My long awaited D90 rebuild....

[Landy_Andy]

As some of you may know when we emigrated from the UK in '07 I brought my Land Rover D90 with me.

Now being a bit dumb at the time we were planning on using it for travel & camping trips.... Canada isn't that big is it.... you don't need to carry 80L of extra fuel & lots of supplies.... DOH !

Now we have the D2 that's really performed well these last couple of years and I decided it was time to give the D90 a makeover this winter. I can then use her for some more serious wheel'in next summer.... ie, panal damage will be had :D

And this is her present state....

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05309_1024x768.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05311_1024x768.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05310_1024x768.jpg

The list of mods sort of goes :

1. Convert from RHD to LHD, so it's easier (bit safer) to drive on the highway.
2. Bin the old Lucas (crappy) engine management & install Megasquirt
3. Move rear axle back from 92.5" to 100" wheel base, that'll improve steep slope handling & departure angle.
4. Mod the rear of the frame to include a winch cage for the spare 8274 I have.
5. Rebuild the exo-cage into a full trayback with the option for a centre winch.

Currently working stage 1 & 2. Once there complete & I can turn her round under own steam we'll get into 3, 4 & 5.

Cheers,
Andy

[Jeremy]

Looks fun! Looking forward to seeing this shape up.

[Root Moose]

So doing the tray back are you shortening the passenger compartment / tub or planning on doing a body stretch like the Mark Evans TV program? Or just doing a competition cut style body modification?

[Landy_Andy]

Am waiting for seals & gaskets to start the axle rebuild so, have dusted the Megasquirt off I bought 4yrs ago.... and started to get it ready for install.

For those now familiar with MS, here is a linky : http://www.megamanual.com/mtabcon.htm

And here is a piccy of my ECU.....

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05312_1024x768.jpg

It's a MS1 V3.0 that has mods for Ford EDIS ignition (already fitted to the Rover 3.9 V8) & Bosch idle air valve, firmware will be MS-Extra.

This is what I'm working towards... :D

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DevonTrayBack.jpg

[Landy_Andy]

So doing the tray back are you shortening the passenger compartment / tub or planning on doing a body stretch like the Mark Evans TV program? Or just doing a competition cut style body modification?

I have a replacement rear bulkhead to fit. Was part of a 110 tub that got butchered up to just leave the bit I needed and looks a bit like a hi-cap one. Fits below the back of the cab instead of the rear tub. Have a look at the Devon 4x4, D90 build gallery here....

http://www.devon4x4.com/index.php?option=com_k2&view=item&id=451:rear-tub-modifications&Itemid=41

[TheOtherSide]

I thought you left that rig back home? Sweet ride!!

[Landy_Andy]

I thought you left that rig back home? Sweet ride!!

Nope.... came on the boat in the 40' container :)

[killer cruiser]

are you looking for interior solutions? a guy i know in chilliwack does door panels and dash components. you may know of him but thought i'd throw it out there. his web site goes by the name iron goat ( tony klassen ) is his name. he has a few older landys. lucas electrics:rant: wise to ditch

[Landy_Andy]

Hi Killer,

Thanks..... heard & seen the IG products. Not sure what I'm doing about that sort of stuff as yet, the doors currently have alum 5 bar treadplate interior skins I made previously. Might just keep them as they stiffen the door and are easy to wash down.

Am now waiting on lots of parts to get the front axle rebuilt and start the engine rewire for the Megasquirt install. Once I get both those little projects sorted, I can start on the trayback conversion..... only 6mths till the snow goes here, got my work cut out. Need to build a tube bender & design a rear cage & tray using Bendtech, still lots of stuff to do ;)

[Lone Ranger]

Awesome to see you rebuilding it Andy!! I had the privilege of checking the truck out last year as it sat at the time in the driveway and I was impressed with it then, its going to be even better afterwards! LR

[ytmonty]

Canada Isn't that big??? Second largest country on the planet with the least amount of people per square km. Man, you need to get out more. Of course i might have missed the sarcasm in your original post... nice 'fender btw!

[Landy_Andy]

Canada Isn't that big??? Second largest country on the planet with the least amount of people per square km. Man, you need to get out more. Of course i might have missed the sarcasm in your original post... nice 'fender btw!

Ugh... ???

[Lone Ranger]

You missed his sarcasm!

Actually, assuming you get half decent fuel mileage Andy, an 80L tank isn't too bad. My Ranger can squeeze in 80L if I top the tank right off, and I have never had an issue getting back to a fuel station. I would love more obviously, but it actually hasn't become a direct issue yet. If I'm heading into an area where I know that I will run short I just carry a couple 6 gallon gerry cans with me. The only major advantage I can see for having a larger or dual fuel tanks is so that I can carry more fuel without having in a gerry can that can possibly leak, and if it's being stored on the outside of the truck, its harder to be stolen. LR

[ssrig55]

ytmonty, you may have missed the "DOH" in that post;) but I have seen the under estimation of the size of Canada before, I was in Quebec city and was chatting to a group of tourists from Great Britian and asked what they had planned for later on in the day,,, they said that they had planned to drive to Niagara falls to check it out, then go visit a few other places:wow: I just had to laugh and give them a heads up that it was over a days drive just to get to Niagara falls!!

[ssrig55]

Then there was the time that I drove across Canada for the first time from the west, well I got to the Ontario border and figured we were almost there, two days driving later and we were still in Ontario:crazy:

[Lone Ranger]

24 hrs driving at the speed limit from the ON/MB border just to get to TO.. its that large of a province!

Canada is a HUGE country. I've been running longhaul for a bit over 10 years now and I haven't even come close to seeing half of it. However, my record for Vancouver to TO was right about 3 days solo, 48 hrs running team! One thing to consider is that TO is only the half way mark for crossing Canada.. LR

[Landy_Andy]

Was more of a case of under estimating a few things really.... in hind sight we should have sold the D90 and got a D110 or a D130 crewcab, ex-utility company type of thing.... like this :

http://i856.photobucket.com/albums/ab130/juddyburton/Land%20Rover/IMG_10954a.jpg

http://i856.photobucket.com/albums/ab130/juddyburton/Land%20Rover/IMG_10001a.jpg

The D90 is just too small once all the camping gear, extra fuel & water, dog & wife are loaded up.... plus it doesn't have aircon, so in summer it's driving with the windows open on the dusty roads..... guess you can work out what the wife would have to say about that :nono: :rant: :(

So, the D2 does a fine job and I get to rebuild the D90 into a fun play truck :D

[R_Lefebvre]

I think that's a great plan. I laugh at the Defender purists who think it's the best long distance vehicle ever made. :huh: I've seen John Deeres with more interior comfort. ;) The Discovery is a much better truck for driving long distance.

[Landy_Andy]

ok..... not posted a pic for a while, been busy pulling the D90 to bits :D

Here is current state of play... front axle rebuilt with all the LHD parts, started to clean up & install the dash stuff, then decide to pull the rest of the truck apart....

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05316_640x480.jpg

Tidied up the ex-MOD 110 'hi-cap' style rear bulkhead I made & got it slotted in place to work on the new back cage.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05320_640x480.jpg

More to come laters ;)

[Landy_Andy]

Treated myself to the Bendtech upgrade to V5 for Christmas, here is the current cage redesign for the 90.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/Cage1_640x386.jpg

Grey is the existing exo-cage, red, the new behind cab hoop & additional bracing & the orange is a basic tray. The connection between the new rear hoop & the existing at the top corners is a bit of a compromise but as we won't be using the truck for comps then I think it'll be OK.

Still working on the tray or something at the back, once I get the new hoop & rear bracing in then I can do a better desing as actual location points aren't clear yet.

Next, got to design the mounts for the cage's back hoop next & finish off the rear winch tray so I can get some parts plasma cut next week. Did get a quote to buy one in from D44 in the UK but shipping was more than the actual cost of the winch tray, so..... Bendtech Sheet Metal to the rescue ;)

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/WinchTrayDesign_640x316.jpg

Then starts the fun cutting & welding...... :welder:

[Landy_Andy]

Had a few hours spare this week so, attacked the rear of the frame.... it lost :D

http://i946.photobucket.com/albums/ad306/Landy_Andy/DSC05322_640x480.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/DSC05323_640x480.jpg

Waiting on the first parts for the rear winch tray to arrive from the water jet cutters in S'Arm, hopefully get them tomorrow.

[Landy_Andy]

Got the cut plates from Custom Cut in S'Arm over the past week or so, and stitched them all together yesterday. Reasonably happy with the welding but my verticals do need improvement.... however, I can state it won't fall off :D

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05342_640x480.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05341_640x480.jpg

[Squiggy]

Lookin good Andy!


:headspin:


Brad

[Jeremy]

Wow supper beef! Awesome winch mount set-up there.

[Landy_Andy]

I can't take credit for the actual design, Devon 4x4 in the UK make a (very) similar one. However, to buy & ship it would have cost me ~$1500, mine stands me at ~$300 in the water jet cut plates etc.

Working on the new 'A' frame & trailing arm mounts now so I can get the axle back in. Did think about going 4 link with new D60 axles to run 35"+ tires but the wife's just lost her job.... :(

So times might get hard if she doesn't find something fairly quick.... :lol:

[Landy_Andy]

Last week or so I completed the rear winch cage.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05345_640x480-1.jpg

Spent this weekend grinding & burning wire.... :D

Front cage mounts, frame end upper & lower link mounts welded up.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05357_640x480.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05355_360x480.jpg

Now to design the axle top mount for the upper links (decided to 4 link it).

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05356_640x480.jpg

[Landy_Andy]

Decided as funds a still tight (wifey still not got a new job yet :( ) I'd repaint the truck a nice green.

Here's the firewall after clean up & a fresh lick of paint....

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05369_360x480.jpg

And now it's time to finally start bolting bits back together..... :party:

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05370_640x480.jpg

[Landy_Andy]

Got the rear spring mounts on but now it's a 100" wheelbase.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05386_640x480.jpg

Rear axle's modified for 4 links, just waiting on the rest of the new joints to arrive.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05383_640x480.jpg

And built a demountable tow hitch.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05385_640x480.jpg

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05384_640x480.jpg

Next to finish off the rear firewall & start building the battery box. Still waiting on seals & other stuff to rebuild the front end but lots to do :)

[ssrig55]

Nice work!

What kind of winch is that on the back?



Oh yeah, green,,,hmmmm,,, not to sure about that colour?? Maybe once its all painted , or just leave the body off so we all can see the framework! But then I'm not very good with colours so I can't talk.

Interesting idea on the removable hitch too.

[TheOtherSide]

Looks great!

[MatS]

SERIOUSLY nice work man!!

Are you going to join the show truck tour when you're done the build? hahaha

[Landy_Andy]

Nice work!
Thanks :)


What kind of winch is that on the back?


Warn 8274


Oh yeah, green,,,hmmmm,,, not to sure about that colour?? Maybe once its all painted , or just leave the body off so we all can see the framework! But then I'm not very good with colours so I can't talk.


I like green & the roof's going to be yellow :D


Interesting idea on the removable hitch too.


90% of the time won't need to tow, just gives some flexability to haul a camping trailer with the RTT on it. I have still got the old rear tub that might get a frame put under it at some point.

[Landy_Andy]

SERIOUSLY nice work man!!
Are you going to join the show truck tour when you're done the build? hahaha

Na.... no where to show it here.... and it'll be too muddy :D

The way Jackies job hunting is going..... it's going to be a very long build :(

[slicky]

Great looking work! I too like your removable hitch idea , I might have to borrow that. Good luck to Jackie , I'd like to see some continued progress on this build.

[Landy_Andy]

Bit of progress this last week or so, got the rear bulkhead reinforced and the top corner cappings tidied up. Now to work on the new twin battery cradle that'll sit just behind it.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05397_640x480.jpg

Rear axle is just waiting for the order of Jonny joints to arrive so I can finish up the 4 links and finalize the pinon angle. Once that's done it can be final welded, painted & rebuilt.

http://i946.photobucket.com/albums/ad306/Landy_Andy/D90%20Rebuild/DSC05383_640x480.jpg

Then we can get it rolling again & start work on the cab rebuild, wiring, brake lines and get the engine running under Mega Squirt ;)

Plan is to have it drivable as a chassis cab then finish the rear cage and tube front wings :D