Coil Series truck build

[TDI Guy]

Here are some pics for you guys to check out. :) Series IIa with a coil chassis, LT-77, series t-case, lots of custom stuff...

[thewap]

Nice! is that a diesel engine?:)

[TDI Guy]

Yes, a Perkins 2.0td

[TDI Guy]

Some new pics... Its getting there but tons of custom work as you can see... Will be sandblasting the bulkhead next and welding the rest of it up. Then its Galv time for lots of parts.. Stay tuned :) :)

[smenzel]

Looks great. You've got quite the truck in-progress. Very impressive.

Got a few questions:
- which axles are you using?
- are you extending the wheelbase (pushing the rear axle back) at all?
- why not galvanize the firewall?

[TDI Guy]

Thanks...

91 Rangie axles
Stock 88 wheel base./ Not stretching anything...
Once I am done welding the bulkhead, it will be galv. I always galv my bulkheads..

[Coiler]

Randy,

Do you have any issues with warping when you galvanize the bulkhead? I have always been interested in doing this and I have always been told it would warp. How did you prevent warping? Or didn't it warp at all?
thanks

[TDI Guy]

I have found the Key to Galv an thin metal and trim is to have the Galv. company not quench the parts after they are dipped to cool them and just have them air dry. This helps with stuff not twisting and warking from the heat..

[mikeslandrover]

I was kust going to ask if you had any tips for galvanising bulkheads..... :)

[TDI Guy]

Tons of Fab work done.. And Tons to go...Errrrrr :angry

[Defender13]

A few months back I was looking at your TDI build. Now this. Thats f'ing cool! If you are ever looking to sell, I am an email away ha-ha. It's too bad I don't have the know-how to do that kinda shit. Anyways, I look foward future updates.
All the best,

[KevinNY]

Where did you get the perkins? Bring it across the pond?

[BCR]

Looking good I am also very impressed by your TDi buildup

[TDI Guy]

Yeah, got the Perky in the UK... Thanks guys. I will post more pics shortly.. Lots of stuff out for Galv. right now..

[Coiler]

Randy,

Have you had any interference issues with the locationof the steering column and the brake servo on the bulkhead? If so how did you work around this?
Thanks
Ernie

[smenzel]

Mmmm ... Galvanizing ... Mmmm ... Galvanizing is a good thing ... Mmmm. :)

[TDI Guy]

Ernie, No problems at all. I will post some pics later today of my galv stuff..

[TDI Guy]

Some parts back from Galv

[mikeslandrover]

THat is exactly th effect I'm hoping for...when I get a chance to get some done.
Looking good :)
Did you specify all of that stuff to cool naturally or was it quenched?

[TDI Guy]

Do not Quench the parts.... THey can warp.. Air dry them..

[TDI Guy]

Buildup Update... Here are some pics. I just got the rear tub painted too but no pics yet. :)

[TDI Guy]

Some new pics

[ini88]

that looks amazing! coming together. i like the Trek in the background too!

[mikeslandrover]

VERY special :) :cool:

[TDI Guy]

Thanks.. there are about thousands of man hours in that thing.... IT will be on the road in a few months

[mikeslandrover]

That will be one tasty truck when it's done. Mine isn't going to be half as tidy as that, I just don't have the time, galv chassis & bulkhead and well used cleaned up bits is the sort of finish I'll end up with.
But yours....better than new :cool:

[brn24whl]

Randy
Who did your galvanizing? Do you have contact info you could share?:grin
Eric

[TDI Guy]

Its a place in Perth Amboy NJ

[aloharover]

Looking good. Why did you decide to use one piece doors?

[TDI Guy]

Thanks, I used those doors because they have been lying around my shop for 4 years now and I galv. the frames and re skined them. It was cheaper then buying entire new doors and tops. I can tell you that they are a really nice fit and much more solid then the half doors on my d-90. Plus I will be putting a Safari Roof on the truck so the rool down door will be nice. The window is quite big.

[mikeslandrover]

Yep with the glass rolled down it's almost the same as taking the door top off :cool:

[KevinNY]

I just got my coiler back from Matt at Overland Enginnering with my power steering conversion and Delco alternator. PS is sweet when you've gone without it. dual ARBs and Longtracks axles/CVs up front are next. I'll edit in some pics later.

Follow-up Post:

Some pics in process.

[TDI Guy]

Kwvin, did they have to move the x-member up or something? Lets see more pics. I will post some more of the series build later today also.

[KevinNY]

Yep, crossmember was cut out and a new one was made and welded in forward.

[kevb]

Hi Randy, I am really impressed by the quality of your rebuilds, nice job! On the coil series conversion have you hade to fabricate or buy loads of custom parts? I am planning a rebuild of a series 2a later in the year, always fancied a designachassis rebuild but thinking of keeping it simple for this one.

[aloharover]

What box is that Kevin?

I am still getting incrediably lucky with the Scout boxes. Just picked up another one for 75$ for my project.

Yep, crossmember was cut out and a new one was made and welded in forward.

Follow-up Post:

Hi Randy, I am really impressed by the quality of your rebuilds, nice job! On the coil series conversion have you hade to fabricate or buy loads of custom parts? I am planning a rebuild of a series 2a later in the year, always fancied a designachassis rebuild but thinking of keeping it simple for this one.If you are going to put coils under a Series frame, a whole lot of fabbing.
If you are going to convert a RRC or D1 frame to fit the Series body, its not as bad. Specially if you have a series frame you can first tkae lots of measurements and photos from. And then cut off the outriggers and rear xmmember from.

If you plan on keeping the 88 tub I would cut 10" out of the coiler frame and make it a true 90. This will center up the axle in the wheel wells.

[KevinNY]

It is a designa chassis. All rover parts, D90 column and a disco box. Did a GM alternator conversion at the same time.

[Coiler]

Randy,

When you painted the bulkhead, what kind of primer did you use since the bulkhead had been galvanized? What kind of prep did you have to do to the galvanizing before you could use the primer?

[TDI Guy]

Kevin, if you do the Desiga chassis, its just a bolt on set up with very minor mods. Thats a killer D-90 you got there too...



Ernie, after galv, sand and scuff the entire thing and get rid of any galv runs or bumpy spots with a sander then you have to metal wash and prep it with special 3M products.. then hit it with the primer.

[TDI Guy]

I will get some more pics today... I actually took it around the block the other day.. All is good. :crazy

[TDI Guy]

Pics

[TDI Guy]

Some pics

[mikeslandrover]

Very neat.....I'm envious...partly over the speed of the build, mine's taking forever.
Are you going to fit some sort of wheel arch extensions or will you get away without? :)

[kevb]

Thats coming along nicely Randy. How many man hours do you recon you have in the rebiuld?

[TDI Guy]

I can't even imagine the hours.. 100's I would guess

[Coiler]

Randy,

The truck looks awesome!!!! I have another question for you. What brake setup are you using on the bulkhead? please tell me which booster and pedal mount you are using. Did you have any interference with the booster and series hood using the D90 bulkhead?
Is that an R-380 transmission?
Before I bought my 90, I was building a coiler with a designa/ECR chassis. I sold my project because I thought I was trying to make a series truck a 90. Anyways, I sold the 90 and I am beginning to start tearing down my 88. I am thinking again about going this route.

[TDI Guy]

Its a standard late IIa-III booster setup. bolts right to the d-90 bulkhead. No mods. ITs also an LT-77s onto an LT-230 t-case.

Its going to be a great little rig.... I wish tere was more leg room like the 90 though. I am tempted to take out the bulkhead behind the seat since I am running d-90 seats anyway. I hate to do that to the tub but it would make a lot more room. Has anyone ever done that before on a series?


I have driven it around already and it really moves. Does not feel like your standard sluggish series truck for sure..

[Coiler]

I am pretty sure that I saw someone use a modified bar from a 109" station wagon and put it in place of the rear bulkhead on a 88".

[kevb]

You could try a bulkhead removal bar and seat rails from Mud UK

http://www.mudstuff.co.uk/Bulkhead_Removal_Bar.html

[TDI Guy]

I would like to see it before I do it. That one will only work on euro d-90s

[KevinNY]

I read back and am a little confused, you useing a series tcase or LT230? Is the rear output moved back a bit with the lt77 in there? Since my OD is toast I am thinking of doing an LT77 but my rear shaft is at max angle now and if the rear output moves back than I am looking at a double double CV shaft to make things work.

[Lucasd2002]

Have you guys seen a coiled 88 with 4.0/LT230/ZF slushbox - i.e. everything out of a later D1? Maybe something Matt B has done? just curious

btw, great lucking truck Randy

[KevinNY]

I know he is going to be working on something like that but with a 300tdi.

[Lucasd2002]

I was thinking that keeping it all in the D1 family might keep it relatively affordable...

[KevinNY]

No reason it could not be done.

[aloharover]

Its going to be a great little rig.... I wish tere was more leg room like the 90 though. I am tempted to take out the bulkhead behind the seat since I am running d-90 seats anyway. I hate to do that to the tub but it would make a lot more room. Has anyone ever done that before on a series?
.I have seen it done a couple different ways.

1. The cleanest was to cut the bulkhead down shorter and remake the galv capping piece.
crappy ASCI art

\__/

So the horizontal bit was maybe 6" above the tub floor. the sides were probably a 60*-70* angle.

2. On my tub I totally removed the bulkhead. I have a full interior cage. The B hoop has tabs that go and bolt to the cappings on the tub sides. No flex or movement when closing the doors. Worked out well.
I have moved my seat back 3-4 inches. made up a new mount for the sliders. The passenger seat was moved back 2. Can't go further due to the fuel neck.

3. Totally removed and then use a 90 type stiffening bar.

4. A 109 3-door tub is deeper behind the seats then an 88. I have seen where someone uses a 109 tub, cut the back end off, and 88 sides.

On my current build I am using the modifed 109 tub, but I am thinking about modifying the tub as in #1

[evilfij]

You can also use a 109 bulkhead and cappings on an 88 tub.

I would just pull the bulkhead out of there (if you do it cleanly you could always put it back in). and put in a NAS style bar between the seats.

[TDI Guy]

Ron, thats what I did on my 90 Euro rear tub. Just removed it and installed the NAS cage. You cant even tell. I will see how It is driving before I do anything to it though..

[badgerman]

Randy,

I removed most of the bulkhead on my tub and don't use any bar. If you look at each end of the bulkhead you will see a lot of bends, and if left on will give plenty of strength. Give me a call and I can go into it at length. I also moved the driver seat 2" in towards the center of the vehicle and then moved the tracks back 2". What a difference. I have Recaro seats in mine and like the snugness the bolsters offer. I will try to take some photos for you. Wasn't there something else that I was suppose to take photos of as well?

[Cirbo]

Have you guys seen a coiled 88 with 4.0/LT230/ZF slushbox - i.e. everything out of a later D1? Maybe something Matt B has done? just curious

btw, great lucking truck Randy

I've wheeled with a few of them. One was a direct transplant from a Range Rover Classic, the other was similar, but had a 4.6 replacing the old 3.5.

Both nice trucks though.

jC

[TDI Guy]

Randy,

I removed most of the bulkhead on my tub and don't use any bar. If you look at each end of the bulkhead you will see a lot of bends, and if left on will give plenty of strength. Give me a call and I can go into it at length. I also moved the driver seat 2" in towards the center of the vehicle and then moved the tracks back 2". What a difference. I have Recaro seats in mine and like the snugness the bolsters offer. I will try to take some photos for you. Wasn't there something else that I was suppose to take photos of as well?


Chris, you will have so send me some pics when you get a chance...


I will try to get some updated pics up shortly. Its mostly done. :cool: lots of odds and ends though.

[badgerman]

I'll try to get my Land Rover in the shop so I can take some photos of the back and front view.

[TDI Guy]

Thanks Chris....

[KevinNY]

Randy,

How have you routed the exhaust? Any chance of a pic? Also have you considered adding an intercooler?

[mikeslandrover]

Randy,

How have you routed the exhaust? Any chance of a pic? Also have you considered adding an intercooler?
An intercooler would reduce any heat stresses on the engine if you dont increase the fuel :cool:

[TDI Guy]

I did not do the exhaust yet. I will be bringing it down the road shortly for them to make one up. DOnt know what type of muffler to use though..

Some teaser pics.. :)

[KevinNY]

You really have a talent for doing this Randy, can't wait to see it in person.

[jorge]

Looks almost ready for your Dad to join us on the rocks . Beautiful job , when it's time for my D90 restoration I know where to go.

[mikeslandrover]

Looking good.
Transmission cover?? is that a D90 tunnel I see grafted to a series bulkhead or a IIA shelf grafted to a D90 bulkhead? It's very well done either way :grin :thumbs :thehand

[evilfij]

IIa shelf on D90 bulkhead. BLING!!!!

Ron

[TDI Guy]

Yup, you are right. You cant even tell when looking at it. It was a bit of a pain in the ass to do though.. Jorge, yours is next.

[LRNAD90]

Yup, you are right. You cant even tell when looking at it. It was a bit of a pain in the ass to do though.. Jorge, yours is next.

You do some incredible work Randy, thanks for sharing with the group. I only wish I were that talented, not to mention wishing I could even find the time try. I'm living vicariously through your work, keep sharing! LOL!

[TDI Guy]

lol... thanks... I'm getting burned out.. Glad its almost done and summer time. Time to wheel and enjoy the work shortly.

[TDI Guy]

A few more details get done.. Along with a test drive... :)

[cellulararrest]

keeping the 90 alloys?

[mikeslandrover]

Outstanding :cool:

[TDI Guy]

Yes, the alloys are staying for now. Will have a set of steelies too

[Oxcart13]

Randy - if the images of you rig is not 'rover crack' I don't know what is.... Mark

[cellulararrest]

Yes, the alloys are staying for now. Will have a set of steelies tooGood to hear. Series trucks just look wrong with silver alloys... :)

[oldscratchggf]

That`s sexy

[TDI Guy]

My dad actually hates the steelies so the Alloys will be stayin' Steelies only for wheelin'.. IT looks really nice actually.

[KevinNY]

So now that you have had a chance to drive it a while, how is that perkins doing?

[TDI Guy]

Runs great. Just stripped the front of the motor down though.. Blew the old water pump that I did not replace... I'm an idiot... lol. Othere then a small oil leak that I think I will have fixed, All is good. I will get more pics up shortly

[chrisvonc]

Coming along nicely!!

[KevinNY]

Did you fit an exhaust gas temp guage?

[mikeslandrover]

You're all obsessed with exhaust temperature :)

[mikeslandrover]

Have you fitted an intercooler or upped the fueling? :sneaky

[TDI Guy]

No EGT gauge... I have no intercooler and have not touched any fueling yet...

[TDI Guy]

Some 88 custom drive train Porn :)

[cgalpin]

I think I see a spec of dirt..... somewhere... sorry it was the ground :)

[mikeslandrover]

Very clean and shiney, what transfer ratios are you running? That looks like a late model transfer box :cool:

[don]

I saw this truck recently in person and the level of cleaniness is amazing and there was absolutely no detail that was left untouch. Wish I had a little more time to check it out some more and maybe hear that diesel mill run. I'm also kicking myself now for not taking a peek underneath.

The alloys do look cool on it although I would love to see what it would look like with some white steelies. Very nice job on it Randy :thumbs:

[TDI Guy]

Thanks Don... I wanted the steelies. It was not my idea to do the alloys on the series... Want to buy it?

[budz]

Nice...

Some 88 custom drive train Porn :)

[don]

Thanks Don... I wanted the steelies. It was not my idea to do the alloys on the series... Want to buy it?haha, your dad was mentioning selling it and the story of some football playing making an offer on it at a gas station. I would love to get it for my dad as he'd love the MPG from the Perkins and having a nice old Rover especially with the coil springs but I can barely keep up with the project costs on my '95 :)

[Buyrovers]

Thanks Don... I wanted the steelies. It was not my idea to do the alloys on the series... Want to buy it?
How much?

[TDI Guy]

I will talk to him to see what he wants for it. He Needs room for the new 90sw..

[TDI Guy]

Its for sale in the For Sale Section Now....

[Bozman]

Link to the For Sale page . . .

http://www.d-90.com/forum/showthread.php?t=19162

Good luck with the sale. That is a great price.

[TDI Guy]

I think so... Turn key COOL ASS Truck... I even have a set of 16" steelies if someone hates the alloys.. I would swap them out or work out a deal..

[Classic Rover]

Randy,

Maybe this is a private question... but if not can you tell us what your motivation was/is on this project? Obviously, you have done a exceptional renovation/upgrade. Really a nice project.

[TDI Guy]

I had the truck for years sitting under a tarp behind my shed along with a Ser III that I just sold. My dad wanted a rover so it developed into what you see. I also had the perkins prima for years. Most of the parts were all there. Bought the frame and new bulkhead and went to town. Took just over a year..

As usual, when I start building something, I go overboard :) Its some sort of Rover problem.. I'm sure you guys can relate..

[TDI Guy]

Wrong page..

[mikeslandrover]

What do you mean...wrong page?

[cgalpin]

http://www.d-90.com/forum/showpost.php?p=290341&postcount=233

[TDI Guy]

I started typing something and made a mistake. It would not let me leave the page black to save it...lol

[jvelador]

Hey Randy,

Someone asked the question about the LT77 being mated to a Series transfer case and if the LT77 caused the rear output on the TC the be farther back.

Do you think I can mate my stock 2.25l engine to an LT77 and keep the Series TC?

[TDI Guy]

Hey Randy,

Someone asked the question about the LT77 being mated to a Series transfer case and if the LT77 caused the rear output on the TC the be farther back.

Do you think I can mate my stock 2.25l engine to an LT77 and keep the Series TC?

Yes u can.... Ashcroft makes a kit to do it. It does make the rear shaft shorter and you have to do some minor tunnel trimming but it is so much nicer of a trans. The setup you see in the build pics actually was sold locally when I switched over to an lt77/r380 setup in that truck. The guy that bought it loves it and gets his truck up to 80mph so he says.