Defender 110 1990 CSW?

Again, sorry for the delay. If you are able to take pictures of the rear cross member and back door of your vehicle, that would be helpful as there are different size mounting plates on the doors of various models and some variations in the chassis/body mounts.


I want... no, need one! Much respect. Elegant design and beautifully executed.
So how do I get on the list for one?

Contact through this thread at this stage is fine. I’m on here regularly. As said above, pictures are good if you can.


Watching intently for the 130 spare wheel carrier as mine has just broken for the third time.

I managed to get a prototype built for a 130 over Xmas and while I was waiting for the laser cutters etc. When I get time, I will start a sepperate build thread for it, but here’s some pics to give you an idea what I’ve done.

https://www.aulro.com/afvb/images/imported/2010/12/1741.jpg https://www.aulro.com/afvb/images/imported/2010/12/1738.jpg

[rijidij]

I feel I must appologise to all who have shown an interest in the wheel carriers.
To quote what I just posted in another thread.........

I do intend to put some more carriers together, but it probably wont be for some time unfortunately. I just have too many other things taking priority at the moment.
I would like to be doing them now, but I simply can't find the extra time I need.
I appreciate your interest. Sorry I can't help you out just now, but I look forward to getting back on to them as soon as I can.

Cheers, Murray

[OrangeZXr10R]

I'd also like to put my name for one, but I'm happy to wait until you have enough time to fabricate more.
Mine is an 02 Defender.

[frantic]

I may be interested next year , I have a 2002 defender 110 wagon. just got to finish and pay for the other jobs first.:D


P.s Why is this not a sticky on the verandah/suppliers thread?

[Shonky]

Put me down for one too - when (if?) you get back into it. :)

VERY impressed with what I see here!

[dullbird]

I may be interested next year , I have a 2002 defender 110 wagon. just got to finish and pay for the other jobs first.:D



P.s Why is this not a sticky on the verandah/suppliers thread?


Becuase he is not a vendor...

Which also means that everyone interested in a carrier should be contacted Riji via PM and not in a thread:)