Defender TD5 Rebuild

Started by grizzlychicken, April 18, 2020, 06:14 PM

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Red90

Oh.  I see the picture now.  You are putting a 4 million dollar pop up roof  ;) onto the truck and wondering how the breadstick sides will prevent it from collapsing.  Apparently it seems to work.  Don't ask me how.  I would not sign off on it.  I'm not sure if anyone tries to strengthen the sides.

I always thought the Dormobiles were the nicest design.  But the Alu-Cab are the current cool kid on the block.

https://www.youtube.com/watch?v=sf1nG4mOU3I&list=PL6dHJg46iIbURZgM6P7twTon8sLBGbg3s&index=2

grizzlychicken

Quote from: Red90 on October 03, 2023, 02:07 PM
Oh.  I see the picture now.  You are putting a 4 million dollar pop up roof  ;) onto the truck and wondering how the breadstick sides will prevent it from collapsing.  Apparently it seems to work.  Don't ask me how.  I would not sign off on it.  I'm not sure if anyone tries to strengthen the sides.

I always thought the Dormobiles were the nicest design.  But the Alu-Cab are the current cool kid on the block.

https://www.youtube.com/watch?v=sf1nG4mOU3I&list=PL6dHJg46iIbURZgM6P7twTon8sLBGbg3s&index=2
Yes just surprised how little structure is in this piece. The b Pilar and c Pilar's seem to transfer load well. Just skeptical of the load transfer at the rear of the 110. The rear tub's top cap does transfer some load through the c Pilar though so maybe I am not trusting the engineering enough!
I love the look of the alucab! And love that you can have a rack on it when using it!


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grizzlychicken

Ok so today worked on the Cookie Monster some more! Attached the front windshield panel to the bulkhead and attached the vents to the bulkhead. If you remember I repaired my bulkhead and had it galvanized. Unfortunately some galv got into the vent pin bracket. Was a bit of a pain to file it out as was very close to the finished bulkhead. The middle was the pain but managed to use a long drill
Bit for the side pieces.





Then went to do the rear tub to window brackets but couldn't find them anywhere! I remembered I got a bunch of little parts powder coated so think I found them. Are these the right brackets? Look right to me.....


They look pretty beefy so perhaps my faith is restored for connecting the tub to the rear window!


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binch

Cheers, Bill

grizzlychicken

Chop Chop!
No takers for my free bent and rusty old defender 110 chassis so off to the metal recycler tomorrow! I might get a whole....$30 for it. Not quite enough to cover the Canmore to calgary trip!  Oh well have errands there anyway!








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binch

What about the truck.....how's the progress coming along??????

Enquiring minds need to know   LOL
Cheers, Bill

grizzlychicken

We'll have been dragging my feet lately!

A little late but John I was talking about how little connects the rear tub to the panel above it. Think there are like 4 bolts. Don't know how that upper rear side panel supports the roof!





Will have to get a few more pics but dry fit the roof so I could drill all my holes. Need to pull it and seal it next.
Finished installing both front wings. The biggest challenge is finding the right fasteners! I spend 5 min installing and 30 min trying to find the bits I need ;)
Working my way through the wiring lions and starting to install the dash now too.
Once dash is in planning to go through system by system.



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grizzlychicken

Pre wiring for cruise control and central locking:<br /><br /><br /><br /><br /><br /><br />And adding about 900w of sound!<br /><br /><br />Also sorting out my duel battery system. Will add solar at some point!<br /><br /><br />And finally pre fitting the dash to see gaps in the install. Particularly wiring that still needs pre wiring before the install and altering the venting size to improve heater performance. Will cut out the heater box to match the wider hole in the bulkhead I made. Will also widen the vent flaps to improve heat flow to the AC box.<br /><br /><br /><br /><br /><br /><br />Sent from my iPhone using Tapatalk


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grizzlychicken

Added some dynamat to the bulkhead and floors for sound.



And cut a slightly larger opening out of the heater box for the floor vents.



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grizzlychicken




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Chris

I cant wait to see this 😍😍
Can you bring it by so I can convince my wife to let me get one?? 🤣🤣

grizzlychicken

Quote from: Chris on July 19, 2024, 04:34 PMI cant wait to see this
Can you bring it by so I can convince my wife to let me get one??
Ha sure thing! Might be next decade the way I am moving....


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grizzlychicken

Ok hibernated a bit in the garage this weekend.
Had the roof dry fitted so today unbolted everything cleaned the surfaces and sealed it all up. Looks straight and roof is good to go now!





Started on the back of the rover. Partially installed the rear bumper hitch. Ran out of fasteners.....
Have to have that in place before I install the aux fuel cell.





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grizzlychicken

Well pulling together the back end and lining up the rear chassis to body mount took way longer than I thought! Needed to adjust the tabs so it all fit. I wish I had smaller hands to reach all the bolts!

Added rubber between the steel/aluminum interfaces too.

Next is bolting on the bumper and installing the auxiliary tank! Baby steps!



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binch

Every little bit puts the end a weee bit closer ;-)
Cheers, Bill