D90 rebuild to 100" wb... plus a few other mods ;) - Defender Source
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  #1  
Old April 2nd, 2012, 10:36 PM
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Landy_Andy
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Andy
1999 D2, 1985 D90 truggy & 1951 S1
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D90 rebuild to 100" wb... plus a few other mods ;)

Was asked by another forum member to post up a few pic's of my D90 rebuild. Short history, been playing with LR's for about 10yrs, emigrated from the UK to Canada almost 5yrs ago and before leaving the UK did the LR show scene with my good buddies from Qt Services.

So, here are a couple of pic's of the truck as I brought it over from the UK after being parked up for the past 4.5yrs whilst I built our new home.
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  #2  
Old April 2nd, 2012, 10:39 PM
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Andy
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Next comes the strip down..... not my most fave part of any project
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  #3  
Old April 2nd, 2012, 10:48 PM
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Now.... to start the work for stretching the wheelbase to 100".... out comes the grinder

Next was time to decide what to do about the back end of the chassis, I could have just extended the old frame but I've always wanted a challenge style truck, so I priced up the rear 8274 winch tray from my old friends at Devon 4x4. Unfortunatly, the shipping was going to cost more than the tray kit. Thus, I drew it up from scratch had the parts water jet cut locally & got to work with the welder. A week later I had a nice & chunky new rear winch tray....

I also aquired the front end off an ex-MOD tub to to make a hi-cap style rear cab bulkhead. The back is still undecided between a trayback or a basic tube tub.... more beer decided to make that decision
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  #4  
Old April 2nd, 2012, 10:58 PM
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Jeff Payne
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Great! I can't get enough of 100" builds right now. Thanks for sharing.
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  #5  
Old April 2nd, 2012, 11:48 PM
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1999 D2, 1985 D90 truggy & 1951 S1
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Here's a pic of the rear tires mocked up at 100" wb, will give a near 90 degree departure angle.

Next to finish off the rear tray & whilst I was at it I added a demountable tow hitch.
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  #6  
Old April 2nd, 2012, 11:52 PM
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Whilst working on the rear tray I also made up a set of front cage mounts and a new set of frame mounts for the rear 4 link suspension.... going 4 link was a bit easier than making an extended 'A' frame.... and it looks cool too
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  #7  
Old April 2nd, 2012, 11:56 PM
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Here is a couple of pic's of the rear axle. I cut off the old 'A' frame balljoint mount & drew up some 1/4" plate parts to make a top truss. Once welded up it's well chunky & should give a solid mount for the new top links.

Still waiting on the rest of my JJ's to arrive, then I can finalize the pinion angle & finish weld the spring mounts & shock tabs.
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  #8  
Old April 3rd, 2012, 12:03 AM
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Just about up to date now, I covered over the RHD steering/pedal holes as I'm also converting to LHD during the rebuild and resprayed it. Also, got the rear bulkhead tidied up, capping closed off on the back corners & generally reinforced with chequer plate.

The screen frame & truck cab back are also painted and ready for rebuild. Next to work on the cab roof & get the rear bulkhead painted.
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  #9  
Old April 3rd, 2012, 12:10 AM
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So, that's it so far..... about 5 months on & off working on the project. List of small stuff still to do is quite long but from major items we have, rear rollcage & some sort of back, rewire the engine for Megasquirt and a general rewire of all the 'add-on' stuff using high grade automotive wire.

Hoping to get the remaining joints this week & then I can get the rear axle back under her & see how she flexes out. I have a hunch that I made the axle top mounts too tight, so they may have to be cut off & remade.... will see

If you want see her flex back in the UK.... http://youtu.be/DgBcgLTieTE

If the wife would let me I'd love to build a truck like this D&G Torus.... http://youtu.be/Vxtq78ARB5I

FYI... all the cut parts were drawn up using Bendtech Sheet Metal & I'll be using it to make the rear cage too. Here is a work in progress drawing of the cage and the model I made of the rear winch tray. On the cage grey is my existing exo over the cab, red the new rear section and the orange a basic tray. Will prob build the rear cage first and then mull over the back once I see how it looks & drives.
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  #10  
Old April 3rd, 2012, 01:42 AM
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Andy this is so awesome. I really like how you made the rear tray. Please keep posting more pics.
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  #11  
Old April 3rd, 2012, 10:12 AM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Awesome. Looking forward to seeing this progress, and very interested in the megasquirt mods as well.
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  #12  
Old April 3rd, 2012, 10:25 AM
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Quote:
Originally Posted by Landy_Andy View Post
Now....more beer...
Andy, love this build....I really like the custom frame mods you are putting in.
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  #13  
Old April 3rd, 2012, 10:28 AM
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Quote:
Originally Posted by MUDSUX View Post
Andy this is so awesome. I really like how you made the rear tray. Please keep posting more pics.
I can't take credit for the design, Simon Buck & the guys at D44 get that..... would have purchased one of theirs & saved some design time & fab work if the shipping had been realistic. Paying more to get the part than the part costs is just not on

------ Follow up post added April 3rd, 2012 07:33 AM ------

Quote:
Originally Posted by cgalpin View Post
Awesome. Looking forward to seeing this progress, and very interested in the megasquirt mods as well.
There is a whole sub-forum here on squirting you RV8....

http://forums.lr4x4.com/index.php?showforum=36

Enjoy
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  #14  
Old April 3rd, 2012, 03:05 PM
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Love the color. It is like porsche signal green.
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  #15  
Old April 3rd, 2012, 06:05 PM
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Bill Adams
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Quote:
Originally Posted by cgalpin View Post
Awesome. Looking forward to seeing this progress, and very interested in the megasquirt mods as well.
C if you wanna fool around with MS I have two you can play with. I even have a MS III daughter card so you can turn on the lighted dancing hula girl when the engine reaches 180 F if ya wants. If you decide that you love it and want to keep it you can pay me what I paid for the kit. This way you save all the build time and go right to the screwing around part. Heck you are free to modify it if you want, but it has all the components to do fuel and spark, so it's a short hop to having it go.
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  #16  
Old April 3rd, 2012, 06:49 PM
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Originally Posted by o2batsea View Post
C if you wanna fool around with MS I have two you can play with.
Hi Bill,

Thanks for the offer but I've already got a board built & waiting to be installed. The engine was already running Ford EDIS on a MS Jnr controller with the Lucas 14CUX when I took her off the road. Just need to get the cab back together & then I can install the new loom & finalize the location of the ECU. Fitting the Ford EDIS was prob one of the best upgrades you can do to the RV8 short of going full MS, even then I'd not bother with spark on the MS, just use the EDIS and all you got to worry about then is PIP & SAW signals.

------ Follow up post added April 3rd, 2012 03:53 PM ------

Quote:
Originally Posted by evilfij View Post
Love the color. It is like porsche signal green.
Actually it's Sico Corrostop Ultra Dark Green, happend to get a 1 gallon can of it for 5 bux at the local Rona, roof will be a nice yellow..... just like the Lotus 7 kitcar I had back in the UK.....
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  #17  
Old April 3rd, 2012, 06:54 PM
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Charles Galpin
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Thanks for the offer and I'll certainly let you know of I ever get the time. The problem is I would *like* to mess with lots of things but really don't have time for any of it. Right now my interest in doing an EV trumps playing with fuel injection systems, and I haven't got the time to do that yet!
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  #18  
Old April 3rd, 2012, 08:12 PM
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Here is a pic of the MS board in a nice alum box I've got for it, plan is to use the Amphanol connectors on the box end for the loom connections and keep the 'not so waterproof' 25way D type inside. I'll mount the relays & fuses onto the top of the case lid so it's all together & prob mount the whole thing behind the drivers seat for easy access. Just wish B&G had put some mounting holes in the PCB then I could have done away with the lower half of the alum case too.
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  #19  
Old April 4th, 2012, 02:30 AM
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Ian Gregory
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Following this with interest, keep the pics coming Andy. Especially the rear 4 link.

What are your plans for the front?

Ian
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  #20  
Old April 4th, 2012, 09:34 AM
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Bill Adams
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Quote:
Originally Posted by Landy_Andy View Post
Hi Bill,

Thanks for the offer but I've already got a board built & waiting to be installed.
Ur, wasn't offering it to you. I was offering it to Galpin.
However, anyone who wants to try is welcome to contact me. I will loan on contingency or sell outright. I also have the Relay Boards and a Stim.
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