Bundalene's Puma project

The cab is now heat insulated. I put 2 layers around the large open space above the transfer box, top and sides and a single layer around the front of the tunnel and across under both front floors beneath the plastic guards.

The material I used has a heat rating of R3.5 and is 8mm thick. Once formed into a shape and taped on it appears to be quite solid.

I don't know how effective this will be, but it should help keep the cab a bit cooler.

This was a bugger of a job and took far longer than anticipated. I was considering running the material up the firewall but don't think I will gain much.

I think the biggest source of heat into the cab is through small holes and gaps.




Doesn't look that pretty, but no one else will ever see it.

http://img824.imageshack.us/img824/8909/dscn0187z.jpg

Uploaded with ImageShack.us





This first piece to be installed was the area of double thickness. The only mechanical support was a piece of aluminium angle attached to the protruding bolts of one of the seat rails.

http://img41.imageshack.us/img41/382/dscn0179u.jpg


Erich

This is what hides behind the Puma dash. Pics taken with the dash removed. I have removed this to rust seal and then sound deaden the inside of the cab.





Right side

http://img152.imageshack.us/img152/6848/dscn0212.jpg





Center section

http://img831.imageshack.us/img831/8981/dscn0211s.jpg




Left side

http://img707.imageshack.us/img707/5136/dscn0210o.jpg


On a good note, Land Rover have replaced all the standard press coolant hose clamps with alloy clamps on all areas there hoses are connected to alloy components. I am in the process of changing all hose clamps with stainless clamps

On the TD5, the likes of the hose to the temperature sensor housing failed on a regular bases due to these clamps.

Also, I like the decent heads on the screws securing the floor panels.



I started on the firewall repair around the lower section of the drivers door. This entailed removing a section of firewall from one I had out the back of the shed. Several AULRO members may recognise this item.:D:D




This is the section removed.

http://img813.imageshack.us/img813/739/dscn0226.jpg






I prefer the solid spot weld drills to the mini holesaw type - always use cutting compound.

http://img32.imageshack.us/img32/5259/dscn0221b.jpg




I dropped the body back onto the chassis temporarily and installed the long firewall bolts, to help with correct alignment.

http://img691.imageshack.us/img691/3248/dscn0228bn.jpg



Erich

As a side thought - just check with your insurance company before you put the exhaust wrap on - some have a problem with it.

Coming along nicely though mate



Cheers
Chris

Spent half the day removing the damaged piece of the firewall. Defenders are great, I doubt this section of firewall has changed since 1983. This red one is out of a 2003 Defender.

We did try to slide hammer the damage out but this just got too hard.





http://img269.imageshack.us/img269/3960/dscn0251y.jpg






All fitted like a glove. The section is bolted back onto the B - C pillar section and onto the chassis. I took lots of measurements and all seems to be good.



I unplugged all controllers I know of - the ECU, the Imobiliser and the Wabco ABS controller before starting to weld the section back in.




http://img705.imageshack.us/img705/5892/dscn0258tc.jpg



Erich

As always, your work is ****ing excellent:)

Good to see some of the old red machine being used. :D

Quote:

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Originally Posted by Xtreme

Good to see some of the old red machine being used. :D

---

Hi Roger,

YES the red car lives on in at least 4 vehicles that I know of, This one, a 2000 model 130, a 100 inch wheel base and a D2 update.


I gave a hint a few of posts back.



The top of the firewall was too difficult to ever starighten and re-use, so I did the next best thing.


Lucky for me I was able to rescue and keep it in my graveyard of spares.

Erich

Quote:

---

Originally Posted by Bundalene

Hi Roger,

YES the red car lives on in at least 4 vehicles that I know of, This one, a 2000 model 130, a 100 inch wheel base and a D2 update.


I gave a hint a few of posts back.



The top of the firewall was too difficult to ever starighten and re-use, so I did the next best thing.


Lucky for me I was able to rescue and keep it in my graveyard of spares.

Erich

---

Yes, I picked up your hint Erich.

Mechanically it was a fine vehicle, I'm glad that there are are few people benefitting from it.

Must catch up with you some time and get some more info.

That puma is going to be a ripper when you finish your excellent work on it.

I found a bit of rust near the lower section of the passenger door support behind the matting. I stripped almost everything off the inside of the firewall, HUGE job. I spent better than an hour trying to remove the air conditioning unit but gave up. I didn't want to damage it. I’d say it is glued in like the Series2 Disco heater assemblies are.




http://img269.imageshack.us/img269/6132/dscn0328i.jpg





I painted the inside of the firewall painted as far as possible, with a rust sealer, should never have a rust problem again in this area.



http://img574.imageshack.us/img574/879/dscn0332w.jpg






Replacing the floor on the drivers side after the panel repair proved a challenge, not the sort of thing to be done too often.







I have started insulating the firewall on the engine bay side.

http://img176.imageshack.us/img176/8470/dscn0336eo.jpg



Erich

Erich,
Is that 'Formshield' you're using in the engine bay ? I'm sure you will be very happy with the result of your insulating efforts. My Isuzu County is much quieter than my 300Tdi 130 and also quieter than the Td5 Defender I had. I also did the underside of the bonnet.

Cheers, Murray

https://www.aulro.com/afvb/images/im...010/11/869.jpg