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Project ZuLander
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jon.g1
Articulating


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



PostPosted: Mon Feb 01, 2010 11:21 am    Post subject: Reply with quote

marky mark wrote:
can i ask.. why a vitara shell Question


well we looked at making a fresh body, reason been we wanted a body that was narrower as the disco body is to wide for the local lanes and events. So we weighed up the pros and cons and decided is would be alot of hassle to get a self built body reasonably weather tight, then the idea of a vit body came about. It's narrow and reasonably well suited to using as just a cab Smile and it will look dfferent, by the time were done there won't be much recognisable as a vit

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Project Zulander
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Winnet
Difflock Royalty


Joined: 03 Dec 2003
Odometer: 14714
Location: Aberdeen


1985 Land Rover

PostPosted: Mon Feb 01, 2010 12:50 pm    Post subject: Reply with quote

Looks like that will be a pretty good machine when it is finished.

G.

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Bored......

All these questions and more after the tea break.
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UK_Andy
Just got MTs


Joined: 20 Dec 2009
Odometer: 301




PostPosted: Mon Feb 01, 2010 2:13 pm    Post subject: Reply with quote

I see you wanted 4 seats but the arches take up too much room, why not have 3? third one being in the centre
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jon.g1
Articulating


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



PostPosted: Wed Feb 03, 2010 5:09 pm    Post subject: Reply with quote

UK_Andy wrote:
I see you wanted 4 seats but the arches take up too much room, why not have 3? third one being in the centre


we're still debating seats, having three has been discussed. when I started project I was after four but now thinking of making removable storage for the rear.

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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 Mar 07, 2010 9:56 pm    Post subject: Reply with quote

Well, the general floor layout has now been finished, although there are still battery boxes to add.






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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 Mar 07, 2010 9:57 pm    Post subject: Reply with quote

All the suspension arms have been painted along with the axles, and have now been fitted to the chassis. Although the steering box and panhard are yet to be fitted.













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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 Mar 07, 2010 9:57 pm    Post subject: Reply with quote

This is the stage the truck is at now, the body is fitted back on, next on the todo list is to finish plating the gearbox tunnel and floors the later of which will be done with checker plate Smile, then i need to make the dash and start on the wiring and plumbing.






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Project Zulander
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ciderdan
Winch Assistant


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



PostPosted: Mon Mar 29, 2010 12:03 pm    Post subject: Reply with quote

lookin good mate any up dates?????
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excossack
Mud Obsessed


Joined: 06 Mar 2005
Odometer: 2902
Location: Somewhere



PostPosted: Mon Mar 29, 2010 12:14 pm    Post subject: Reply with quote



Cracking build, but i cant help but think this ^ looks like a smiley face with gozzy eyes!

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jon.g1
Articulating


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



PostPosted: Tue Mar 30, 2010 5:47 am    Post subject: Reply with quote

excossack wrote:


Cracking build, but i cant help but think this ^ looks like a smiley face with gozzy eyes!


lol, i thought the same Smile thats why i posted it, kinda reminded me of Jonny 5...

not really much more to report atm, we found the first lot of tube we brought was to hard for bending so are in the process of getting more tube. really itching to get it done mnow in time for the summer Smile

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jon.g1
Articulating


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



PostPosted: Wed May 05, 2010 9:59 pm    Post subject: Reply with quote

Ok, well I know I said I wouldn’t do it, but I’ve finally decided to loose the overhangs!! Yup both of them! As the radiator is going on the rear we’ve decided to mount the front tray as far back as we can to allow for maximum approach angle. We’ve yet to weld in the tray and trim the front down as we wanted to have a play with the rear Wink



Firstly a length of angle is welded across the front of the chassi to hold it in shape, then the front X member is removed and the winch tray trimmed to fit



A couple pics of the winch been test fitted to check clearance




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jon.g1
Articulating


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



PostPosted: Wed May 05, 2010 9:59 pm    Post subject: Reply with quote

Ok, now onto the rear, firstly a bit of weight loss….



Then the bottom is cut level and the sides of the tray welded in, later the welds are capped over to add extra strength, the tray in use here was the bolt on front tray I had originally fitted to the front. But we wanted something stronger upfront.





Once the tray is welded together, neil started work on capping the ends to add even more strength, also note the large angle welded under neath, this is to add strength and to doube up as the mounting point for my nato hitch.





Just a couple shots of the winch in place, you may notice that although the winch is mounted bottom back, the clutch is facing up, to do this I dismantled the winch and rotated the gearbox, it sits at a slight angle but has good clearance, my winch is a t-max so I’m not sure if this can be done on others.




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ciderdan
Winch Assistant


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



PostPosted: Wed May 05, 2010 10:15 pm    Post subject: Reply with quote

looking good mate glad u did the chop on it keep up the good work
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Ldavis2010
Gate Opener


Joined: 09 May 2010
Odometer: 1
Location: Chard



PostPosted: Tue May 11, 2010 7:04 pm    Post subject: Reply with quote

Thank god u chopped the over hang off m8 will pop out soon m8 to see how it's going
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ciderdan
Winch Assistant


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



PostPosted: Sun Jun 06, 2010 4:09 pm    Post subject: Reply with quote

hows the build doing any updates?
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jon.g1
Articulating


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



PostPosted: Mon Jun 07, 2010 7:56 pm    Post subject: Reply with quote

Just a little update, project has taken a back burner atm as had other jobs to get on with, but we now have chopped down the body into just a two seat cab Smile






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Project Zulander
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ciderdan
Winch Assistant


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



PostPosted: Mon Aug 23, 2010 11:58 am    Post subject: Reply with quote

hello mate any updates on this build???
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jon.g1
Articulating


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



PostPosted: Mon Oct 11, 2010 7:25 pm    Post subject: Reply with quote

Well it’s been I while since I updated, the workshop has been busy lately with paying work so my trucks had to take a backseat due to a big job we took on. Well I’ve been doing little bits hear and there and have just had a week off so spent some of it working on the truck, I’ve put framing in on which the twin batteries will sit one under each seat. We’ve started to profile the back end of the cab, has been a little bit of a mission to make enough room to sit the main LPG tank behind the passenger seat. I’ve now decided that I am going to run fully on LPG and use all three tanks, a mate has taken on the new manifold (stromburg we think) to machine down the top and fix a new plate on which to mount the propane carb I have














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Project Zulander
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jon.g1
Articulating


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



PostPosted: Mon Oct 11, 2010 7:26 pm    Post subject: Reply with quote











Well, these last couple of pictures might interest some, I did a bit of hunting around on the new a didn’t really turn anything concrete on mounting a second alternator. Then I was nattering to a mate who’s stripping down his old RRC trailer who happened to have a second alternator bracket. So a few ££ later I had the bracket and another 80A alternator.




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N.R.G97
Off-Road Guru


Joined: 09 Dec 2009
Odometer: 1501
Location: somerset.


1966 Land Rover Hybrid

PostPosted: Mon Feb 14, 2011 7:46 am    Post subject: Reply with quote

hows it getting along? tagging soon Wink Laughing
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landrover 2a hybrid
http://www.wellspacedout.co.uk/home
http://www.winch-it.com/index.php
http://www.profendersuspension.com/
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jon.g1
Articulating


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



PostPosted: Tue Feb 15, 2011 11:32 pm    Post subject: Reply with quote

it hasn't really changed much since the last update, we've been busy re-locating the workshop to taunton, should mean once we're all up and going i can get more done on it as new workshop is only a couple of mins from home Smile so hoping to push it along more quickly now.
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jon.g1
Articulating


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



PostPosted: Thu Oct 27, 2011 11:14 pm    Post subject: Reply with quote

Well it’s been many months since I’ve updated, a number of things have slowed us up, my mate has relocated his workshop to a bigger unit nearer to home, also taken a break from the build whilst I build up funds to complete as we had a lot more to buy.

Before we left the old unit we had started to chop the over hangs, I didn’t like the look of the RSJ winch tray in the previous pictures so went and brought a weld in tray from Devon 4x4, it’s a lovely bit of kit, what we found was that after chopping out the front X-member that there was a bit of play, so we used a length of threaded bar through the mountings on the chassis and pulled in the top and placed a couple of heavy tacks, then repeat for the bottom, then fully weld in.














I’ve just had a week off, so work has started again on the truck, firstly some pictures of how it stands atm. As you can see we’ve maximized the approach and departure angles Smile











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jon.g1
Articulating


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



PostPosted: Thu Oct 27, 2011 11:15 pm    Post subject: Reply with quote

Next Neil started work on the roof, the original panel was badly warped after we had it upside down to weld the floor in, also I wanted something much stronger…….

Neil trimed back the inner skins and seam welded together for strength before making and welding in a roof frame, this serves a couple purposes, I can mount things like a cb to the roof out of harms way, storage and I’ll let the last pic tell the rest Wink this will have a sheet of checker plate to finish it off.
















Then work moved to the rear of the cab, plating, and welding the B-pillars to the remains of the C-pillars, hopefully this will mean no breakages Smile over engineered in true British Fashion Smile














And finally my new toy, after some practices with the hydraulic center press bender we got, we decided it wasn’t up to the job, so I’ve saved up and brought a pro tools 105HD bender, bend-tech software and a whole load of Certified CDS tube Smile it’s cost a fare few bob, but I want this done properly Smile





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muddymesser
Mud Obsessed


Joined: 17 Jun 2008
Odometer: 7819
Location: preston



PostPosted: Fri Nov 25, 2011 11:37 pm    Post subject: Reply with quote

looking good Cool

dont know how i managed to miss the updates Embarassed

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aniesigh
Articulating


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


1991 Suzuki Samurai

PostPosted: Sun Nov 27, 2011 9:30 pm    Post subject: Reply with quote

i missed the updates too, again not sure how Confused be interested to know how you get on with the bender and Bend-tech, its all reasonably high up on my shopping list if things go well Cool its looking good though!
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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: Mon Nov 28, 2011 12:04 am    Post subject: Reply with quote

lol, hopefully more to come soon.... we've cut a bit more of the zuk body away.... A pillars were rotted badly so started to replace with 3" box and the doors (well pass side so far) will reside on lift off hinges, so i can have some summer tube doors Smile.

i got the 3d version on bend-tech to start with, but then after a play decided on buying a pro upgrade (cost the same buying 3d and upg as buying pro) as the pro version allows you to design the whole cage as where 3d allows only one tube at a time. need to sit down and have a good play with it. i will let you all know how i get on..

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Joe Hawkins
Gate Opener


Joined: 06 Nov 2011
Odometer: 48
Location: Cardiff



PostPosted: Wed Nov 30, 2011 6:25 pm    Post subject: Reply with quote

jon.g1 wrote:
lol, hopefully more to come soon.... we've cut a bit more of the zuk body away.... A pillars were rotted badly so started to replace with 3" box and the doors (well pass side so far) will reside on lift off hinges, so i can have some summer tube doors Smile.

i got the 3d version on bend-tech to start with, but then after a play decided on buying a pro upgrade (cost the same buying 3d and upg as buying pro) as the pro version allows you to design the whole cage as where 3d allows only one tube at a time. need to sit down and have a good play with it. i will let you all know how i get on..


Been thinking about getting bend tech pro for a while, how much did you get it for? let us know how you get on. great build by the way.

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1994 200tdi disco challenge trayback (in the making)
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Disco Bov
Winch Assistant


Joined: 29 Sep 2011
Odometer: 66




PostPosted: Wed Nov 30, 2011 8:33 pm    Post subject: Reply with quote

what size are those new tyres??
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hairyguy4
Just got MTs


Joined: 08 Oct 2010
Odometer: 136




PostPosted: Wed Nov 30, 2011 9:58 pm    Post subject: Reply with quote

i like the concept, its starting to look like a really handsome truck so far Cool
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toyota hdj80
suzuki samurai
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jon.g1
Articulating


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



PostPosted: Fri Dec 02, 2011 8:22 am    Post subject: Reply with quote

Joe Hawkins wrote:
Been thinking about getting bend tech pro for a while, how much did you get it for? let us know how you get on. great build by the way.


i had a hunt around and found by far the cheapest way to purchase is direct from the people who made it

Online shop
https://www.2020softwaresolutions.com/shop/

Home site
http://www.bend-tech.com/

i have yet to have a proper play, but will update everyone once i have.

i'm over the workshop tomoro so will snap a couple pics of the hinge setup were using, also i've now got a set of 30mm spacers.... Razz only fitted the back ones so far but defo looks better Smile




Disco Bov wrote:
what size are those new tyres??


There Silverstone Xtreme 35x10.50x16 they actually measure in at about 34" high inflated on rims, but coupled with my suspension lift i've got one hell of a gound clearance and breakover angle atm, i guess it'll probably settle down a bit once i'm using the truck thou Sad




hairyguy4 wrote:
i like the concept, its starting to look like a really handsome truck so far Cool


Thank you, i'm trying to keep it looking different, we've lost and have plans to loose most of what is left of the vitara curves... mainly to add in some strength ie: side bars in the doors to protect against caving them in, entire bulkhead gone so far except the section housing the wipers.... but thats going soon Wink floor, roof, rear door and frame below the window. pretty much all we will have used it the windscreen and frame, and about 90% of the main doors and there frames Wink and about 30% of the back door lol. this truck should hopefully stand up to a fair bit of harsh use.

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