'87 110 CSW 300TDi Build - Page 2 - Defender Source
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  #21  
Old July 24th, 2013, 11:44 AM
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Diego
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Quote:
Originally Posted by Nomar View Post
This 110 isn't on the Outer Banks now, is it? (your profile)
It will be this Friday when I pick it up from the shop that completed the work.
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  #22  
Old September 6th, 2013, 11:02 AM
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Update:

Been having a bit of hard times making this drivetrain fit. Engine mounts are in the correct locations, used the supplied jig, and verified with measurements.

Problem is the transfer case is hitting the driver's side (right) floor plate. Also, I believe I have the correct crossmember for the R380, but it seems I am missing a few brackets.

Images provided for reference. Any help would be greatly appreciated on how to correct the following issues:

Trans hitting floor (modify floor?)
Missing mounts for trans to crossmember
Rear driveshaft seems too short (modify shaft?)

Or, do I have a short version of the flywheel housing that is throwing everything behind it off?


Thanks, Diego
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  #23  
Old September 6th, 2013, 11:54 AM
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Diego, hit up Robert Davis in Chesapeake/direct him to this thread.

I KNOW he can sort this out.
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  #24  
Old September 19th, 2013, 08:15 AM
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Huge Progress...It's a runner (not driver yet)

Since I have been spending most of my free time on getting the vehicle ready to be driven, have not updated this thread in a while. I'll do so now.

Engine being de-greased and pressure washed.
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  #25  
Old September 19th, 2013, 08:19 AM
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After a lot of trial and error, in and out, back and forth, the engine, trans, and transfer case found their new home.
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  #26  
Old September 19th, 2013, 08:25 AM
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The engine brackets were ordered from Overland Specialties, and with the provided jig, a simple weld in job. The trans/transfer case mounts were a different story. I decided to attached them to the frame rails as opposed to the crossmember.

Old holes in frame were welded closed, and new ones drilled.

With some spacers, and 1/4" stainless steel backing plate, it is a solid install.
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  #27  
Old September 19th, 2013, 08:31 AM
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Radiator lower and upper mounts needed to be trimmed about a 1/2", and the fan is now sitting perfectly centered within the shroud.

All fluid reservoirs needed to be relocated, along with new lines and hoses needed to be fabricated. In all, I am very happy with the results and appearance of the engine bay.
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  #28  
Old September 19th, 2013, 08:34 AM
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Still need to clean up wiring, and reassemble the interior (to include new aluminum were I needed to cut the floor, seat box, and metal surrounds for clearance). At least it will drive down the road.
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  #29  
Old September 19th, 2013, 12:12 PM
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Beautiful!
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  #30  
Old September 19th, 2013, 11:50 PM
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What about the drive shafts? the 300tdi ones are different lengths that the 2.5/200tdi ones.

You also have the wrong seat box and you need the fiberglass 300tdi style transmission cover. How did you sort that out?
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  #31  
Old September 21st, 2013, 10:50 AM
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Quote:
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Beautiful!
Thanks

Quote:
Originally Posted by evilfij View Post
What about the drive shafts? the 300tdi ones are different lengths that the 2.5/200tdi ones.

You also have the wrong seat box and you need the fiberglass 300tdi style transmission cover. How did you sort that out?
Ordering driveshafts from Lucky8 this Monday. Will figure out the trans tunnel area when I get it driving. (looking at fabricating aluminum seat box bump out, and maybe acquiring a fiberglass R380 tunnel. The original LT77 is not too far off, so I might work with it to make it fit).
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  #32  
Old September 21st, 2013, 12:34 PM
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If you have a chance, can you post some pictures of where you had to modify the seatbox? I am almost done with my engine rebuild and then its time to throw in the 300TDI/R380.
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  #33  
Old September 22nd, 2013, 10:05 AM
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Quote:
Originally Posted by red64chevelle View Post
If you have a chance, can you post some pictures of where you had to modify the seatbox? I am almost done with my engine rebuild and then its time to throw in the 300TDI/R380.
I cut 8" from the trans surround and up 2". Plan on fabricating an aluminum rectangular bump out to cover it back up. You may need more or less room depending on the height of the transmission. I placed mine to match the pinion angle of the rear diff. The trans tunnel and bulkhead metal surround have yet to be figured out.
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  #34  
Old September 22nd, 2013, 12:49 PM
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Just a heads up, the front 300tdi driveshaft is the same as a disco 1 or NAS D90/110 and the rear is the same as a NAS 110.

I have a spare fiberglass tunnel if you are interested although I don't see why you could not make one out of aluminium.

The NAS trucks have the flange that goes on the bulkhead as a separate piece. Might make sense to find one of those.
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  #35  
Old September 22nd, 2013, 01:11 PM
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Diego
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Thanks, I'll PM you about the tunnel, and place a WTB ad for the shafts .
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  #36  
Old September 30th, 2013, 08:34 AM
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Tom Woods driveshafts should arrive today, ordered through Justin at Lucky8. In the meantime, running only on the stock rear shaft with plenty of spline showing (couldn't help myself, had to go for a drive).

Great feeling, no leaks, coolant temp at highway speeds a tad above mid way on the gauge (I think that's normal), and my son loves choosing his seating position (of course, a different one each time of the 10 available).

Still in need of an R380 trans tunnel if anyone has one laying around they are willing to part with, figure out the seat box and floor alterations, and the usual upgrade of the 12V wiring. But, at least it's on the road. First trip already planned for URE in a few weeks.

Will post images once the driveshafts are installed.
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  #37  
Old September 30th, 2013, 09:08 AM
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Doug Crowther
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Interesting bit of fabrication. It appears you have a discovery transmission (aka short stick) and thats why you had so much fun making it fit. You will have to make a custom trans tunnel as that short stick disco trans wont work with anything made for the defender. It also appears you have mounted it high in the rear which may give you some pinion issues.
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  #38  
Old September 30th, 2013, 09:59 AM
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Doug, Thank you.

I was wondering why the proper "trapezoid" shape R380 trans crossmember was of no help to me. I have it installed, but just as a stiffening brace for the frame (much like the rectangular old one). You answered that question for me. Thanks again. It was a pain to install, with the tools and skills I have, but very much pleased with the end result (structural, functional, and cosmetic).

Also, I'm actually only 2 degrees off from parallel pinion angles (still needed to go higher with the rear transfer case output, but I am pretty much maxxed out on room). I am confident low speed vibration will be minimal, if any.

Diego
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  #39  
Old September 30th, 2013, 11:59 AM
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always cool to see people make things work with ingenuity
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  #40  
Old October 6th, 2013, 07:57 AM
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Doug, Thanks for the complement. I, as well, am quite pleased with the results.

So, the journey has both ended (the build), and begun (my plans for this vehicle).

Took it to the beach yesterday, aired the pizza cutter tires down to 18psi, and spent a great day with my family and friends. The 300Tdi, once out of the low boost, low rpm dead zone, did impressively well in diff lock high, in the soft, track littered sand and up the small dune back onto pavement.

Below is the image of the before (and only trip) in blue, and the after, with many more to come...
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