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Project ZuLander
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sun Nov 01, 2009 11:24 pm    Post subject: Project ZuLander Reply with quote

ok this is the writeup of my new build "Project ZuLander"

well as most of you know my last project was a diesel conversion in a vitara. well since then i started entering local tagging event's, and in a desire to get my truck to go places it couldn't and i was looking along the lines of fitting LR running gear including engine and box..

so i started to hunt around when i stumbled across a Discovery V8i fitted with LPG for a steel an ideal donor vehicle i though until we went to see it... well it was apparent the body had long passed it's best before, but the chassis apart from a slight bit of surface rust was perfect, so ££ was paid and the truck driven home. it didn't take long to decide that the chassis was to good to scrap and that a new body was the way forward Smile

as the truck was mot'd and taxed for another 6months i decided to make the most and get used to the truck, it was soon apparent whilst out laning that the disco body was to big and bulky as i found out when i removed a rear quarter window :s

it wasn't long after we started taking it tagging, where it soon picked up alot of body damage to the point where i gave up fixing it and took it on a beaver tail to events.

so where to go with the body?

there are many different options available

Blitz
D-Lander
Tomcat
Tornado
Whitbread challenge frame

amongst many others, now i had a look and most of these kit's run in to a good few k's the whitbread kit is of a more reasonable cost but i was looking for something more weather proof as i'd like to use the truck for laning and trips away laning, also most of the kit's available have you cut off the rear chassis behind the axle, this i wanted to avoid cutting the chassis as it's an instant IVA test Sad

so we looked into other ideas, one was to build a custom tubular body, but we thought it would be time consuming to make doors etc to seal it up. i was sugested that a possibility was to use a external cage from something like a suzuki as a base for a tubular body with doors from the same truck type.

then the penny dropped and the idea was formed, it was obvious which route we were to take. the vitara was nice and compact as where the landrover was big and bulky on a nice strong base, though both have soft wings and panels which dent when your trying to squeze in on a punch.

now the work is been done myself and my good friend neil at www.neilhandburyracing.co.uk

so the idea:

-to find a swb vitara body

-remove front inner and outer wings

-shorten the rear, enough to keep rear seats but loose space behine seats

- build a tubular front end, allowing maximum clearance

-build a tubular rear end like above

-relocate lpg tanks from under sills to rear end

-add third lpg tank to increase range

-loose petrol tank and replace with 20l reserve tank

-configure to start on lpg

-build external cage

-fit twin 6l air tanks



that was our general idea, as we started the project we decided on a couple of changes.

-decided to loose efi system

-loose lpg feedback system and mixer (due to backfiring on start spliting pieps)

-fit lpg (propane) carb from states, works simular to SU carb but with gas Smile

- build the rear more like a pickup bed allowing enought room to mount twin tanks one either side and third to front of bed/under body depending on room (one 36l tank will be on a twoway switch to give a switchable reserve)

-remove roof panel, strengthen and replace with checker plate, (simplifys the shortening)

i expect there will be many more changes as we start to think more twisted thoughts Very Happy but enought for now and onto the build....

i'll let the pictures do most of the talking here:

firstly the disco as i brought it, looks tidy but body is hanging


note the modded rear windows Smile


this is a rough sketch plan i did on a tablet, this is to give us an idea to work from Smile


these next pictures were taken straight after and event this was that last time the disco was complete....

as you can see she's quite battered





and the stripdown comences Smile



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Project Zulander
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sun Nov 01, 2009 11:25 pm    Post subject: Reply with quote

the chassis after, this is what we have to work with, using standard mounts and holes with no cutting allowed!





i expect quite a few may recognise the body as been atached to a SS member by the name of ben, these pics where taken at 0330am when we finally arrive back at the unit with the body Smile




on closer inspection the floor plan of the body is in quite a bad state as are the arches, but we had been wondering allready about replacing the floor and have now decided to replace the sills with large box and the floor will be made of smaller box and alloy checker plate, the arches are to be chopped back and plated.

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Project Zulander
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sun Nov 01, 2009 11:26 pm    Post subject: Reply with quote

these next pics are of the test fit, the tunnel and a section of the floor have been cut away to allow us to asess and measure where the body will sit. we've opted to keep the body back slightly this is to allow the sills to match up with both the front and rear body mount outriggers and secondly it allows better access to the rear of the engine.





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Project Zulander
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sun Nov 01, 2009 11:27 pm    Post subject: Reply with quote

now the body is back off and the shortening starts, firstly neil welds in some angle across between the b pillars then a diagonal, this is to keep the body ridged whislt we shorten and replace the floor plan. the roof will stay atm solely to help keep the structure ridged, once the floor is done the roof will be replaced.








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g1oves
Just got MTs


Joined: 08 May 2008
Odometer: 448
Location: Bolton, LANCS. 3.0L TD HILUX & 2.4 TD DCAB HILUX & 3.0ltr td trayback 4runner



PostPosted: Mon Nov 02, 2009 12:04 am    Post subject: Reply with quote

Very Happy Very Happy Very Happy i like it !!! you dont mess about do you !!!!

and i like the capri !! that yours ????

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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Mon Nov 02, 2009 12:17 am    Post subject: Reply with quote

lol, nope we don't do anything by halfs Smile

it's one of our mates capri, it's a 3.0 v6 essex, we had it in for some custom work on the front and smoothing rear and side trim fixings and a custom cage.

theres more pic's here if you'd like to see
http://www.facebook.com/album.php?aid=115344&id=514413286&l=d8b5af4ef6

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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Mon Nov 02, 2009 10:01 am    Post subject: Reply with quote

i forgot to add, here are some nice pic's of lot's of shiney metal Very Happy



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scotty wong
Just got MTs


Joined: 22 Nov 2008
Odometer: 472
Location: kent



PostPosted: Mon Nov 02, 2009 8:33 pm    Post subject: Reply with quote

interesting!! will enjoy this build.


scotty

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Kitesurf
Difflock Royalty


Joined: 28 Feb 2005
Odometer: 14197
Location: Luton, Beds


1994 Toyota Surf

PostPosted: Mon Nov 02, 2009 9:18 pm    Post subject: Reply with quote

You have another watcher. Looking forward to seeing your build progress.
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4x4rick
Off-Road Guru


Joined: 06 Dec 2007
Odometer: 1900
Location: J25 M25



PostPosted: Tue Nov 03, 2009 5:56 pm    Post subject: Reply with quote

off topic slightly.........how much was the ali/checker plate £££££££££ per sheet
and lastly did you see the pic's when Ben took that body off Laughing Laughing Laughing

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Jimmy
Just got MTs


Joined: 01 Nov 2006
Odometer: 307
Location: Wirral, Cheshire


1992 Toyota Landcruiser

PostPosted: Tue Nov 03, 2009 7:15 pm    Post subject: Reply with quote

Kitesurf wrote:
You have another watcher. Looking forward to seeing your build progress.


Ditto Smile

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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Tue Nov 03, 2009 8:49 pm    Post subject: Reply with quote

4x4rick wrote:
off topic slightly.........how much was the ali/checker plate £££££££££ per sheet
and lastly did you see the pic's when Ben took that body off Laughing Laughing Laughing


i'm not to sure on the price tbh, as we brought just over £500 worth of tube, box and sheet. as theres only really one stockist in the area that we knew would have the stuff we didn't shop around.

na didn't see any pic's i don't think, you got a link?

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ciderdan
Winch Assistant


Joined: 01 Oct 2009
Odometer: 94
Location: taunton, somerset



PostPosted: Wed Nov 04, 2009 7:27 pm    Post subject: Reply with quote

nice build john can wait to see it tagging. good luck.
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sat Nov 07, 2009 12:19 am    Post subject: Reply with quote

well another part turned up today, this time it was the propane carb i've had shipped over from the states (cheapest way to buy), it's rated to cope with bigger/more powerful engines than mine, but will allow scope for further engine tuning in the future (next size down is on small side), this will simplify the engine bay wiring and make the engine less foulable to water Smile


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g1oves
Just got MTs


Joined: 08 May 2008
Odometer: 448
Location: Bolton, LANCS. 3.0L TD HILUX & 2.4 TD DCAB HILUX & 3.0ltr td trayback 4runner



PostPosted: Sat Nov 07, 2009 12:41 am    Post subject: Reply with quote

Very Happy THAT LOOKS NICE ,and not being a machanic i havn`t got clue were it goes !!!!!!!

reminds me of one of thoughs patato pealers you had in school Laughing

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RobotMan
Just got MTs


Joined: 06 Jun 2008
Odometer: 251
Location: Bishop Auckland



PostPosted: Sat Nov 07, 2009 11:11 am    Post subject: Reply with quote

Jon,

Could you post up a link to where you got your propane carb from, it looks just the thing for my 'Mog and would save me having to repair my existing carb and find a petrol tank!

Nice build btw Very Happy

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MonkeyMotorSport
Big Dog Engineering
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Sat Nov 07, 2009 9:50 pm    Post subject: Reply with quote

did you by any chance buy that disco from north devon? looks like one that used to be parked down the road.
nice build by the way! what do you plan on using it for? (obviously offroading) but laning, P&P, challenge events?

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1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Sun Nov 08, 2009 12:12 am    Post subject: Reply with quote

the propane carb was from Nash lift truck supply co in the Us ebay user Propane-kits
http://myworld.ebay.com/ebaymotors/propane-kits/

i brought a CA200-6-2 carb, this is a 200m-2-2 mixer with AT2-6 Thrtl body, there are many different combinations of both thrtl body and mixer, inc different mixer types both vary mainlt in diamentions of inlet/outlets. have a look at

http://www.teecoproducts.com/catalog/PDF%20Files_Catalog/IMPCO/IMPCO%202006%20CAT-200%20Series.pdf

scroll to page 4 for details of the different mixers and thrtl bodys, and page 2 for the full carb (mixer and body) combos

please note that some ebay sellers are listing mixers only (no throttle body!)

depending what size engine your using the carb i have might be to big, have a look at the impco training manual

http://www.impco-beru.nl/IMPCO%20Training%20Manual.pdf

scroll to page 91, this has table and equations (simple to use) to help you calculate which size of carb you'll need.

hope this helps.

aniesigh wrote:
did you by any chance buy that disco from north devon? looks like one that used to be parked down the road.
nice build by the way! what do you plan on using it for? (obviously offroading) but laning, P&P, challenge events?


yea, it came from north devon Smile can't remember the name of the place though, body had rotted out underneath before i brought it but for the price for a tidy v8 with lpg couldn't say no Smile, going to be using it for a bit of everything really, been taking part in punch events once a month, can't see that keeping the chassis the same length is going to hold me back a couple months ago i finish second with it as in the battered pic's Smile, we've decided more on a tubular pickup type bead on the back to keep a little storage room, and to make it that little bit more interesting Smile

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Project Zulander
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Sun Nov 08, 2009 9:26 am    Post subject: Reply with quote

thought so, combe martin? but theyve also got a farm/ quad biking activity centre in the middle of no-where,
recon he'll be very interested to see pics of the final product!
keep up the good work Very Happy

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1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Wed Nov 11, 2009 11:10 pm    Post subject: Reply with quote

Well we’ve got some more done on the truck, we’ve been busy bracing up the body across the doorframes so that we can remove the floor without risk of warping the body when we removed the floor.

We attacked the floor with a more un-usual method Very Happy well not so un-usual on here…. We turned the body upside down, as we decided this would make it easier to remover the floor and replace the sills.



The sills are made of a 80mmx80mmx3mm box doubled up and welded together off the truck

This is my mate Neil welding up the sills:




I even had a go at the welding Smile up until now I had only used my little sip hobby welder whish I taught myself to use, I was very happy with the quality of my welding with a decent industrial mig Smile, though I must say that neil had already setup the welder at this point



Now the following picture are of the sills resting in place on the body, we’ll tack them in place at the weekend and then test the body back on the chassis to make sure there right, after which we’ll weld them fully and then start on the floor.




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d86
Articulating


Joined: 27 Aug 2008
Odometer: 635
Location: bath,somerset,u.k.



PostPosted: Thu Nov 12, 2009 9:25 pm    Post subject: Reply with quote

Shocked christ Shocked Shocked Embarassed

tony Very Happy

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jon.g1
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Joined: 07 Nov 2007
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PostPosted: Thu Nov 12, 2009 10:56 pm    Post subject: Reply with quote

yup, no half measures here Very Happy

i forgot to say you can see in the pic's where the body has been shortened Smile, though the arch flares will be going as the arch comes in a different place.

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jon.g1
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Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Tue Dec 08, 2009 11:37 pm    Post subject: Reply with quote

been a little bit since i posted been repairing my car after a mishap involving a truck back in oct, all sorted now and back to the build Smile

i was trying to decide between bigger tyres and a locker, well decided my existing tyres where pretty cut up so would need replacing and that it was pointless buying the same size when i wanted bigger Smile

so i ordered up a set of silverstone xtreme tyres from silverline, was chuffed with next day delivery Smile

they look huge compaired to my old vit, and still look big compaired to existing wheels on the disco Smile






have also ordered up new bushes, HD steering arms, turrets, shock mounts, cones, and a 2" lift with extended shocks.

plan is to weld sills to body and attach mounts to sills, weld in box to mark out tunnel/floor then whilst neils welds in floor plan, i'll strip down top a bare chassis so we can rub down and paint, then we'll re-build with all the new parts and start on the tube work.

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ciderdan
Winch Assistant


Joined: 01 Oct 2009
Odometer: 94
Location: taunton, somerset



PostPosted: Tue Dec 08, 2009 11:46 pm    Post subject: Reply with quote

looking good mate should be a beast out tagging. keep up the work
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jon.g1
Articulating


Joined: 07 Nov 2007
Odometer: 753
Location: Taunton, Somerset, UK



PostPosted: Thu Dec 10, 2009 10:59 pm    Post subject: Reply with quote

Ok well we’re back to working on the truck again Smile got all the new parts today, looking forward to the build up

Sat untop my tyre stack Smile there is five but one is bolted on the truck


Umm, lot’s of new parts

All unpacked


And a close up


I’ve still got a few more bit’s and bobs to order up, but nearly there, have gone for terrafirma 2” med lift springs, along with the +2” shocks, skeleton turrets, standard height, dislocation cones back and front, and standard rear mounts, also I have a full set of standard bushes, and bolt’s, also a set of extended brake hoses.

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(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5805
Location: aldershot



PostPosted: Fri Dec 11, 2009 2:14 am    Post subject: Reply with quote

im looking forward to this write up/build its going to be a corker of a wagon
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nicks90
Mud Obsessed


Joined: 25 Feb 2003
Odometer: 2181



1995 Land Rover Defender

PostPosted: Fri Dec 11, 2009 11:37 am    Post subject: Reply with quote

fantastic - really looking forward to you crackin on with this.

ps. dont use those blue shock boots, they just trap muddy water in them and corrode the shock shaft.
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jon.g1
Articulating


Joined: 07 Nov 2007
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Location: Taunton, Somerset, UK



PostPosted: Sat Dec 12, 2009 8:41 am    Post subject: Reply with quote

Well we done a lot more done last night Smile , we’ve got the sills welded into place on the body, the old suspension has been removed, then finally we lifted the body onto the chassis, put the new 2” lift springs in place and put the new wheels and tyres on to get a idea of the final size of the truck, the pic’s don’t do it justice! Its going to be a beast Smile

Also note this is the first time the shortened body has been on the chassis, the flares in the rear wing are to be removed, so going to look a little different in the end,






This is only a mock up atm, this is so we can start putting the floor together, once done the body will come back off and the chassis completely striped and painted

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Mook
Off-Road Guru


Joined: 31 Jan 2009
Odometer: 1106
Location: Basingrad


1995 Suzuki Samurai

PostPosted: Mon Dec 14, 2009 11:55 pm    Post subject: Reply with quote

oh Gawd thats startin to look tasty!...........................................................................................................................................................................PAINT IT BLACK! Laughing
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muddymesser
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Joined: 17 Jun 2008
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Location: preston



PostPosted: Tue Dec 15, 2009 6:18 pm    Post subject: Reply with quote

Mook wrote:
oh Gawd thats startin to look tasty!...........................................................................................................................................................................PAINT IT BLACK! Laughing




that doesnt suprise me Laughing

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