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  #1  
Old December 10th, 2005, 01:32 AM
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JimC
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Jim Cheney
NAS 110 #145
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Rebuild and Tdi Conversion Pix

I've got a shed-load of pix from the rebuild and I've never gotten around to finishing the website I started, so I'm just going to post a heap of pix here. They aren't necessarily in rigorous order and I'll throw in comments as appropriate. I'll also probably get banned from the site because of bandwidth issues...

Follow-up Post:

First row is how it started - George at RDS had a galvanized rolling 300tdi chassis "on sale" - I bought it so I could build up my project and keep the Rover on the road.

Follow-up Post:

Row two: So I got about cleaning up and painting everything. I wanted the chassis to be black so I painted it with POR15 and POR15 Chassis-Coat. I painted the axles and suspension parts the same way.

Follow-up Post:

Third row of pix: After a while I finally got the motor and it wasn't long before I had it in the chassis. Its much easier to move a 600 pound motor on wheels than on a pallet.

Follow-up Post:

Row four: At this point it was time to start tearing the old girl apart. Evilfij came down and shoved the entire v8, r380, and lt230 into the back of his LWB fully assembled. I'm glad he was the one taking it out at the other end...

Follow-up Post:

Row five shows the stacking of the driveline and the installation in the chassis. It was lots of fun trying to get the crossmember into the chassis, I had to use the hydraulic ram from the engine lift to spread it apart a wee bit to get the thing to go in.

Follow-up Post:

Row 6 - more teardown, the bulkhead gets is own little wheelie cart. This proved very convenient for working on it.

Follow-up Post:

Row 7 - setting up the side tank - I used an aircraft-style filler cap from MOCAL - great stuff.

Follow-up Post:

8 - More teardown

Follow-up Post:

Nine - the bulkhead needed some work to fix some spilled hydraulic fluid problems. I also cleaned up what little rust was there and went to town with clear POR15. The front part I repainted with color-matched spray cans from Tower Paint and then clearcoated with 2-part catalyzed clear from POR15. Note that the v8 air cleaner bracket had to be removed.

Follow-up Post:

row 10 - very exciting stuff - I had to cut off the 300tdi sway bar mounts since I wanted to remount my NAS tank. Pendy made sweet replicas of the NAS tank brackets that I bolted onto the chassis. It took a lot of playing around to get the alignment correct, but once it was all together it looked great with one of Dave Lucas' stainless skid plates installed. I then primed and painted the brackets before installing.

Follow-up Post:

11 - installing brake lines, mmm sweet. These are all stainless back from when ECR would actually sell them to you. I used braided stainless lines sourced from EE.

Follow-up Post:

Row 12 - setting up the chassis, wiring, fuel lines, plumbing the bulkhead and motor. Its amazing how long it takes to do all these little things...

Follow-up Post:

13 - the seatbox had to be modified with the removal of the passenger side locker to accomodate the secong fuel tank. Removing the locker involved drilling out some rivits and cutting some spotwelds, removing all the adhesive gunk crap involved hours of crummy scrubbing. Fortunately, my wonderful wife stepped up to the plate! After everything was done, the underside of the seatbox and floors were rhino-lined.

Follow-up Post:

14 - tail lights light up, diesel sticker applied, and it starts to look like a truck again. This is where your friends come by, cheese for the camera, and make completely predictable Flintstones jokes.

Follow-up Post:

Row 15 - damned thing started on the first crank.

Follow-up Post:

Last Row - after its running it all gets down to little stuff. Time to do some upholstery, install checkerplate, hood release lever, etc. Now its all fun and games as I work out all the kinks over the next few hundred miles.
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  #2  
Old December 10th, 2005, 06:51 AM
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sheki
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David Shechter
97' D90 SW 2.8L diesel
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Jim,
What an amazing project! How long did it take you? Nice work too.

Do you have any more of those LR "diesel" stickers left? If not where did you get it?
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  #3  
Old December 10th, 2005, 10:49 AM
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Jesse McCoy
'89 RRC SWB (needs work)
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Man,
All that AND a 110 on the way. Nice Jim, Nice...
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  #4  
Old December 10th, 2005, 11:10 AM
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flippedrover
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Tyler
'94 D-90
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Location: Ashburn,va
Posts: 3,125
I soo need a better paying job!!!
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Can't you feel 'em circlin' (closin'in) honey?
Can't you feel 'em swimmin' around?
You got fins to the left, fins to the right,
and you're the only bait in town.
You got fins to the left, fins to the right,
and you're the only girl in town.

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  #5  
Old December 10th, 2005, 11:52 AM
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JimC
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Jim Cheney
NAS 110 #145
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To answer Sheki - I collected parts through most of the first half of 04. I brought the chassis home in April but the motor didnt arrive until August. I worked on the truck basically every weekend (for approx 15 hours per wkend) from Sept-January. So 5 months of weekends and a few months prep.

And I'm not exactly made of money - my wife and I are Army officers - the pay is fine but this consumed all my disposable income for the better part of a year. I also dont have any new car payments, children, or anything like that.

The 110 isnt going to come together nearly as fast...
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  #6  
Old December 12th, 2005, 05:00 PM
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JimC
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Jim Cheney
NAS 110 #145
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Sheki - the sticker came from George at RDS - I'm sure he'll have more when he opens back up - it cost like a dollar-fifty.
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  #7  
Old December 13th, 2005, 02:26 AM
sheki's Avatar
sheki
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David Shechter
97' D90 SW 2.8L diesel
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okay, thanks. I have my list of parts for him, just one more to add.
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Originally Posted by MuddyOval
Sheki, you are a wang too.
A wang is another word for, you guessed it, A DICK!

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  #8  
Old December 13th, 2005, 09:50 AM
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Chris von C
No Defender at this time
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That hood release is far to bling.

Nah you wont get banned. I will most likely pull the pictures from the forum DB and redo the write up like I do the Trip gallerys to save load on the DB performance though. I think I should do that to Randys as well. Looks like might be enough going on to finally get the "Large projects" section going.
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Originally Posted by Lriwater: As you know, most wives don't like Series trucks due to the ride and lack of creature comforts. Girlfriends seem to like those, but some sort of magic happens during the wedding ceremony.
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  #9  
Old January 9th, 2012, 11:11 PM
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323jamie
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jamie
83 D110 RHD 300tdi Disco conversion
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well thats neat
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  #10  
Old January 10th, 2012, 04:58 AM
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Skeena river rover
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jeroen
1997 300 TDI 110
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Posts: 358
very nice.
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