Custom built rear bumper, chassis repair and rollcage installation - Defender Source
Defender Source  

Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Smaller Projects


Reply
 
Thread Tools
  #1  
Old July 5th, 2015, 11:19 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
Smile Custom built rear bumper, chassis repair and rollcage installation

I can finally share the latest upgrades to my 1997 D90, the old Cube II

It all started when - a couple of years ago - I found out the rear crossmember was rotten beyond repair; not a big surprise, being a well known "mud trap" due to poorly thought design, and made of thin foil too

I immediately binned the idea to replace it with a standard spare part, simply not worth the money and effort required; I looked instead at a better solution (read: custom-designed and fabricated), and I liked the idea of some heavy duty, bolt-on rear bumper, Jeep style! Yes Jeep...I said that. I saw a picture of a GenRight HD bumper on the web and decided it was simple and practical.

Pros:
1)stock looking (stealth mode: ON)
1)easy to remove/repaint/repair if needed
2)better designed and made, a simple open "]" profile, built stoutly out of, say, 6mm plate

While there, it happened that a few months ago I was finally able to afford a proper rollcage, beautifully built by Protection & Performance; sooo, to kill two birds with a stone, all I needed was the right person to do the job, my way.

Meet Edoardo, the brain behind Payustech Performance.
With a straightforward approach and armed with a 3D scanner, the rear section of the chassis was checked and scanned, and a HUGE jig was built to ensure precise fitment of the new repair sections and crossmember.

All the rotten metal was chopped, the whole structure was designed in 3D, checked and approved, then and laser cut, bent and assembled.
The Protection & Performance rollcage came already welded and painted, but the supplied mounts need to be welded to the chassis.
Edoardo didn't think twice and incorporated the rear mounts into the design, along with gussets and bracing to ensure bomb-proof rigidity.

Beads of weld were laid down on the chassis and the puzzle went together.
The result is a stock looking chassis, until you get closer and start noticing the big bolts which hold the new bumper in place...

Here's a link to a bunch of photos I shared on FB:

https://www.facebook...=1&l=d6a1098f12

An cool 3D video showing the whole puzzle:

https://www.facebook...284162753972044

Also a couple of pics of the Cube now
Attached Thumbnails
Click image for larger version

Name:	CubeII_Rollcage_017.jpg
Views:	257
Size:	90.7 KB
ID:	124322   Click image for larger version

Name:	CubeII_Rollcage_013.jpg
Views:	265
Size:	72.5 KB
ID:	124323  

Click image for larger version

Name:	CubeII_Rollcage_020_CROP.jpg
Views:	232
Size:	62.2 KB
ID:	124324  
__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
Sponsored Links
Advertisement
 
  #2  
Old July 5th, 2015, 12:25 PM
Scottyoh's Avatar
Scottyoh
Status: Offline
Enigma RnR
'87 127"
D-90 Source Vendor
 
Join Date: Jul 2013
Location: Orlando, FL
Posts: 416
Facebook links aren't working for me.
__________________
Pres - Florida Land Rover Club
Rovers 'n' Racing
407-720-9450

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Reply With Quote
  #3  
Old July 5th, 2015, 01:58 PM
JimC's Avatar
JimC
Status: Offline
Jim Cheney
NAS 110 #145
Site Team
 
Join Date: Sep 2003
Location: Stuttgart, Germany
Posts: 7,154
Registry
Not working for me either. I'll just go to FB.
__________________
Jim Cheney

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Reply With Quote
Sponsored Links
Advertisement
 
  #4  
Old July 7th, 2015, 07:06 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
Weird :-/

Silly links!
I'll check tonight or tomorrow...
__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #5  
Old July 7th, 2015, 08:22 AM
Rocky's Avatar
Rocky
Status: Offline
Chris
72 + D1 drivetrain
Member
 
Join Date: Sep 2006
Location: Colonies Aka Boston
Posts: 8,789
Quote:
Originally Posted by Cube II View Post
Weird :-/ Silly links! I'll check tonight or tomorrow...
Just you tube them!
__________________
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.
Reply With Quote
  #6  
Old July 7th, 2015, 08:58 AM
Howski's Avatar
Howski
Status: Offline
Kevin
2002 Land Rover Discovery II
Member
 
Join Date: Jul 2012
Location: Greenville, SC
Posts: 657
Registry
While it's not the topic of this thread I really like that front bumper. I've always wondered why there haven't been more simple and tidy winch set-ups like you've got. Is it custom?
__________________
My other car's a Land Rover
Reply With Quote
  #7  
Old July 7th, 2015, 09:01 AM
Z.G's Avatar
Z.G
Status: Offline
Zack
300Tdi 95 D1
Member
 
Join Date: May 2013
Location: Burlington, VT
Posts: 4,684
Registry
Quote:
Originally Posted by Howski View Post
While it's not the topic of this thread I really like that front bumper. I've always wondered why there haven't been more simple and tidy winch set-ups like you've got. Is it custom?
You can get a Rockware that's pretty similar and has great lines IMO, I know Chris has one and I believe Charles does too
Reply With Quote
  #8  
Old July 7th, 2015, 09:12 AM
sonoronos's Avatar
sonoronos
Status: Offline
Ed
None
Member
 
Join Date: May 2010
Location: Arlington, VA
Posts: 5,542
Registry
Looks great, Michele!

His front bumper is totally custom. It looks similar to a Rockware, but there's a lot of custom touches...the most obvious is the 8274 winch mount.

It's Michele's style...a lot of the differences are in the details

Here's the facebook link. As you can see although it might look like a rear Rockware bumper on the outside, on the inside, it's nothing like it...

https://www.facebook.com/Whitedog.Comics
Reply With Quote
  #9  
Old July 8th, 2015, 05:30 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
Quote:
Originally Posted by Howski View Post
While it's not the topic of this thread I really like that front bumper. I've always wondered why there haven't been more simple and tidy winch set-ups like you've got. Is it custom?
Yes, fully custom, made on my own design, but it's really simple...oh, 100% stainless steel
Just like the rocksliders, it will never rust.

__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #10  
Old July 8th, 2015, 05:43 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
Smile

Quote:
Originally Posted by sonoronos View Post
Looks great, Michele!
(cut)

It's Michele's style...a lot of the differences are in the details
(cut)on the inside, it's nothing like it...

https://www.facebook.com/Whitedog.Comics


Thanks for the kind words!!!

I always try to keep things simple, stock looking and therefore matching the boxed shape of the D we all love...no tubular things for me. Well, rollcage apart

Maybe it's easier to attach pics the old way...and the video too, so you can see how it's built

If you guys are on FB, feel free to befriend me
Attached Thumbnails
Click image for larger version

Name:	3DSCANNER-WA0004.jpg
Views:	141
Size:	65.0 KB
ID:	124555   Click image for larger version

Name:	3D_bumper_and_chassis.jpg
Views:	122
Size:	44.9 KB
ID:	124556  

Click image for larger version

Name:	11207771_10206465341942651_842089356_o.jpg
Views:	118
Size:	46.1 KB
ID:	124557   Click image for larger version

Name:	Cattura1.jpg
Views:	112
Size:	31.8 KB
ID:	124558  

Click image for larger version

Name:	Cattura 2.jpg
Views:	108
Size:	36.9 KB
ID:	124559   Click image for larger version

Name:	Cattura3.jpg
Views:	109
Size:	37.8 KB
ID:	124560  

Click image for larger version

Name:	Cattura4.JPG
Views:	105
Size:	58.0 KB
ID:	124561   Click image for larger version

Name:	JIG-WA0006.jpg
Views:	137
Size:	98.4 KB
ID:	124562  

__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #11  
Old July 8th, 2015, 06:06 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
A couple more.

You can see how the bumper ends are "closed" and the two holes are for the bolt-on corner guards (coming soon).
These will be "minimal" and low profile, as usual
Attached Thumbnails
Click image for larger version

Name:	newxmember_1684.jpg
Views:	152
Size:	82.9 KB
ID:	124563   Click image for larger version

Name:	rearbumper_cagemount_1690.jpg
Views:	146
Size:	81.7 KB
ID:	124564  

__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #12  
Old July 8th, 2015, 06:23 AM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
Video

As suggested, I uploaded it on Youtube.
Since I can't get a clue of how to make the cool preview work,
you only get a simple link to click on!



https://youtu.be/GMxY_v2DQVw
__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #13  
Old July 8th, 2015, 08:26 AM
Reese_D90's Avatar
Reese_D90
Status: Offline
Reese
97 D90 ST and 93 D110
Member
 
Join Date: Oct 2009
Location: Dallas, Texas, USA
Posts: 1,260
Registry
Outstanding!
Great design. Obviously you have skills
__________________
NAS 1993 D110 CDN #11/25
1997 D90 ST #1953
2006 Range Rover
1997 D90 SW #701 (sold)
1995 D90 ST (sold)
Reply With Quote
  #14  
Old July 8th, 2015, 11:14 AM
don's Avatar
don
Status: Offline
Don Bunnell
'86 110 3dr ST
Member
 
Join Date: Sep 2007
Location: Rumson, NJ
Posts: 4,272
Registry
Wow! Really nice. Now that is how LR should have done it from the factory. Instead of the mud/crud catch and hold design they use.
Reply With Quote
  #15  
Old July 8th, 2015, 03:15 PM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
I have ideas

3D engineering courtesy of the mate at Payustech

Quote:
Originally Posted by Reese_D90 View Post
Outstanding!
Great design. Obviously you have skills
__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
  #16  
Old July 27th, 2015, 07:08 PM
defenderholty's Avatar
defenderholty
Status: Offline
Russell
1985 LR Ninety 200tdi
Member
 
Join Date: Jul 2013
Location: Cartersville, GA
Posts: 490
Looks fanhonkin'tastic.

I just bought one of those tailgates, but they didn't send me the pins. I may have to buy them separate if I can't figure a way to make it swing. I may follow suit.
Reply With Quote
  #17  
Old July 28th, 2015, 03:27 PM
Cube II's Avatar
Cube II
Status: Offline
Michele
1997 D90
Member
 
Join Date: Nov 2003
Location: Italy
Posts: 900
Registry
LOL, thanks!

Yes the tailgate may be "modified" to swing,
you need a couple of SW rear door hinges, and an handle.
Then either cut a window for the handle, or use the antiluce catch.
__________________
Michele
D90 VNTdi
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
+109" IIA ex-military

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Sketches and doodles:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

[O]===[O]
Reply With Quote
Reply

Lower Navigation
Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Smaller Projects

Tags
bumper, cage, installation

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Expedition built 110s, custom 135s Talleyrand Misc. Chit-Chat 6 February 19th, 2014 05:13 AM
Rockware rear bumper & tire carrier Installation Tips nycjdp Defender Technical Discussions 2 May 24th, 2009 01:33 AM
What is this Bellargio, 1959 TDI5 custom built SafariHP The Flea Market 5 July 23rd, 2008 01:06 PM
Custom Built Defender :) playing in the mud Frankie Carbone Misc. Chit-Chat 1 April 11th, 2008 12:35 PM
rollcage rollcage rollcage javablack Wanted 0 October 9th, 2005 05:06 PM


All times are GMT -5. The time now is 06:40 AM.


Copyright