100" Hybrid Rebuild - Defender Source
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  #1  
Old February 26th, 2012, 02:01 PM
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Jeff Payne
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100" Hybrid Rebuild

I got a truck that is in need of a frame swap and some other minor things... It's a Series body on a RRC frame. Part of the package includes a spare frame and a LHD bulkhead. So far I have just started to take it apart.

The goal is to have a very capable trail rig that can also possibly be a daily driver. I want to put 24 spline axles and 4.7x gears, lockers, full roll cage, removable hard top, maybe color change, new suspension...

I am pretty sure along the way there will be many "if you have to ask, you don't need it" questions. I will ask these questions anyways because I want to learn. I am open to people's input on how to proceed in building this monster up since I have never done this before. I don't want to overdo anything but I want to have a rig that has decent street manners and great trail capabilities.

Jeff
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  #2  
Old February 26th, 2012, 02:41 PM
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Jeff. AWESOME! Glad you ended up with this! Can't wait to see your progress.
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  #3  
Old February 26th, 2012, 04:58 PM
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Looks like you are making great progress!
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  #4  
Old February 26th, 2012, 05:45 PM
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Hope to see it at Uwharrie this year
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  #5  
Old February 26th, 2012, 05:55 PM
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Quote:
Originally Posted by rover4x4 View Post
Hope to see it at Uwharrie this year
That's secretly the goal. Not sure how realistic that is though. Fortunately most everything is there.

There will be a bit of engineering type stuff to get the body to fit the new frame. And switching to LHD will add a few minutes of work. I'm hoping it all goes back together smoothly.
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  #6  
Old February 26th, 2012, 09:03 PM
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there are a plenty of brains in the area I am sure would be glad to see you. I really am looking forward to going wheeling, I think that the Defender will start sitting out on these trips.
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  #7  
Old February 26th, 2012, 09:09 PM
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Defenders are alive and well in NC and if they're not, they're going to find a way forward and make it happen.
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  #8  
Old February 26th, 2012, 09:31 PM
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Quote:
Originally Posted by JSBriggs
So what did you tell U-haul you were transporting?

-Jeff
I think it ended up as a Toyota corolla or something! The Series didn't want to go into their system and for some reason it didn't like Range Rover either.

There are lots of brains in the area fortunately. I want to do as much as I can myself and if I get in a jam I can get it to a shop.
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  #9  
Old February 26th, 2012, 09:33 PM
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Usually tell them its for a F150 from the 70's
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  #10  
Old February 27th, 2012, 10:18 AM
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Looks like you have quite the project but a 100" Hybrid should make a very nice trail rig.

Will be very intersted in how this turns out and the seeing the progress.
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  #11  
Old February 27th, 2012, 05:07 PM
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If you are looking for a good way to do the chassis outriggers, look up a 4x4 is born on youtube. Episode 2 or 3 has the frame mods, they end up doing a decent job of hanging the bulkhead outriggers. It should be possible to use off the shelf rover outriggers everywhere, I think that goes a long way to making it look good underneath...

Good luck! I think 100 inch trucks are cool.
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  #12  
Old February 27th, 2012, 06:55 PM
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Awesome. Looking forward to seeing this build!
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  #13  
Old February 27th, 2012, 07:24 PM
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Got the bulkhead off today. Had to cut the two bolts at the bottom because they seized in the bulkhead.

I'm having thoughts of stainless brake lines and galvanizing the frame and bulkhead after all fitting is done. Is that crazy or what? The old frame has so many holes in it that it makes me cringe to think of putting all back together on a something that will rust away. I could go deep in a rathole with that line of thinking but I don't want to see it go through this again.
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  #14  
Old February 27th, 2012, 09:35 PM
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Not crazy Jeff.

Without going too overboard, you should not hesitate to invest 'built to last' upgrades. I only advise that you don't spend too much time/effort on the exterior.

Dents and scratches will only enhance it's looks and ensure you don't hesitate to wheel it...Don't ask how I know.
Currently, I have Beater Truck Envy!

Good luck with the build!
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  #15  
Old February 28th, 2012, 05:18 PM
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Charles Galpin
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Go for it man. We were talking about this over the weekend. My initial thought was a galvy frame was overkill for a trail truck, but the more I think about it, it's a good idea. Yeah you'll beat on it a bit, but the last thing you need is your truck rusting away from the inside out.
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  #16  
Old February 28th, 2012, 05:59 PM
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The inside out rust is definitely worrying. That is the thing that would cause problems in the long run. I was thinking of sandblasting and POR 15 but then the inside would be vulnerable still. I feel like it will never be stripped down this far again so why not do a bit extra to make it last.

That 4x4 is born video has already given me some great info. Thanks ini88 for posting those. Is it ok to use defender bulkhead outriggers with my series bulkhead?
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  #17  
Old February 28th, 2012, 07:02 PM
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I bought the galvy thing. Planning using it wherever safe in my build
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #18  
Old March 5th, 2012, 11:12 PM
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Jeff Payne
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I might be backing off the galvy idea now. If only so I can feel free to make adjustments to the frame in the future without undoing the benefits of galvanization.

I want to do a heim joint or maybe the johnny joint for rear trailing arms. I think they will help articulation a bit but also will help with clearance on the frame at that low hanging dog ear by locating the mount on the side of the frame. Has anyone gained much by lengthening the trailing arms?

Has anyone done anything in the way of moving the front radius arm up to the side of the frame so it isn't as vulnerable down there? I think the bulkhead outrigger might be in the way for that one.

After seeing the carnage on this beater frame it makes me want to relocate both of these mounts

I'm thinking something like this for the rear:
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  #19  
Old March 6th, 2012, 08:01 AM
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Charles Galpin
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I agree with Jeff. I had all the same reservations - you'll beat it up anyway, and if you need to make mods you have to grind off the galvy and that area is now unprotected. But like Jeff says, just cold galvy or paint those areas and you still get the protection on the rest of the frame, including inside.

Of course if you do all the initial fab work before galvanizing then it should minimize how much you'll change after the fact.
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  #20  
Old March 6th, 2012, 08:30 AM
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I have seen those mods on comp trucks over in the UK, so it has been done. Should find something on sites like LR4x4 forum or Devon4x4. Read some of the comments on here about using heim or johnny joints in this part of the country and there are mixed reviews cause they seem to get so chewed up quickly with all the mud/wet conditions.
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