Thread: Cookie Monsters Puma D90 Build

Nice 90. I'm partial to them myself
What colour is yours?

Thanks Toxic.
The colour is Corris Grey Metallic.
Cheers Cookie

Mine is Orkney grey, looks like yours is a shade darker though.

We need more pics!
My defender is in getting some repairs, so I need to live vicariously through others!

Ok, so here is the start of the drawer system build. I have basically copied the commercially available design of a single 750mm wide x 1000 deep x 220 high drawer. I used 2mm aluminium for both the frame and the drawer and had a friend fold and weld them up.

First up though I wanted to make the rear a little more dust proof, so run a bead of silicone along the sides of the rear floor area where the floor is riveted to the wheel arches.
I had found that wisps of dust had already started to show themselves, even after some very light gravel road use !

[IMG][/IMG]


First job was to attach the 220kg rated full extension runners to the frame. The holes were marked onto the frame and 5mm dia holes drilled through.







The same was then done on the drawer, allowing for clearance both top and bottom. I had a diagonal 'set' folded into the base of the drawer to strengthen it, as 750 x 1000 is a large area for 2mm aluminium and I didn't want to use a plywood base in the drawer to strengthen it.





Once the runners had been fitted, I then transferred the positions of the rear seat locating holes and the tie down mount positions on the passenger side of the car onto the frame. The seat mounts & tie down mounts would secure the frame onto the floor and the side of the wheel arch.

A packer was made from the 17mm ply that I had bought for the shelf, to space the frame out slightly so that the drawer would clear the rear door frame.



Floor and side mounting holes for the rear seats


Trial fitting of the assembled frame & drawer








Cheers Cookie

Hi all,

Just a plug for my build thread over in the Projects and Tutorials Section

Hope this link works:

http://www.aulro.com/afvb/projects-t...d90-build.html

Ill be covering the build up of my D90 as a touring vehicle. Items ill be fitting include:
Aluminium drawer system
ARB bullbar and Warn magnum 10k fitment
On board compressor
Custom switch panel
Custom drinks bottle holder
Fixing up a second hand roof rack
Dual battery install
IPF LED Spots

and plenty more along the way...

Hope you can pop in and say gday.

Cheers Cookie

Looking good mate. Look forward to seeing it at Melrose next year...

Originally Posted by Tombie

Looking good mate. Look forward to seeing it at Melrose next year...

Thanks Tombie , yes we should be there as it was s great weekend this year. We are also members of the SA Register now, so hoping to get a bit more involved involved.
Cheers Cookie

Mate, it looks great! Very impressed... a hard act to follow!

So, what are the plans for the 90? Sounds like a 'lap' may be brewing?

Cheers, Pete :>)