RRC ute conversion

I was having a think about this and a few things you mentioned earlier.

Just going to list some thoughts, you probably already have considered and chosen a path, but not mentioned...

1. Rear-end. You mentioned aframe boge removal / polyair springs etc. Does your RRC have swaybars?
Some thoughts around this are:
remove bars, keep boge, new balljoint, clean upper balljoint. forget polyairs unless you're going to randomly cart heavy loads or the load won't be 'constant'
by that I mean, you'd be better off with a set of springs more-suited to your application as well as dampers to match.
Ditching the swaybar for the additional articulation - but also again requires spring & damper modifications if you want to get the most out of your suspension - alternatively, you can use a swaybar disconnect - a cheap pin style or the super-duper locking hub style that LRA make for exhorbitant fees.

2. propshafts - I know you said you were looking for non-donut version, and that you currently don't have propshafts that you could use / modify.
It may be worth your while having a couple sent over from the USA from Tom Woods - at least then you know exactly what you will get for your $$$ is top shelf and pretty much unbrakeable. (Tom Wood's Custom Drive Shafts - Tom Woods Custom Drive Shafts Custom Driveshafts Specialist)
I've had local engineering firms make propshafts for me in the past as well as rebuilding and customizing MB ones (which have non-replaceable centre uni's) and Tom's prices for a brand new shaft are cheaper. Hate to say it... but worth thinking about.

3. R380 - is not a bad box, but it's not without it's known issues. Perhaps it is worthwhile rebuilding and performing necessary upgrades to make it a bulletproof unit? Same as the LT230 - they are good for what they are and pretty reliable, but can still do with quite a few improvements to make them 'bulletproof' - more time consuming than financial... stuff like double-row bearing mod on the rear output, crossdrilled gear, maybe an ashcroft atb centre if you have some flash money or something.... I'm just throwing ideas out there - you have the stuff already and don't have to remove it from the vehicle, so you're already more than one step ahead.

Like I said, you probably have already thought this stuff through and have a plan, but it would be interesting to know if you've decided what path you're thinking of taking on the suspension side of things, because the use case for the vehicle is a very specific guideline for suspension choice and modifications(if any).

Interested to know your thoughts. Got any more pics of the shell?

Mercguy

Thanks for the insights, they are certainly a lot of very good options and ideas.

Essentially, the ute will be used as a business vehicle for what I do on the side, as a mechanic. It will house my tools and other gear.

So at this stage, there are no immediate plans to use it in any off-road capacity other than dirt roads of course.

BUT, due to my partners employment, our location can change and we could be living anywhere else and that can change things.

That is why I am trying to keep everything pretty simple. If I can get it to work and be reliable, job done, but I will design the tray/toolbox with the idea that it could be turned into a tourer if mechanic-ing stops or I decide to move it on.

In time though, there will be changes, like a 300tdi conversion, maybe a lift and traction devices.

I am still undecided whether to remove the boge and fit airbags, keep the boge and fit airbags or just hope the boge will be enough to maintain a tray and tools. I was looking the other night in a owners manual and noticed that the kerb weight is around 1900kgs with a GVM of about 2600kgs. So that gives me about 700kgs to play with in terms of fitting a tray and filling with tools, then I need to allow for towing a trailer. But that hasn't included the weight I will remove with the rear section of roof, side panels and rear floor(couldn't imagine it would weight too much). Any input into this decision would be appreciated.

The vehicle itself is a 88 model, so no sway bars to worry about. On that though, I might be getting a 92 model for free and I'm sure that after 90 they had sway bars fitted and I am contemplating the task of doing a axle swap which would have a few benefits; better brakes, more stable suspension and it solves my tail shaft problem. Just a pity the air suspension has been removed, cause that would have been cool!

The one consideration that I have to keep in mind is where I am located. The closest place with access to engineering or machining is 300kay away in Darwin and even then if it can't be done, Adelaide (2700kays) is probably the next easiest. I really don't want the projects budget spent on freight which in most cases can cost as much if not more than what you are purchasing. So keeping it within my available resources is key. And considering this is Toyota town (I get looks as if I am a foreign dictator), those resources are limited.

I am leaving to do a quick trip to Adelaide tomorrow, but when I return, I should be back at work and able to get a couple of fresh pics of where I am up to. And hopefully make some meaningful progress.

As I said earlier, thanks again for your ideas and I hope I answered your questions, even if it was Ross Noble style.

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Konradical. So, without going back to read all posts, have you had a talk with your local LR guru in Katherine namely Dave - Blknight?

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Originally Posted by gavinwibrow

Konradical. So, without going back to read all posts, have you had a talk with your local LR guru in Katherine namely Dave - Blknight?

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Not directly. I know who he is and have briefly spoken.

The job that he does is what I used to do.

I haven't spoke with him regarding this, didnt really intend to, but if he wants to come have a look or offer some advice I am open to that.

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*UPDATE*

Finally!!

Two weeks ago I received the "Approval in Principle" from the MVR and after chasing some answers to questions the approval raised, I finally got to make some progress!

Basically what you see in the pictures is after only three hours of work. I only have a couple of rivots and two bolts to undo and the back section will be off.

The whole issue of finding time is slowing me down. I have been working seven days a week and luckily today was a public holiday, so I could sneak away for a couple of hours.

I was very surprised at how easily the roof came off AND how light it was.

Once the back is off, I will test fit some panels to ensure I get the right cuts.

Hopefully I can make some real progress and get these updates more regular.

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Another update..

So the back section was a bit more than rivots and a couple of bolts. There is stuff left right and centre under there holding it together.

As you can see in the pictures I managed to get it off and started to see where the panels go.

Will need to give the whole floor a bit of rust treatment and remove the years of dirt built up on the chassis.

From seeing this now, I figured I can fit a tray about 1600-1700mm long without any overhang past the rear Bar.

Hope three progress can keep rolling..

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A couple of pictures from today's progress..

Didn't get as much done as planned, but I fitted some new tyres so I can roll it around and I cut out and cleaned the old frame parts that get reused. I then tacked the new 'c' pillars into place ready for the door replacement panels.

Starting to take shape now and I am getting a few comments on it.

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Er, were they nice comments??? :)

Are you going to drop the fuel tank? The rear mounts are a complete rust trap, probably the worst on the whole car, which is saying something.

Funnily enough they were nice comments. A lot of people can't wait to see it finished. Wish they put that enthusiasm into helping..

I didn't plan on dropping the fuel tank, but since you mentioned it and it is really easy to get to atm, I might just do that and get the tank a proper flush while at it.

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I did mine "while I was at it" at that end of the car, and found a hose inside the tank from some long-ago siphoning attempt. You just never know.

So, you live in the North and people are saying nice things about a Range Rover??? Everyone here thinks I'm crazy because it isn't a Prado.