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Thread: RRC 2.8L CRD Project

  1. #11
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,300
    Thanks for the comments, yes it is a big job as when you modify one thing you find you have to modify three other things to still make things work. but it's all a good challenge.

    I've recently seen a few photos of RRC rollovers and noticed that the junction point or node at the a-pillar and forward roof rail is particularly weak. I'm not fitting an internal cage as these are not easy to get through engineering so I'm planning to reinforce this area over the next few weeks by welding in reinforcing behind the a-pillar to connect into the b-pillar. Would love to hear some of your comments or recommendations on strengthening this area.
    Will post up some progress pics on this.

    Recent update:

    I have started to build in the heater box, which will require the slight modification of the the dash. Also made a custom air filter box from aluminium to fit a Donaldson Powercore air filter, these are excellent in dusty conditions, while providing plenty of air flow as well. I will post up some more photos of the next few days.

  2. #12
    Join Date
    Aug 2016
    Location
    Brisbane
    Posts
    233

    A-Pillar Junction

    Hendrik,

    Can you post up some pics of the A-pillar junction so I know what I'm looking at??

    Cheers,
    Tricky

  3. #13
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,300
    Ok here are some photos of the A-Pillar and front roof section that I will attempt to strengthen over the next few weeks:
    IMG_2412.jpg

    IMG_2414.jpg

    Also, here are some photos of my custom aluminium airbox that will house the Donaldson Powercore air filter. Plan is to run the aluminium intake pipe on along the RHS of the engine bay and run a RHS snorkel.
    IMG_2418.jpg

    IMG_2411.jpg

    Finally, I have also done a test fit of the colorado heater/air box to be fitted under the dash. The fan inside this thing is huge, so expecting much better heater and air con performance compared to the old RR system.
    IMG_2416.jpg

    So plenty to do over the Xmas break, I plan to finish the install of the heater/air box and also complete the A-pillar strengthening.

  4. #14
    Join Date
    Jun 2008
    Location
    Milton, Queensland
    Posts
    1,300
    So it's been a while since my last post, I've had a number of other things on but still managed to get a bit done.

    I've been focusing mainly on strengthening the a-pillars and roof frame, so off came the roof, which makes so much easier to work on. I then drilled out all the spot welds on the piece of sheet that closes the top hat section on the roof frame, so I can add some internal reinforcement. I drilled a rather large hole at the bottom of the A-pillar and then pushed a 20mm 4140 steel rod down the A-pillar, which I bent into shape to go all the way up to the b-pillar, while still allowing access for the roof screws.

    Close up of the steel rod inside the A-pillar
    IMG_2434.jpg

    The steel rod transitions into a piece of angle which fits nicely inside the existing top hat section
    IMG_2437.jpg

    This was taken all the way to the D-pillar and a gusset formed to the back piece of the roof frame
    IMG_2439.jpg

    This was then painted and finished off with 1.2mm sheet spotwelded back into place
    IMG_2441.jpg

    Other side completed as well
    IMG_2535.jpg

    I have now removed the windscreen and the front upper section of the roof frame is also very weak. I intend to reinforce this with a piece of angle that will join back in with the A-pillars. I didn't really anticipate that I'd need to do this much to the body, but at least I get to use my new MIG welder!

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