Thread: The Redemption Land Rover bobtailed 110 Build

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Found a Land Rover Discovery Front Diff/axles assembly for $80 after finding out swivel balls had bad corrosion pitting and chunks taken out due to rock damage.


Built one assembly out of 2.5 of them and 3 adults and to teenagers learnt how to rebuild and assembly to whole lot one adult apprentice gained the skills to remove a diff assembly and was assessed in the process.

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After 3 months with out access to a welder the teenagers and some of the young at heart started to loose interest once a Business on the north side of Brisbane lent us their CIG 175i Inverter Mig welder to build the front GL extended style shock mounts and install the +5 shocks.

While waiting another 6 months for a welder we designed the tray/front bar and extreme duty roof rack that the back section will attach to a roof top tent later on.

In this time we also begged borrowed and scrapped some donations for steel.

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After waiting the 6 months for a welder CIG supplied us with a CIG Transmig 250i Tig/Mig/Stick welder and Trade tools supplied a trolley to keep the project rolling.

With the steel we had gathered we made some Rock sliders.

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Well we were donated a Pipe bender for the project and knowing how bad they can be we struck up a plan. Pack the pipe with clean white sand and cap the ends then bend the pipe to make the Cage/Heavy duty roof rack light bar.

Epic fail...

So we do the same but weld up a custom metal strap out of 12 mm steel to stop any kind of movement while pipe is bending. Still massive (as we began to call it catastrophic failure...).

Also tried using the next size down than what is meant for the pipe and no luck....

We gave up on the pipe bender and started looking to borrow an electric hydraulic radius bender and in the mean time started on making the custom tray.

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started to build tray and work out layout.

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Traded a carton of beer for the use of a Electric Hydraulic Radius bender to bend front and rear hoops and the upper brace ends.

We then started welding them up and making sure it would still fit and protect the 50" LED Light Bar that was donated.

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We traded the knowledge and a lesson on how to make a front winch bar for a Winch. Which we then installed on our new winch bar.

We have made a stop motion video of this process with instructions for a future video of the basics of how to do it.

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We finished the cage/tray and painted ready for fitting.

Some generous Donors (wanting to remain nameless) wanted to see this project finished plus everyone involved chipped in Financially and put in hundreds of hours.

We received funds to order from Dave and the amazing team at Ashcroft Transmissions in the UK a set of heavy duty CV's and axles. I have got to say that dave and the Team have some of the best customer service I have ever dealt with and have a great product. thank you.

Trimcast Poly Tuff cases were supplied. Massive thank you.

Then we were able to get a set of Superior Engineering Superflex arms and spacers. (Massive thank you to Greg and the Team at Superior for going ahead am making a version that fits Land Rover and fixes the weakness in the Land Rover suspension design. And thank you the Wayne here on the AULRO Forums for helping test the first set and ironing out any fitment issues.