Diamond the Dormobile 110

[evilfij]

Hello all,

Background:

This project has been eight years in collecting parts. It started when I bought two dormobiles and a third series III parts truck off a gentleman in Canada. I kept one dormobile and sold the other off. The SIII was parted out, but its bulkhead and title lives on another series truck.

The base 1964 dormobile was complete, but completely rusty and corroded. I took it all apart and started shopping for a frame. I bought a set of new t-pieces and restored another SIIa bulkhead I had available with new footwells. I nice guy named Geno in California had an arrow designa galvanized 109/100 hybird chassis for sale on LRX.com (this was about 2002) so I bought it and had it shipped. It is a coil sprung chassis that was set up for a 300Tdi/R380/LT230 and a 110 front end, but had the 109 style rear crossmember and fuel tank mount. I found someone parting out an 87 Range Rover and bought the axles complete and steering and suspension. I then located a salisbury axle for the rear and found proper 110 springs. I then started shopping for a drivetrain. When JimC went Tdi, I bought the drivetrain out of his 1995 D90. I did all this while I was an investment banker so I was basically collecting parts as I had no time to drive to new york and work on it (other than christmas and thanksgiving). Then I went to law school and had no money. It sat at my folks place in new york waiting for inspiration/money/time. I graduated law school, but due to some personal issues, I did not work on it. I did get a great score from Mike at ECR about two years ago when he sold me a bunch of NAS 110 parts from one of the ones he rebuilt. The parts needed work, but it was complete enough for what I needed to get donor for the body which is what I was after. I still did not have a garage, so I rented space, but I could not work in it. Since I finally had some money, I had a garage built so all the pieces were finally there (except time and the 100s of little bits to complete a project of this magnitude). It was great, except it was getting cold (my garage was completed in fall of 2008). So, I resolved that come spring I would finally get working on Diamond the Dormobile 110. She got her name because the initial purchase was in lieu of an engagement ring or because she was a diamond in the rough--I am no longer married so you figure out which one it was. The only remaining big piece I needed was a defender bulkhead as the one in the donor 110 body was rotten and needed some serious repair. I found a new TD5 bulkhead in Virginia and picked it up on the way home from MAR in 2008.



[i]Follow-up Post:

Decontruction of the NAS 110 body:

The first task this spring was to disassemble the NAS 110 body from its chassis to get it ready to go on the new frame to replace the rotton body on the 109. I sent the new bulkhead and new t-pieces (which were from 2001!) with JimC to be galvanized.

I pulled the doors off. The front four are in good shape with minimal rust and appear to have been replaced (see pic below). The fifth door is rusty, still salvageable, but I have a new one so no worries. I pulled the interior out (easier said than done), removed the seat box (I had done this earlier as I had sold the LT230 and LT77 off). I also had the broken windscreen replaced with a non-heated one. I took the roof off using two ropes to support it. I then removed the t-pieces and then removed the tub (all this was time consuming because of the corrosion on all the bolts). Then I took off the rad panel and fenders. Just this past weekend I removed the bulkhead by disconnecting the wiring from the motor (see pics below). So the body is now free and scattered about the house and garage (see pics below--yes, I live alone, well alone with puppy, see pic below). All that is left is the chassis. This weekend I am getting my galvanized parts back from JimC. The following weekend, I am hoping to make the run to New York to get the rolling chassis and roof so I can finally begin to put it all together (I will try to take pics).

Follow-up Post:

I realize this is possibly the worst set of photos anyone has uploaded to this website, but bear with me as I am a luddite.

Follow-up Post:

Project Plans:

Body:
NAS 110 body with new t-pieces, new TD5 bulkhead and new cappings all galvanized. Dormobile roof refitted to 110 roof. New canvas and bulks fabric in roof.

Interior:
Stock front defender seats and middle row seats with an eventual retrofit of the original doromatic seats when I rub enough C-notes together to have Chris at badger redo them. Stove unit from dormobile and wardrobe from dormobile in the back.

Chassis:

Designa with V8 motor mounts welded on.

Drivetrain:

1995 D90 with 4.6 short block and rebuilt GEMS heads installed.

[dave_lucas]

Congrats for getting some pics posted Ron :)

You have now mastered the interweb thinga a ma jig

Looking forward to seeing more pictures as you post updates ;)

[evilfij]

Thanks Dave,

Here is a picture of a mocked up interior.

Follow-up Post:

Here is the 4.6 short block. (edit: and yes that is a 300Tdi r380 I have had since 02 sitting next to it).

[Retrofit]

Looking forward to seeing this one come together ! This is going to be a pretty cool combo !

Keep the pics coming as you go !

Pat

[bjf]

Hey I need one of those square knobs from your 110 controls? want to sell?

[evilfij]

Sorry, I need those. One is broken on mine anyways.

Ron

[evilfij]

Here are some pictures of the donor NAS 110 body before I took it apart.

I am using most of the body, with the exception of that I have a better hood (off another NAS 110!) and I bought new t-pieces, bulkhead and a new rear door.

I may or may not run the NAS windscreen (I replaced the broken windscreen with a new one) as I may just run the series roof an an SIII windscreen to save having to transfer over all of the dormobile bits to the 110 roof (and having to fill the apline window holes). I also have galvanized cappings for the rear tub.

Ron

[JimC]

You're not going to do anything to the roll cage holes in the side of the body other than just cover them up are you?

[evilfij]

I bought a station wagon front cage for the front. I am just going to cover up the holes in the rear tub by using pieces cut from a series door (to match the contour) painted alpine white.

I can't run a NAS cage with the dormobile top and a new tub or new tub sides is too much $$$ and work.

I don't think the patches look bad at all:

http://www.copleymotorcars.com/nas_defender_1105_3_15.3.1vo1475.html

If it is good enough for an $80k truck, it will be fine for my truck.

[rmuller]

Wow... your house really is full of rover parts, I knew it!

[Stmpede]

Ron, you could have a couple bars made that bolt in place and act as tree sliders for the rear tub cage holes. I don't know if I am explaining it well, but basically a bar on each side that connects the two holes in the body and just runs parallel to the body capping. It might look kind of cool that way.

[evilfij]

I thought about that, but I can't tie it into anything because the dormobile cooker and wardrobe will be in the way.

Ron

[Stmpede]

Ahh, I forgot about all the other interior stuff in a Dormobile.

[evilfij]

No rover work this weekend. Real work calls. Where is MY recession?

[TDI Guy]

I showed my wife the pix of the rover parts in the house.. She now does not think I am the only one with a problem... She did say not to ever bring stuff into the house or I will be sleeping in the Garage.. lol

Looks good Ron. It always looks so overwelming at first with parts all over..

[evilfij]

Randy, you should see the rest of the house! I even have parts in the freezer (bushing so I can do the panhard).

I worked on work, work for most of this weekend. I did remove the bulkhead fully from the chassis and started pulling the rest of the crap off of the chassis (anyone want a 110 chassis with a bad crossmember and a mouse nest inside of it?). Man, there are a TON of wires on that bulkhead and it is heavy. Next weekend I am headed to NY to pick up the motor for the lotus and the galvanized stuff from JimC. I figure the lotus will kill a couple weekends, but before I tackle it I need to put the cappings, cage and top back on chiquita so she can sit outside while the lotus takes her spot. I need to buy or borrow an engine hoist. Probably end up buying one.

In other news, I am in serious lotus withdrawl. I caught myself driving way to fast and attempting to drift the RRC around a turn coming home from work on friday. There is an 07 exige S in buffalo (where I am from originally) for 38k on ebay. I am so tempted to buy a second lotus.

Ron

[evilfij]

Here is the old chassis that is going bye bye.

[JimC]

Is that the motor out of my yellow truck?

[evilfij]

No, that is in the new chassis in NY. That is the motor out of the donor 110 parts.

edit: you want a spare motor?

[JimC]

No thanks, my plan is for my truck to get a 2.8 while I'm deployed. I'm thinking of just shipping it to M&D.

[evilfij]

Before you do, you should take detailed pictures of everything for your (cough -- my) reference.

[JimC]

Oh, there will be lots o' pix, but this summer all I'm doing is fixing everything up and reassembling it on a new chassis. There will also be an RDS run in there too, so let me know if you need anything brought back.

[cgalpin]

The donor had a motor? What was it missing?

[evilfij]

The donor had a motor? What was it missing?

You saw it when you came to look at Janey.

Follow-up Post:

but this summer all I'm doing is fixing everything up and reassembling it on a new chassis.

JimC works faster than I do. Let me know when you are heading to RDS and I will give you a list and gas money.

Ron

[cgalpin]

You saw it when you came to look at Janey.
But I have a crap memory :)

JimC works faster than I do. Let me know when you are heading to RDS and I will give you a list and gas money.

Ron
I'm assuming you'd be swinging by my place to pick up your doors, so give me a reminder too, and maybe I'll throw some cash at George too.

[JimC]

No prob guys.

[evilfij]

I wire wheeled and primered one hinge tonight.

edit: yes, that is my kitchen counter.

[JimC]

Very impressive progress. I am nominating your for MVP though with your newfound picture posting skills. You even posted pix in that other thread about doors.

[cgalpin]

I wire wheeled and primered one hinge tonight.

edit: yes, that is my kitchen counter.
LOL. Nice EE reference there.

Yeah Ron's a madman with the photos now, although yesterday I gave him a perfect opportunity to throw a circle around a cage part and he didn't fall for it. It'll wear off quickly :)

[JimC]

Yeah, I lol'd at the watch.

[bjf]

what type of primer?

[evilfij]

Epoxy primer from lowes. I started by wire wheeling them clean as I could, then spraying them with rust converter, then two coats of primer. Tonight I spray with the group buy alpine white. This is a test hinge to see how it holds up.

[evilfij]

New bulkhead and T-pieces are here and I bought her a front cage.

[evilfij]

Work is killing me (why am I so busy when it is nice out), but I was able to refinish the front panel. I sanded and primered and painted it from the JimC group buy alpine white and then put on the LAND ROVER 110 sticker. It came to me in a sad state (originally green and then repainted red). I decided I liked that sticker the best as I could not find the one that said just 110.

Now, where do I get the really short M6 screws?

[bjf]

Ron,

I searched far and wide for this

http://www.britishparts.co.uk/.sc/ms/cat/Defender--Badges-Decals/1

[evilfij]

BJF,

Thanks, but too late now. I like what I have.

Ron

[130Tdi]

I wire wheeled and primered one hinge tonight.

edit: yes, that is my kitchen counter.
whats with the watch ? copying/spoofing expedition exchange ?
MTL on the kitchen counter-nice !

[evilfij]

whats with the watch ? copying/spoofing expedition exchange ?
MTL on the kitchen counter-nice !

Yes. EE parody for the cogniscenti.

[JimC]

anywun fur cajun?

[evilfij]

So, can evilfij swap a bulkhead in a weekend?

I got the dash out in two hours ....

[evilfij]

More progress today.

Four more hours of work. I hate taking off the passenger side fender on NAS 110s.

Ron

[mightymg]

Very cool man.... Kick ass!

[bjf]

Looking at pic 6, I have no understanding of how a 110 bulkhead rots like that. you would think they prime it will salt based paint. The under heater box rot scares me.

[dave_lucas]

Ron,

I thought you were building it on a new chassis?

[evilfij]

Ron,

I thought you were building it on a new chassis?

True, but the most recent donor had a good chassis and bozman sold me a new galvanized rear crossmember.

The new chassis will wait for the next build.

Ron

edit: it is 1:35 am and I am drunk. I better remember to wake up tomorrow am.

edit2: how the heck do you get the steering colum off? I had to mangle the steering column bracket to get it off. Don't tell me I have to drill out the bolts on the ignition switch to make it work properly.

[JimC]

You have to drill out the bolts on the steering column to make it work properly.

Of course you could also cut slots in the bolts with a dremel and take them out with a screwdriver.

[TDI Guy]

Yeah Ron, the column comes out through the engine compartment so you have to remove all the interior stuff first.. Looks good..

[evilfij]

Yeah Ron, the column comes out through the engine compartment so you have to remove all the interior stuff first.. Looks good..

I mangled my bracket to get it out the other way. :cool:

So, I sort of got it swapped in a weekend. I would have done the harness, but I do not have the right size hole saws. I measured the ECU hole at 2 1/4in and the main harness hole at 1 5/8ths.

Ron

[bjf]

are you not going to paint your bulkhead?

[evilfij]

are you not going to paint your bulkhead?

Nope, nor am I going to paint the t-pieces or the galvy cappings I have for it.

[130Tdi]

Bulkhead vents ?

[evilfij]

Bulkhead vents ?

Going to permanently bolt down some series covers and run a quasi 1993 NAS 110 dash set up.

[cgalpin]

You are truly an enigma Ron. You'd galvy your balls, but are not going to do the chassis. You build a monster garage but still work out in the dirt. To each his own. Looking forward to seeing the results!

[MUDSUX]

That is the way of the Ninja. It keeps his enemies guessing, especially for parts. I take that back, we all know Ron will buy it. Haha

Looking at your progress makes me cringe at the thought of the task before me. I have owned my 110 for almost 1 year and driven it all of 3 weeks.

[Campbell]

Love the picture of all the rovers lined up

[evilfij]

You are truly an enigma Ron. You'd galvy your balls, but are not going to do the chassis. You build a monster garage but still work out in the dirt. To each his own. Looking forward to seeing the results!

I should be done by 2020. I put in most of the harness this weekend (melting a wood hole saw, but it did work) and the wiper motor assembly (I did not realize that the td5 bulkhead was so different and I had to cut some brackets off), but I was substantially held up because my order from RN did not show up on friday as I thought it would, plus I need some more stuff I forgot to order, namely rivnuts for the steering column bracket.

I did buy the last of the stuff (I think) I need to convert the rear axle to discs. With the detroit I will be into the axle for over $1000 :( but it will have new axle shafts, new rotors, calipers, pads and DI hubs and flanges. I can't make up my mind whether to leave well enough alone and save the parts for the other truck or do this one up.

Eventually I may galvy the chassis but it is in pretty good shape and I figure it has another 10 years in it. My biggest decision now is whether to fit the dormobile roof to this one or save it for the other one.

Ron

[rover26c]

Ron, i thought you sold chicky (95 D90)?

Love the picture of all the rovers lined up

[evilfij]

Ron, i thought you sold chicky (95 D90)?

I did, she is just waiting to be picked up by the transporter guy.

[grnrvrs]

Nope, nor am I going to paint the t-pieces or the galvy cappings I have for it.

Agreed!

[evilfij]

No work this weekend. It was raining so I put the motor back in the lotus with the help of Dom. (lotus was holding the spot in the garage). Some pics tonight.

Ron

[Ren Ching]

so lotus is back up and running?


No work this weekend. It was raining so I put the motor back in the lotus with the help of Dom. (lotus was holding the spot in the garage). Some pics tonight.

Ron

[evilfij]

so lotus is back up and running?

Amazingly so.

*knock on wood*

Still need to bleed the rest of the coolant but it started on the first turn of the key after we put it back together.

[Ren Ching]

very excellent. so, entire engine replaced, rebuilt, ??

Amazingly so.

*knock on wood*

Still need to bleed the rest of the coolant but it started on the first turn of the key after we put it back together.

[evilfij]

very excellent. so, entire engine replaced, rebuilt, ??


Pulled and replaced with one out of an 05 with less miles. Had to swap the intake manifold to make the 05 work on the 06 (different throttle bodies). Entire car reassembled with anti-sieze on everything.

Keeping the old motor around for spare parts.

[evilfij]

Motor out and work pics. All back together pics will have to wait until I get home in daylight. Note the factory duct tape in picture 2. No that is not a joke, there is duct tape on a lotus from the factory (it holds the shims under the clam in place).

[MUDSUX]

Parts Ninja, sell me your T posts! It's just sitting there in the garage, up to no good. God I must be desperate as that's the first thing I saw in the picture. Nice Lotus.

[evilfij]

One is rotted at the joint at the dog leg.

I will go wander out and get a pic or two.

Ron

I have included a couple dark lotus pictures and a pic of the dormobile roof.

[evilfij]

I suppose I could repair them (I have an even worse set I can cut up for parts) and make them "ron good" and sell them to you. I know you have that crushed 97 bulkhead I have been eyeing.

[MUDSUX]

Damn that looks as bad as mine. I just placed an order with Craddocks today for a set but I have this funny suspicion I'm gonna get an email saying they're not in stock. Got one from "Sophie" this week at Paddocks. Funny thing is it was signed Sharon. I don't think Sophie is a real person.

Wow, you have a good memory. I posted pics of that bulkhead months ago. It's just sitting in the garage up to no good too. Okay I will trade you the bulkhead for the Lotus then. Pm me your address!

[cgalpin]

Forrest, don't wait for emails. Call them. You'll get an immediate answer and will know if you are going to be waiting or not.

Ron, good to see you have made some space for the 110 build. Go easy on the Lotus so it stays out!

[evilfij]

The lotus failed of no fault of me or my driving. The oil cooler line separated from its fitting (it was one of the rubber ones that have a metal fitting on it and the rubber popped out of the fitting) while the figure skater was driving to the hotel from a wedding on long island at 2am. Oil dumped out. Shut off quickly. Towed home from 3am-5am. Fixed line ("ron good" with hose clamps). Restarted: sounded like diesel but still ran. Bought used motor. Done. ;)

[Ren Ching]

so what are you using for an oil line now?

The lotus failed of no fault of me or my driving. The oil cooler line separated from its fitting (it was one of the rubber ones that have a metal fitting on it and the rubber popped out of the fitting) while the figure skater was driving to the hotel from a wedding on long island at 2am. Oil dumped out. Shut off quickly. Towed home from 3am-5am. Fixed line ("ron good" with hose clamps). Restarted: sounded like diesel but still ran. Bought used motor. Done. ;)

[evilfij]

Same one. I hacked off the outer portion of the metal and put on two hose clamps. Apparently this is a lotustalk approved "ron good" repair and will do until I get a chance to pull the front clam to replace the oil cooler lines with braided SS lines and AN fittings.

[evilfij]

After a lengthy series of 80 hours weeks, I took a day off today (my first in over a month and -- to be fair, I did work from midnight to 4:30am and a couple hours during the day so really it was a lazy friday's worth of work).

My buddy dom came over and we took off the roof, dragged it with the range rover and then pushed it with the range rover into the garage (using a series wheel and tire as a buffer) and then we cut off the rear cross member and pulled the cappings. Pics tomorrow. I need a little advice about the crossmember as I have an unforseen issue.

[evilfij]

One more day of work in. :)

[cgalpin]

A little more info please. How did the crossmember go?

And we need pictures!

[evilfij]

A little more info please. How did the crossmember go?

And we need pictures!

The crossmember is being held on by ropes, but lines right up. I don't want to weld it until the whole body is together ... getting there now. I also need some 8in C-clamps so I have to go to harbor frieght (I hate that place but sears wants $20 each and hf is $7 each and I need 4). Almost done with the dash, have the cappings you sold me installed.

I will remember to take pictures in daylight tomorrow. No real work to do so I work in the garage! :cool:

Does anyone have a template for a ST tailgate so I can convert my ROW one?

[MUDSUX]

...Does anyone have a template for a ST tailgate so I can convert my ROW one?

X2, if this is the side opening setup. I got a drop gate I need to convert.