aaronmorris · Dec 1, 2014

So this is the story of my 90.
It was bought in March (ish) this year with the intention of a full strip down and rebuild.
This may take a while as the pictures are spread over 3 photobucket accounts, so bare with me

Although it may be slightly pic heavy

This is it as I bought it. Not too bad really for what was to be a project and was a better base vehicle then intended.

So I striped it to the bare bones and ordered a new one from Richard's chassis.

In the mean time I striped, cleaned, painted and rebuilt the axles.

2 weeks later I went and picked my new chassis up

And got it into a rolling chassis.

Stuck engine in and stripped it for a bit of an spruce up.

Engine built back up and gearbox in, Which I stripped to change the 5th gear baulk ring.

Bought a late td5 bulkhead, Chose a colour and painted it.
It was a lot brighter than I imagined it would be

Same for the tub.

0

Trial fitted everything to set the bulkhead up.

And painted everything a panel or so at a time in me garage.

Painted wings, bonnet and front panel and that's the painting done and dusted finally.

And that's it for now. Will add more later.

warrior · Dec 1, 2014

Looks nice, keep it up

MrNasty · Dec 1, 2014

Nice job that, liking the attention to detail.

FlatbedPilot · Dec 1, 2014

Awesome work. Hoping I can get mine as good.

aaronmorris · Dec 1, 2014

So at this point it was all but finished, If I remember right, A set of shocks, paint and fit cills and a bumper.

Now I had been out of work for the best part of the build so I was pretty skint by now, So I took the roof and back door off and stuffed it back in the garage for a few months.

And then with having too much time on my hands, I kept thinking about building a cummins powered lr.
Now I'd wanted to do one for a while but always put it off as too big of a job.
So I get looking and was offered an engine that was just too cheap to turn down, and the plus point was he could cut the chassis in half and deliver it in a few days.
So I went and viewed it, saw it running and I was sold

Left a deposit and true to his word was delivered in a couple of days later on a big hi-ab that only just fitted on the drive

The day of arrival caused much commotion with the neighbours

Now they don't like me as it is and apparently I'm running a business, But this must have been the last straw and she came steaming out :lol:

Here's just a few of the things she was screaming at me.
"What the hell is that thing!"
"What is it"
"Look at it! What the hell is it"
"This is the last straw! what the hell are you building now"
"Send it back on your little truck"
"You're running a business and I'm going to report you"
"I'm always seeing them coming and going"
"I'm going to report you to the police"
I'm going to make your life hell"

And so on, this was about 8am and the whole street must have heard her for a good half hour.
Not sure the bloke driving the hi-ab new where to put himself either with her going off on one.
I just turned my back on her shaking my head.
She started going off on one saying "Don't you turn your back on me"
"Look at me! What the hell is it!"
I just turned around and laughed at her which didn't go down to well either.
It was obvious she wasn't going to go away so once it was unloaded and the bloke paid up I just went inside until she f*cked off.

THEengineer · Dec 1, 2014

did you tell her to fk off nosy old bint

trax · Dec 1, 2014

is hers the red hippymobile?

one of my new neighbours is a right mad old bat. just ignore her and with a bit of luck she'll do the same.

but nice job, looks ace!

FlatbedPilot · Dec 1, 2014

Wow. What was the truck that came out of?

aaronmorris · Dec 2, 2014

warrior said:
Looks nice, keep it up

Cheers bud.

MrNasty said:
Nice job that, liking the attention to detail.

Cheers

Just want it finished now, to much time and money for it so just sit their

DefenderPilot said:
Awesome work. Hoping I can get mine as good.

Cheers

Easy done mate, Nothing difficult about them.
Just take your time and it'll be fine.
I've done everything myself and got on fine, if I don't know how to do it I learn or try at least.

THEengineer said:
did you tell her to fk off nosy old bint

Haha, Nah, I'd rather not fuel the fire, Just smile/laugh at her and that make her mad.

trax said:
is hers the red hippymobile?

one of my new neighbours is a right mad old bat. just ignore her and with a bit of luck she'll do the same.

but nice job, looks ace!

Cheers

It was actually next door but one that was shouting and balling at me, although red hippymobile woman came out too and doesn't like me either and has reported me to the council, several times actually as her and her mother said the other day they where going to report me again

Oh and just ignoring her aint going to work, she, or they should I say just want me to stop!
No negotiations or compromises, that's it, "JUST STOP AND DON'T DO IT NEAR MY HOUSE"
"So should I pay someone?" I say
"YES, IF I WANTED TO LIVE NEXT TO A GARAGE I WOULD"
Me "But I have the time and skill to do it myself, why would I want to pay someone?"
"I DON'T CARE, JUST DON'T DO IT NEAR MY HOUSE"
Apparently what I do isn't normal, blah, blah, blah, and loads of other stuff she goes on about.
So I've decided theirs just no pleasing some people as much as you try.

DefenderPilot said:
Wow. What was the truck that came out of?

Engine is out of a Daf 45 (7.5T wagon)
Also fitted to Daf 55, Leyland roadrunners and a few others I think.

chunkymunky · Dec 2, 2014

I had a cummins out of a bin lorry. Apparently you gan get them with a turbo :0

v8geoff · Dec 2, 2014

Like it looks lovel

aaronmorris · Dec 2, 2014

And so it continued, so with it finally here it was much more daunting than I had ever imagined, All I kept thinking is, What the f*ck have I bought and where do I even start!

I didn't even touch it the first day, just looked at it and thought, What the f*ck!

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With pipes, air pipes, wires and god knows what else it was still vary daunting, thinking what the hell are all these

But with the best part of them removed and all the other excess crap gone it started to look a little easier

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Also removed and kept the air tanks as I'd be needing one of these later for the air assist clutch

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And now we was ready to take it out of the chassis.
Now I had serious concerns about my engine crane coping with the weight

But it managed with ease luckily.
So with the engine in the air we tried to move the engine crane, Would it move? Would it chuff!

So we decided to pull the chassis out from underneath the engine.

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With that out of the way we reset the crane so it wasn't half in the mud and moved it down to the garage.
That was a task on it's own, took absolutely ages and was a nightmare, tugging and pulling on the engine crane moving a foot at a time at most. If at all sometimes. All this was made much worse with the cobly driveway!

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But with the engine down where I wanted it, it meant I could make a start.
The first job being to split the engine and gearbox.
Why? Just to make it that little bit easier to move about

Although at nearly 500kg it still isn't exactly light

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Will do more later if photobucket stops signing me out every 2 minutes.

aaronmorris · Dec 2, 2014

So I continued to strip the engine down a little with the intentions of making it easier to move about.
And the more I stripped it the more I realized that in reality it's just a big tdi and theirs nothing to be scared of!

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Sheered about half of the manifold bolts when removing so that was another job on the to do list.
I knew it was going to happen to be fair as the bolt shanks where about 1/3 the size they would have been originally.
But my thought where it's better to do it now than 12months down the line when it's in the vehicle and a #### to do.

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So drilled and tapped them out.

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Even the clutch was a heavy bastard.

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The engine was then given a thorough clean and painted in epoxy primer.

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While I was waiting for the other paint to arrive I removed the sump and reversed it.
Plus extended the oil pickup pipe and painted.

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And the gearbox cleaned and painted too.
Which shortly after went off to a nice man to have an adapter designed and made.

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Paint arrived and well painted it, Erm.... Bright red

Because everyone knows painting yer engine red adds at least 50hp

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The rocker pots had about 10 layers of paint on them and looked ****'e so I stripped them back to bare ally.
Although I may polish them too one day

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So at this point I was all ready for install, but the old 200 had to come out first.

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Which left a nice gap.

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And as soon as that was out it was filled again as I tried the new engine for size

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And it wouldn't go in fully due to the bulkhead needing slight trimming.

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trax · Dec 2, 2014

chunkymunky said:
I had a cummins out of a bin lorry. Apparently you gan get them with a turbo :0

wow, the things people chuck away

trax · Dec 2, 2014

that's looking really good! keep it up

vegari · Dec 2, 2014

Need to know more, how's it going???

aaronmorris · Dec 2, 2014

v8geoff said:
Like it looks lovel

Cheers

trax said:
that's looking really good! keep it up

Cheers trax

Just wish it was on the road at this point.

vegari said:
Need to know more, how's it going???

Well it's further than this, it's in and mainly plumbed in.
But still got bits to do.
Will update thread as and when I can.
What do you want to know more about?

vegari · Dec 2, 2014

Just interested in how well it all goes, build looks great!

trax · Dec 3, 2014

seen the other cummins thread? http://www.landyzone.co.uk/lz/f7/cummins-110-csw-build-262286.html .

funny cos his is now a blue 110 and yours is a blue 90.. done at the same time.

aaronmorris · Dec 3, 2014

So once the bulkhead had been trimmed slightly it went in.
So this is roughly where it would sit.

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Engine mounts now, I used a re-drilled tdi engine mount on the drivers side and this gave me my position.
So I made an engine mount to suit the passenger side the next day.

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Leaving it sat something like this.
Front of crank pulley is 50mm off the front crossmember if I remember right.

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Refitted the manifold and turbo.

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Fitted a 12volt transit alternator with vac pump for the vac assist on the brakes.
And refitted the 24volt starter motor with a series parallel relay for 24v starting 12v running.
This was after much messing trying to find a 12volt starter to suit.

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Fitted a series 3 brake master for the clutch with a remote reservoir off ebay.

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Used a full width td radiator. The other option was v8 rad but as I already had the td one I used that.

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Mounted an air tank in the back, although the eventual plan is to stick it underneath somewhere.

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About this time I was getting skint again, so was umm'ing and ah'ing about whether or not to intercool it.
Anyway I was talked into doing it so I bought a universal one off ebay.

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Mounted.

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And drilled a hole through each wing for the pipework.
Not what I wanted to do but had little choice with having a full width radiator fitted.

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And then the lovely man brought me my gearbox back along with me new adapter

So the engine bay was left and concentrated on getting that in instead before getting to far ahead of myself.

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