Rover /toyo truggy HI-ROVER FINISHED (FOR NOW)

[discothrasher]

Kelvin...do yourself a favour now and save work later on.

Take all of those pre-cast bends and throw them in the bin. They are not good enough for sliders and definitely not good enough to hang a cage onto. I did the same thing a while ago because they were easy and neat, but they are not good enough for our application. You're much better off bending up a 90 degree and using a one piece.

And if you can't be farked changing it, put two more gussets on that slider near the pre-cast bends.

thanks on the pre bends yes they are very easy and neat and will put extra gussets in now and was planning on plating the corners to help there ...
would love to hear more info like this to improve the build,as i want to try get this build as spot on as our aim is to make it proof

[def90]

i would use notched tube instead of flat bar for the gussets too, hell of alot stronger, what wall thickness and size tube is that?

[discothrasher]

i would use notched tube instead of flat bar for the gussets too, hell of alot stronger, what wall thickness and size tube is that?

Hey Sam as said in earlier picture post the frame is not completed strenghing welds and gussets are not done yet and yes we are using notched tube for the gusstets
box section 3mm tube is heavy duty scaffold tube which is the strongest tube you can get for our price range

[def90]

ah kool, dunno if 3mm scaff toob would be the strongest tube you could get? you mean for the premade bends?

[discothrasher]

ah kool, dunno if 3mm scaff toob would be the strongest tube you could get? you mean for the premade bends?

heavy duty scaff tube is the strongest tube in steel for that size which we can afford and thats the tube we will be using for entire cage and whats been used in the sliders got many 6m lenghts which hopefully get full runs once we bend it so welds will be minamal
pre - bends have now idea on there strenghts but will be heavily gusseted and braced in the area

[def90]

no worries, i thought greg had a bender?

[RAY185]

ah kool, dunno if 3mm scaff toob would be the strongest tube you could get? you mean for the premade bends?

heavy duty scaff tube is the strongest tube in steel for that size and thats the tube we will be using for entire cage and whats been used in the sliders got many 6m lenghts which hopefully get full runs once we bend it so welds will be minamal
pre - bends have now idea on there strenghts but will be heavily gusseted and braced in the area

Yeah a mate of mine was telling me they used that scaff tube on the landing struts of all the hovercrafts on the English Channel that cross from Dover to Calais, but it was only 2.4mm. It is good shit and you definately won't find stronger. 3mm is probably overkill on a roll cage and sliders but at least you know it will NEVER fail.

[discothrasher]

no worries, i thought greg had a bender?

no , i have just bought one awaiting delivery

[def90]

kool, u'll have her knocked in no time at this pace

[discothrasher]

kool, u'll have her knocked in no time at this pace

yeah hopefully main thing now is to get it all wired up running 100% before the jungle jim goes up around it and learn to use the pipe bender properly at least i will have to do less welds with the new bender
can't wait to get it out test it then cals creek is on the cards hopefully see you out that weekend

at least my D2 can take a break and start getting some panel beating done so it goes back to my extreme tourer and tow car
[/url]

[def90]

Any progress kelvin?

[discothrasher]

Yeah Sam saturday was a big day removed gear box and transfer got the torque flite all ready to go in and realised we where missing one adaptor so thats put a hold on getting that in ,so cut off all the outriggers and sanded them back and removed as much as we could that was not needed then did all the bracing gussetting for the base frame which does not seem like much but we worked solidily all day all the stuff done was all the tricky finicky welds ect.. super strenthened the trailing arm brackets all round so in a whole the chassis and base frame is definately completed we have definately gone overboard in the stenghining but it will be well worth it in the long run,now its just to find the spacer plate from the crankshaft to the torque flite flywheel so we can get that in and get the body back on to start rewiring .
At least all the hardest parts are done now its just getting it back together .

also picked up my 40"sticky treps and get my 17x9 rims in early January
those 40"treps are one mean mother fucker of a tyre.
cheers Kelvin

[def90]

How u doing your links?

[uninformed]

does anyone have specs on what scaff tube really is???

nice work Kelvin, what bender did you buy? your flying through this work mate.

cheers,
Serg

[discothrasher]

Yeah Sam for now its the std but Greg from Outcast is in the middle of devoloping something very special and will let you know down the track
here is some info Serg my scaffold engineer is getting some more high teck specs if ya still want them i got a JD squared model 3 the die for bending scaf tube was more expensive than the bender

HomeProfileNewsProductContact UsEN39 Steel Pipes standard
Shanghai Sonitic Steel Trading Co.,Ltd,Products - Steel Pipe Standard - EN39 EN39 Steel Pipes standard
We are a professional manufacturer and exporter specializing in Scaffolding tube. Our Scaffolding tube has been strictly tested according to the EN39 international systems. They enjoy excellent market and high reputation among our customers.

Scaffolding is a temporary platform, either supported from below or suspended from above, on which workers stand when performing tasks at heights above the ground. Construction jobs may require several kinds of scaffold to permit easy working procedures. Steel Scaffold may range from individual planks placed on structural members of the building to involved patent scaffolding.


EN 39 2001
TUBE TYPE 　 Outside Dia. of Black / Galvanized Tube 　 Weight of Black / Galvanized Tube
SIZE Minimum Maximum Wall thickness Plain Ends Pieces
NB (mm) Inches mm Inches mm Inches mm Inches Kg./Ft. Kg./Mtr. per bundle
3 40 11/12 47.8 1.882 48.8 1.921 3.2 0.126 1.09 3.56 61
4 40 11/12 47.8 1.882 48.8 1.921 4 0.157 1.332 4.37 50
1 TOLERANCE :a) On Specified OD + 0.5mm (Ovality 0.5mm)
:b) The Inside Diameter of ubes shall allow insertion of a guage of 37.7mm dia for a minimum length of 200mm.
:c) On Wall thickness -10%
:d) The mass deviation on a single tube shall not exceed -7.5% of the specified mass.
2 ENDS : Cut cleanly and nominally square with the axis of the tube and free from excessive burrs.
3 PROPERTIES :a) Chemical (Maximum) C - 0.20%, SI - 0.05%, MN - 1.40%, P - 0.04%, S - 0.045%, AL - Min. 0.02%.
:b) Mechanical = UTS - 340 to 520 N/mm2, YS - 235 N/mm2 (minimum) & %Elongation on 5.65 S0 - 24% (minimum).
4 FLATTENING TEST WELD AT 90 DEGREES (COLD) :a) For weld : Distance between the platens, measured under load is not greater than 75% of the OD of tube.
:b) For Material :Distance Between the platens, measured under load is not greater than 60% of the OD of tube.
5 STRAIGHTNESS : 1 in 500 (In 1 meter it should not exceed 3mm).
6 ZINC COATING (GALVANIZING) : Minimum local coating thickness on the outside surface 40 microns.

7 MARKING : a) We can emboss mill sign "EN 39 UTP 3 or 4." online at every one meter interval over the length of pipe.
b) We can do online stencilling as per customer needs.
8 PACKING : Hexagonal type.
9 MILL TEST CERTIFICATE :We can issue a MTC, certifying that the tubes supplied comply with this Standard.

[discothrasher]

so today was quite productive in setting up all the wiring totaly stripped all the heater box dashboard drank some beers then stripped all the shit which is not needed in a comp truck removed the steering lock and key assembly will be push button start,drank some more beers it was hot okay ,also fitted the brand new bucket seats which needed all new holes drilled but was not to hard ,they really comfy ,fitted the handbrake and connected also we are going to fit a good rangie top section of there dash will be cut down as will not fit in the hilux cab drank some more beers it started getting hotter , removed the AC condensor to free up some space in the engine bay ,would be nice ,but no drank some more beers then ran all the wires back into the hilux cab set up the computor postion for the fuel injection which fits nice and high on the rear hilux cab wall ,and removed the hood linning sorry no pictures but doing wiring is not to picture friendly ah yeah did i tell you fuck i hate rewiring stuff and finished of the day with some more beers

more wiring next year
cheers Kelvin

[discothrasher]

Okay so after recovering from a rather large new years eve party ,i have done the first work of 2011

i re ran and bent into place the rear brake lines and conected and did the same for the front brake lines

did some more placing of the electrics in the cab

and connected the fuel lines to the engine and re bent and ran those to behind the cab ready to connect upto the steel fuel cell which am waiting to get back from the acid washers

so next will be plug away at the electrics and sand done the passenger door and spray same colour and the part i am really looking fwd to is sanding back the fibreglass bonnet and then respray (itchy for a week)
cheers Kelvin

[that_kid]

I guess this means ur not chopping the d2 up anymore? Thats a shame why did u got a hilux cab and not a series?

[discothrasher]

hilux cab is lighter/smaller and sits better and lots of trucks have been built with series i wanted something different and also had a good quality hilux cab available

[that_kid]

that explains it then,

Is this getting all the goodies you were sorting out for the d2 high pinion conversion now i take it? GQ/GU housings is still a cheap easy option since your not stickling over brand loyalty.

I dont think this build would be well recieved on the aurlo forum mind you

i like it alot!

[discothrasher]

that explains it then,

Is this getting all the goodies you were sorting out for the d2 high pinion conversion now i take it? GQ/GU housings is still a cheap easy option since your not stickling over brand loyalty.

I dont think this build would be well recieved on the aurlo forum mind you

i like it alot!

no my D2 is going to stay how i finished it not raping anything from itat least i know it can get to some prity extreme sections for a recovery/tow vechile if needed
i am not going nissan diffs ... toyota diffs are my choice ,i know varoius different arugements can be had that nissan are stronger ,i believe a well setup toyota is as strong

as in brand loyality i am still loyal to the ROVER but just mixing it up abit

[discothrasher]

so i recieved some realy cool and very shiney stuff from keith today 2x longfields cvs 2 x rovertracks toyo conversion front axels and drive flanges and 2 x toyo rovertracks rear axels
i have never seen stuff so shiney

[that_kid]

Will be a shame to cover em all in grease and oil!


I was thinking about it and im not so sure that the hilux cab is going to be lighter then say a series 2 single cab. I picked up the firewall and entire front clip of my s2 with bonnet etc the other day n it ways stuff all. If the hilux, steel is lighter then a coke can, S2, ill be surprised. The hilux cab would fit in at TT this year, there about 10 hiluxes nominated.

I see the disco is up for sale! What model rangie is replacing it?

[jbell]

Yeh I saw it 4 sale too!! must be a good rangie !!



Jeff

[discothrasher]

Luxy cab stays

so i sold my D2 and have the 49% gear reduction going into the truggy so thats going in soon ,which i really think with the 4,88 diffs and 49% its going to be fully sick ,rewiring is going good ,torque flight cooler lines are all hooked up next will be fuel cell ,,going to have problems with batery positioning so will be dodged up front untl front cage is done to see if there is room if not in the back it goes, due to the floods the 17' rims have been delayed and should get em early feb

also cut and molded a rangie dash into the lux cab fitted well with some minor trimmings
i am aiming for around march first run if all goes well

[discothrasher]

so i changed my mind about the 49% gear reductins when the buyer fr my D2 asked for it to be left in for a extra charge so i sold it and now am ordering a underdrive from ashcrofts http://www.ashcroft-transmissions.co.uk ... oductId=16" onclick="window.open(this.href);return false;
so just checking when my brother comes out from the U.K should be late feb and he hopefully can bring it out if not i wil just get him to post it out , this will give the TOY-ROVER alot more options in gearing for different terrian than the 49%
good decission i think

so todays work on the truggy comprised of me buying a flaring tool to marry up the rover brake lines to the toyota master cylinder it took me about a hour untill i got it worked out and did half a dozen test on scrap brakelines
,so brakes are all done now ,and then we good bored and took the new rangie out for a spin reedy creek ah its a good feeling having GQ front diff and 80series diff under it ,so during the week will be making sure the fuel cell and pumps line are all connected ,so when the wiring completed which should be not long now we can start it up and take it for a drive to ensure all is working before the cage starts,it does seem like its going slow but the brakes and wiring and fuel we want to do it properly before the jungle jim goes around it
cheers Kelvin

[discothrasher]

so after having a slow start to the year due to many different thing

today Myself and Greg ripped out all the wires we where trying to marry up to the rover setup and started from scratch plumbed up the fuel system and redid all the wiring and after a few trouble shoots we now have the TOYROVER RUNNING
so now this week i am going to make the dash board out of alloy and center consol out of alloy to
then all is left is the exo cage which will only take a couple weekends

so progress today is a big one
truggy is running yeah

been slack on photos i know ,but not much excitement in taking pics of wireing

[discothrasher]

yesterday Greg and Darren and myself completed the running process by mouting the battery behind the center console we made during the week out of alloy this fitted unbelievable without a need for a battery tray or moderfication the accelerator was another ah **** we need to join weld cut ect .....but no a 3.9 disco accelerator cable fitted straight in ,shifter all conected fitted the raidiator which we destroyed last week when we started it forget to tie it back:eek: so removed one from a rangie down the back and fitted the twin thermos removed the viscous fan this creates a little bit extra power.
Wired it all up to the ignition so i dont forget to turn the fans on ,and also wired up with a button in cab for the fuel pump so i have a emergency fuel cut in cab we mounted this so its reachable from both sides of the car.

We had a bit of a alternator problem so removed it and replaced it with one on the shelf.

then cranked it up and took it for a short drive, a bit more break bleeding and power steering has air in it to.

here are some interior pics i did take a video on my phone but my phone and computor are chucking spears at each other

[discothrasher]

so fuel gauge volt meter oil pressure and temp gauges are all wired up now taco wired up ,so electrics are completed now to the cage building stage ,,i have also decided to go Fox air shocks so more chassis is coming off ,more pictures when the cage work starts this weekend

[discothrasher]

so now that all the final touches on the enterior wiring all switches lights rock lights themo fans (engine and trans cooler) windscreen wippers fuel pump lockers ect and external wiring is completed 110% and yes it does have bling bling.

Because of the hilux cab we had come with a manual,the brake pedal was very small and wanted a larger one for the auto Greg and i decided we would cut and weld ,but before we did that Greg decided to check the bolt pattern and whalla it just fitted straight in ,it is amazing how much rangie toyota stuff is the same and in the future i am not going to be limiting the search of parts to range rover but all makes and models because you will be amazed at the amount of stuff that fits .

So seen the welding is all about to start i took the step and went and got a big gas bottle and gas wire ,it works out way cheaper as a 5kg gasseless wire is around $90 on special 15kg of gas wire $22 at BOC refill for gas $75 so a big saving ,so this saturday weld my bead locks on get the wheels done then get the stickys on and then we can start the cage ,full steam ahead from now on in ,hopefully be ready by easter break