Thread: Project Roverkill D2a

Originally Posted by igaitcho

Yes the ones i am talking about can go into a blind hole, thats why i really love the things.

Awesome, thanks! Do you recall what size rivnut you used?[/QUOTE]

No worries mate, 6mm threaded nutserts, best of luck with your project. Use 6mm dome head allen bolts, or counter sunk allen head bolts to make your project more aesthetically pleasing. I had normal allen head bolts on it for a while but my mates kept yelling at me to change them because they looked "discusting"... (i have good, honest mates).

Hi Folks, long time no see!

This car has been in storage for 2 years whilst I let life get in the way - but now I’m back at it.

Cue the OM606 – I found this in 2018 and mothballed it, couldn’t believe my luck really (probably less than 100 in Australia). The plan since then has been to put it in my Disco, using the following bits and pieces:

• OM606 turbo motor with HX35 holset
• Mercedes 722.6 transmission from an ML270 (includes bolt pattern at rear)
• Red winches 722.6 to LT230 adaptor plate and spud shaft
• Either a compushift or “Ofgear” gearbox controller, undecided currently
• Baldur systems DSL1 engine controller
• Custom programmed crankshaft signal emulator to retain the standard rover V8 ECU / traction control etc, I have a working prototype

Note: The HX35 is unlikely to be a responsible choice of turbo for this application, however I’m going to do it for the meme.









May as well dive right in.



The first two jobs have been small ones. I mounted up the Mercedes 722.6 shifter module into the center console. I’m currently getting a shroud / cover 3D printed, the aim is to have it look relatively stock.









The other small job was to utilise the Mercedes throttle position sensor. This sensor will feed into the DSL1 ECU, there will be no mechanical connection to the motor. For anyone curious, the DSL1 will take care of the cruise control duties.









Will keep you all posted.

This weekends work.

I 3D modelled a surround for the gearbox shifter unit which blends it into the centre console. It took one or two test prints to make it right, but the end result is great. Expect to see more 3D printed parts in this conversion, the process is just to easy. Please excuse the lighting - I am working under flood lights at the moment as the shed has just been built and I havent completed the electrical fitout.





I have begun to tackle the wiring side of the conversion too. See below image showing the original V8 ECU relocated to the passenger side glovebox compartment, together with the new Baldur DSL1 unit strapped on it's back. As you can see, the plastic structure of the glovebox was cutout to make room for the ECU's.

The idea was always to relocate the original Bosch unit to a higher location than stock - I was never comofrtable with the standard position, granted things would need to go seriously pear shaped in order to have water up that high. Anyway, there will peace of mind now.

If anyone is curious, you can read up on the DSL1 controller here: DSL1 controller

Nice work, keep the pics coming

Hi Everyone.

So, things changed a little bit whilst you’ve been away lol. After some careful consideration I sold the OM606 and purchased it’s bigger and more modern brother, the OM648. For those that don’t know anything about these engines, they are a 3.2 litre inline 6 common rail diesel which were supplied in the mid 2000’s E class estates and sedans. As normal, the euro guys have found ways to make massive power from (no surprise there). My understanding is that these engines were never supplied in Australia, my particular engine was imported from Europe.
The reasons that I went for this engine are as follows:

1. The torque placement is lower in the rev range than the 606. 606’s are known for having little torque until on boost.
2. They create less heat when in large vehicles. A lot of guys seem to be having issues with keeping the 606’s cool in 4WD. This could be especially challenging in Australia.
3. You can include a “popcorn” rev limiter in the tune, sometimes also called “hard cut”. It’s going to sound fully sick in the dunes.
4. These engines were released until around 2007/8. Meaning that they post date the vehicle. This may prove to be a big help when it comes time for the final engineering signoff.
5. It’s different. As far as I can tell this will be the first OM648 discovery 2 in the world.

Further to that, I have also swapped the 722.6 Mercedes box in favour of an 8HP70 unit (8 speed auto from a BMW X5). The gearbox will be controlled by a “TurboLamik” TCU – Google for details. I have a friend who has an 8HP / Barra discovery 1 who gave me a demonstration of the 8HP + TurboLamik combination, It’s truly awesome.
As you can imagine this change took a lot of thought, but I am already happy with my decision. I would be regretting my decisions if I didn’t make this call when I did. This engine and gearbox combo is expected to perform very well and will likely serve as a modern and respectable retrofit to the classic D2.

Here is the engine when it arrived to Perth.







TurboLamik transmission controller to manage the 8HP70. Also seen is the DCT sequential style shift to be used to run through gears which will be mounted in the factory gearshift location.





Treated myself to a hoist in the meanwhile. Never realised how much I needed one lol.













Foreshadowing…



Started to mockup all of the mounts. Transfer case mounts had to move back approx 60 mm.





















I’m this deep already. May as well just restore the chassis too eh?





















Chassis painted and re-assembly begins.

Engine mounts welded in for the final time.









Mock fit-up with the body. Looking good.





Got a chance to begin the exhaust. 3” from turbo back. Turns into 3.5” just after the transfer case. No, it does not need to be that big. Yes, I did it anyway.







Fuel supply sorted. The stock tank supplies an aluminium surge tank. A Bosch 200 series pump collects from the bottom of the surge tank and supplies it to the high pressure common rail pump.
I also mounted an oil cooler for the transmission. It’s not in the most favourable position I know. We will see if it needs a guard or to be relocated entirely down the track – time will tell.









At this point it would be rude not to also paint the engine bay…

















So that’s where I’m at. Here is what’s left:

• Hookup transmission cooler
• Finish power steering plumbing
• Mount body on chassis
• Coolant hoses
• Mount water to air intercooler + front radiator
• Aircon lines
• Turbo oil feed / drain
• Propshafts
• Wiring

Currently aiming to have this vehicle on the road by middle of January 2025, we’ll see if I can pull it off!

I think I followed you on Instagram today to watch this build! It looks like it will be a great one!

Ahhh Die Schnelle Kafer!

Originally Posted by DieSchnelleKafer

You are crazy!
And I like it!


Great job, pease keep us updated!