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Thread: RRC 2.8L CRD Project

  1. #11
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Thanks for the comments, yes it is a big job as when you modify one thing you find you have to modify three other things to still make things work. but it's all a good challenge.

    I've recently seen a few photos of RRC rollovers and noticed that the junction point or node at the a-pillar and forward roof rail is particularly weak. I'm not fitting an internal cage as these are not easy to get through engineering so I'm planning to reinforce this area over the next few weeks by welding in reinforcing behind the a-pillar to connect into the b-pillar. Would love to hear some of your comments or recommendations on strengthening this area.
    Will post up some progress pics on this.

    Recent update:

    I have started to build in the heater box, which will require the slight modification of the the dash. Also made a custom air filter box from aluminium to fit a Donaldson Powercore air filter, these are excellent in dusty conditions, while providing plenty of air flow as well. I will post up some more photos of the next few days.
    Discovery RockSliders
    [URL="https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html"]https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html[/URL]

  2. #12
    Join Date
    Aug 2016
    Location
    Brisbane
    Posts
    236

    A-Pillar Junction

    Hendrik,

    Can you post up some pics of the A-pillar junction so I know what I'm looking at??

    Cheers,
    Tricky

  3. #13
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Ok here are some photos of the A-Pillar and front roof section that I will attempt to strengthen over the next few weeks:
    IMG_2412.jpg

    IMG_2414.jpg

    Also, here are some photos of my custom aluminium airbox that will house the Donaldson Powercore air filter. Plan is to run the aluminium intake pipe on along the RHS of the engine bay and run a RHS snorkel.
    IMG_2418.jpg

    IMG_2411.jpg

    Finally, I have also done a test fit of the colorado heater/air box to be fitted under the dash. The fan inside this thing is huge, so expecting much better heater and air con performance compared to the old RR system.
    IMG_2416.jpg

    So plenty to do over the Xmas break, I plan to finish the install of the heater/air box and also complete the A-pillar strengthening.
    Discovery RockSliders
    [URL="https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html"]https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html[/URL]

  4. #14
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    So it's been a while since my last post, I've had a number of other things on but still managed to get a bit done.

    I've been focusing mainly on strengthening the a-pillars and roof frame, so off came the roof, which makes so much easier to work on. I then drilled out all the spot welds on the piece of sheet that closes the top hat section on the roof frame, so I can add some internal reinforcement. I drilled a rather large hole at the bottom of the A-pillar and then pushed a 20mm 4140 steel rod down the A-pillar, which I bent into shape to go all the way up to the b-pillar, while still allowing access for the roof screws.

    Close up of the steel rod inside the A-pillar
    IMG_2434.jpg

    The steel rod transitions into a piece of angle which fits nicely inside the existing top hat section
    IMG_2437.jpg

    This was taken all the way to the D-pillar and a gusset formed to the back piece of the roof frame
    IMG_2439.jpg

    This was then painted and finished off with 1.2mm sheet spotwelded back into place
    IMG_2441.jpg

    Other side completed as well
    IMG_2535.jpg

    I have now removed the windscreen and the front upper section of the roof frame is also very weak. I intend to reinforce this with a piece of angle that will join back in with the A-pillars. I didn't really anticipate that I'd need to do this much to the body, but at least I get to use my new MIG welder!
    Discovery RockSliders
    [URL="https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html"]https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html[/URL]

  5. #15
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Ok so been a while since I've posted up an update so here goes.

    Finished off the roof frame strengthening by laminating the upper corner where the A-frame meets the roof frame. Also added a plate up top to close everything off nicely.





    I noticed some cracking in the corners of the dash panel (the steel sheet that holds the whole dash together). So I decided to laminate this area to give it a bit more strength:



    Following this work, I picked up the HVAC box work again by mounting it properly. I cut out the firewall section from the donour Colorado as the holes for the air con and coolant lines are all ready in the right place and suited to the box. I then cut out a section out of the RRC firewall to make it all fit. I also made up a new fresh air intake for the HVAC box, and relocated the blower fan so it sits up higher in the dash. This required a bit of poly welding using a heat gun.



    Now that the box was properly mounted, I could refit the factory RRC dash to make sure it all fits with the Colorado HVAC box. I still have to do a bit of stuffing around with the ducting to the demister and the vents, which is a super fiddly job.


    Finally, I was also able to fit the Colorado auto gear selector. For this, I had to make a purpose built box, recessed into the tunnel as the Colorado selector would be way too high if just fitted to the top of the tunnel. I also had to make some minor modification to the auto selector cable bracket on the gearbox, to make sure that the cable angles are not too extreme. I made an inspection plate on the side of the tunnel to allow me to work on the auto cable more easily if required. The only problem now is, that due to the size of the auto shifter, there is no way I can fit a high/low/CDL shifter where it would normally go, so I'm considering using IP67 rated electric actuators bolted straight to the LT230, but I will do that when I have lifted the body off for easier access.





    With the auto shifter fitted, I now need to workout how to mount the Colorado HVAC controls without ruining the whole look of the dash so that will be this weekend's job. I also think it's time to clean up my work area a bit as well, as it's getting a bit hectic!

    Discovery RockSliders
    [URL="https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html"]https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html[/URL]

  6. #16
    Join Date
    Jan 1970
    Location
    In my D2a Ripping It Up
    Posts
    9,588
    Loving this thread keep up the good work
    cheers chris


    My Toy 04 D2a Td5 Manual With Lots of Goodie Goodness
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  7. #17
    Join Date
    Oct 2011
    Location
    Sunshine Coast
    Posts
    803
    Great work!

  8. #18
    Join Date
    Nov 2008
    Posts
    69
    X3

  9. #19
    Join Date
    Feb 2013
    Location
    Ballarat,Vic,Aus
    Posts
    2,387
    I don't think your going to be able to use that dash switch panel. Those switches will all talk to the CAN bus ... you will need to install the body computer in order for the switches to work. I bet you can wire it as normal circuits that if you access the wiring directly to the fan motor.

    seeya,
    Shane L.
    Proper cars--
    '92 Range Rover 3.9V8 ... slugomatic
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    '85 Series II CX2500 GTi Turbo I :burnrubber:
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    '72 DS21 ie 5spd pallas
    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual :zzz:

  10. #20
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    That won't be an issue at all. I have ripped out all the RRC wiring as I will be installing all the Colorado wiring, BCU etc so will just be plug and play. Sure will have to fit things like the Colorado window motors, wiper motor etc, but it's much easier to retro fit that instead of stuffing around with programming.
    Discovery RockSliders
    [URL="https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html"]https://www.aulro.com/afvb/the-verandah/246751-rocksliders-discovery-series-1-2-a.html[/URL]

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