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Thread: RRC 2.8L CRD Project

  1. #21
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Right so I managed to get two weeks off work. I spent one week on a trip to Tokyo, Japan and even saw this mint RRC in the streets.



    The 2nd week I was able get some work done on the project. I started off by mounting the HVAC switches from the Colorado to work the HVAC box. Looks OK for now, there is plenty more leg room compared to the old RRC trim piece that held the switches. The ugly gap between the dash the switch panel will be filled and tidied with a strip that will hold various switches such as Hi-Lo, CDL, Lockers etc.




    I then moved onto the instrument cluster. I need to use the Colorado one for everything to work, but I wanted to keep the square look from the original RRC one. I was able to use the rectangular RRC binnacle that surrounds the original instrument cluster, and made up a backing plate (metal coloured with the blue protective tape in the photo below) in order to retrofit the Colorado one. Once the plate is cleaned up and painted black you will barely even know it is there. The original instrument cowl also fits the new set up, I just have to get a new one as mine has split open.





    Next job was retrofitting the Colorado wiper motor to the wiper system. This was pretty straight forward, as I was able to bolt on the new motor to the mounting plate, by drilling out the old mounting holes and making new ones. I made a protective disk which incorporates the lever arm to the wiper arms.





    Most of the hard fiddly work has been completed around the dash area now, except for the ducting from the HVAC box to the vents which still needs to be finalised. I decided to move back to the engine back and tackle some relatively simple jobs. First was making a new battery tray for the main battery, now located near the firewall on the passenger side due to the layout of the engine loom. The second battery tray will be located on the front factory battery tray on the passenger side.

    New Battery tray


    Battery fitted, yes I did check that the bonnet clears the terminals. Only need to install a securing clamp to hold the battery in place.


    I was also able to test fit the location of the fuse box and ECU, these will be fitted next weekend along with the coolant expansion tank, PAS tank and ABS modulator which will be located on the driver's side.



    Can't wait to get back next weekend and continue on, things are really starting to come together now. Not long until I can pull the body off the chassis for painting of the chassis and underbody.
    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. #22
    Join Date
    Feb 2008
    Location
    Ferntree Gully, Vic
    Posts
    1,491
    Great work. The classic look with a modern touch. RRC 2.8L CRD Project
    We have a select range of products to suit your needs.From radiators,alternators,starter motors,water pumps,battery isolators,solar panels and more.Feel free to email for any enquiries including prices at [email protected] or PM.
    Chris

  3. #23
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Didn't manage to get a whole lot done this weekend, was stuck fixing air con belt issues on my Minx, but still managed to get bit done on the Rangie regardless.

    I made the fitting brackets for the fuse box and the ECU. Decided to go for a sturdy option for the ECU, as it is quite a delicate piece of equipment. Made it out of 1.6mm plate and rolled the edges over with the bead roller. Still needs a bit of panel beating but it holds the ECU quite nicely.





    Next job is to mount the ABS modulator, which needs to sit close to the brake booster.


    I have also had a bit of rethink regarding the position of the 2nd battery. I was initially going to put it on the passenger side in the dedicated battery tray, but I think having two batteries (up to 60kg) on that side of the car might throw the weight distribution out a bit. So I have decided to move the airbox closer to the brake booster, and put the 2nd battery where the main battery used to be. This means I will have the other tray free for the windscreen washer reservoir and possibly an air compressor.



    Hope to post up some more updates next week.
    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. #24
    Join Date
    Oct 2011
    Location
    Sunshine Coast
    Posts
    803
    Iím jealous you just happen to have a bead roller sitting aroundRRC 2.8L CRD Project

  5. #25
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,305
    Got a little bit more done on the weekend, progress has been a little slow lately due to lack of time:

    Fitted the ABS modulator and ran the brake line against the firewall for the LH front wheel.



    Also made a bracket to hold the coolant and PAS reservoirs. I mounted these against the firewall to get it the coolant tank higher than the radiator.





    Next job is to get the TIG welder out and weld up the aluminium piping for the turbo and intercooler.
    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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