Outer Limits 4x4 Board

Okay, front is in already after having started only this morning. I thought it was pretty funny that 2 15 year olds can do a diff swap before lunch

Heres the pics

The new disco lift kit
























Nibby, James says this ones for you posting about rim action on his auction



Then its out



Playing with the nissan front



Then we got the nissan front in
With a 31"



Then with a 33" on the other side (the only spares we have)



Heres me posing



Width



Then I decided to put a creepy on to see what it looks like.










Is it big enough for ya














Bing ba da bing ba da bing yeehaw

well done, not something I would have tackled at 15. What have you got left to do? Brake lines and draglink? What about pinion flange to tailshaft?

Lokking at the pic of the Patrol diff it looks like you used the Nissan lower arms, is that the case? and if so did they just bolt into the Disco mounts?

At 15 that is excellent! Well done mate.

I always thought that you were a hell of a lot older. This is who I thought you were

Slunnie wrote:At 15 that is excellent! Well done mate.

I always thought that you were a hell of a lot older. This is who I thought you were

Na mate, thats my dad. He does alot of the work on the rover too. I require his help a lot, but do manage a heap of it on my own.

merv wrote:well done, not something I would have tackled at 15. What have you got left to do? Brake lines and draglink? What about pinion flange to tailshaft?

Lokking at the pic of the Patrol diff it looks like you used the Nissan lower arms, is that the case? and if so did they just bolt into the Disco mounts?

We've done a lot of the research to get er done. The nissan arms bolt straight in (thankfully). The way its sitting there is with standard nissan springs. We are going to get some longer springs for it though as it doesnt look like it will fit 35's with out alot of rubbing, and there is barely 2" of uptravel before the bump stop hits the errrm..... bump stop pad.

We have adjusted a standard rover draglink to fit (with a loose taper) so we can steer it around the yard. No one will drive it on the road like that though.

We will need to make a new panahrd, but before I do, Ill have to make a couple of caster correction plates. Thankfully we've already got a magnetic angle finder from doing the D-shafts on the rover, so it makes this task a whole lot easier, and so it will have to run on nissan caster angles.

Then we'll have to figure out how to make the brakes work (rover has 4 lines, nissan has one and then it splits), theres to options, thats to make the 4 lines into one and run into the nissan splitter with a new flexi, or combine each sides 2 lines into one and use 2 custom flexis.

So drag link, panhard, caster, and brakes then we can move onto the back. The brakes for that are going to have the rover splitter mounted on the nissan axle, and use the rover flexi.

Well done mate!!!

Wish i was doin diff swaps at 15 rather than pissing my hard earned on a tree in parks and stuff...

yea we are both very happy with our outcome for the day....got the nissan front in in about 3 and a half hours those things are bloody heavy!!! Thankfully i have turoa and his dad they are the brains of my err operation .......will keep you guys updated.....

Nice work.

As for the brakes, it's easy to convert the double front line rover to a single line per side.

You want one port off the master cylinder to the front and one to the back. The extra banjo used to mount two lines to each port just unscrews and the single lines screw right in.

I swapped my rangie to single line fronts and used defender calipers (25% bigger pistons). Stops really well now.

[quote="KiwiBacon"]Nice work.

As for the brakes, it's easy to convert the double front line rover to a single line per side.

You want one port off the master cylinder to the front and one to the back. The extra banjo used to mount two lines to each port just unscrews and the single lines screw right in.

I swapped my rangie to single line fronts and used defender calipers (25% bigger pistons). Stops really well now.[/quote]

SWEET!!! cheers mate

What is with the discussion of duel front brake lines on a disco?

Rangies have duel front brake lines, but my 300Tdi disco I, only has single front brake lines.

Bush65 wrote:What is with the discussion of duel front brake lines on a disco?

Rangies have duel front brake lines, but my 300Tdi disco I, only has single front brake lines.

I'd never heard of it before either. But you can see them in the top photos (unless that other line is the pad-wear sensors).

Bush65 wrote:What is with the discussion of duel front brake lines on a disco?

Rangies have duel front brake lines, but my 300Tdi disco I, only has single front brake lines.

The nissan diffs have a setup rather like the rear rovers ones. They have two flexis from the calipers to some steel brake lines. The steel brake lines then meet in the middle of the diff to a splitter, the splitter has a single flexi attached to it. The only thing is trying to connect all 4 lines together to atatch to the flexi, or getting new flexis made and converting the rover to single front lines and connect long flexis straight to the caliper. If that makes sence

Early D1s have dual front lines - I know cause we had to mod them/remove one each side to fit the Defender calipers. Worse than that, the early ones have four ports off the master cylinder so you have to blank off the ones you don't want, or just run one side back on itself to close it off. You can also swap later model master cylinders in, eg., later D1 or Defender which have 2 ports - front and rear.

Good work on the diff swap. PS don't worry about the up travel too much - they only have about 3 inches up travel standard anyway, especially when the springs sag, but they always have heaps of drop .

Reddo wrote:Early D1s have dual front lines - I know cause we had to mod them/remove one each side to fit the Defender calipers. Worse than that, the early ones have four ports off the master cylinder so you have to blank off the ones you don't want, or just run one side back on itself to close it off. You can also swap later model master cylinders in, eg., later D1 or Defender which have 2 ports - front and rear.

Good work on the diff swap. PS don't worry about the up travel too much - they only have about 3 inches up travel standard anyway, especially when the springs sag, but they always have heaps of drop .

Thanks mate, good info there. I might suggest to him to leave it as is, and make an adjustible panhard so if its a major problem we can lift it later. It saves lifting the rear because its pretty much level with 35's on the back. Thanks for the info on the brakes aswell. Ill have a looksee tommorow at them.

KiwiBacon wrote:Nice work.

As for the brakes, it's easy to convert the double front line rover to a single line per side.

You want one port off the master cylinder to the front and one to the back. The extra banjo used to mount two lines to each port just unscrews and the single lines screw right in.

I swapped my rangie to single line fronts and used defender calipers (25% bigger pistons). Stops really well now.

Did the conversion affect the pedal travel by much?

Where do the 2 lines split to. Do the calipers have pistons on either side of the rotor or is it just a line per pot? Seems a weird way to do things.

Turoa wrote:

Slunnie wrote:At 15 that is excellent! Well done mate.

I always thought that you were a hell of a lot older. This is who I thought you were

Na mate, thats my dad. He does alot of the work on the rover too. I require his help a lot, but do manage a heap of it on my own.

Holy crap you guys are doing some awesome work. I'm still marvelling at the LC/Hilux hybrid axle that you made for the IIa!

great job.im only 15 and waiting 2 find a project the same.well done

Slunnie wrote: Did the conversion affect the pedal travel by much?

Where do the 2 lines split to. Do the calipers have pistons on either side of the rotor or is it just a line per pot? Seems a weird way to do things.

Pedal travel was affected only a fraction, about the same as you'd get from having one small air bubble in a normal setup.

Factory was 1 line to two pistons in each front caliper, other line to the other two pistons in each front caliper and also to the back.
Now one line does both front brakes, other line does both back brakes.

[quote="KiwiBacon"][quote="Slunnie"]
Did the conversion affect the pedal travel by much?

Where do the 2 lines split to. Do the calipers have pistons on either side of the rotor or is it just a line per pot? Seems a weird way to do things.[/quote]

Pedal travel was affected only a fraction, about the same as you'd get from having one small air bubble in a normal setup.

Factory was 1 line to two pistons in each front caliper, other line to the other two pistons in each front caliper and also to the back.
Now one line does both front brakes, other line does both back brakes.[/quote]

ahh that makes sense now....cheers and any lines that are not needed you just block off correct?

mroffroader wrote: ahh that makes sense now....cheers and any lines that are not needed you just block off correct?

Yep, I only ended up with one. It was one the pressure reducing valve for the back brakes.

when i converted my 72 to the single line front i just put a bleed nipple in the end of the pipe i was not useing piss easy

460cixy wrote:when i converted my 72 to the single line front i just put a bleed nipple in the end of the pipe i was not useing piss easy

The thread is M10x1 on the later ones, so you could probably use a small sparkplug.

okay guys..... didn't really get alot accomplished yesterday but every little bit helps eh!?

we went and picked up my new rims and put them on the simex's

[IMG]http://i93.photobucket.com/albums/l60/t ... C_0088.jpg[/IMG]
thats them on the nisco .........i want bigger!!!!! the rear wheel is a 35"

the simex's are 33.75"

[IMG]http://i93.photobucket.com/albums/l60/t ... C_0084.jpg[/IMG]
turoa plasmaded off all the old nissan stuff that we dont need on the rear diff and i ground most of it off right down so it looked good


[IMG]http://i93.photobucket.com/albums/l60/t ... C_0085.jpg[/IMG]
bye bye nissan bits!!!!!!!!


[IMG]http://i93.photobucket.com/albums/l60/t ... C_0097.jpg[/IMG]
[IMG]http://i93.photobucket.com/albums/l60/t ... C_0096.jpg[/IMG]

then we cut and tacked on the spring cups off a rover so we can use the rover rear lift springs

and we also cut out a few more little plates that we will need for today.......more progress will be updated today.....hopefully we get the rear in

It seems the pics havnt worked

http://s93.photobucket.com/albums/l60/t ... guestlogin

go to that link and use the password: 4wd.net

mroffroader wrote: http://i93.photobucket.com/albums/l60/t ... C_0088.jpg
http://i93.photobucket.com/albums/l60/t ... C_0084.jpg
http://i93.photobucket.com/albums/l60/t ... C_0085.jpg
http://i93.photobucket.com/albums/l60/t ... C_0097.jpg
http://i93.photobucket.com/albums/l60/t ... C_0096.jpg

Or just click on the links above.

The rear is in.......

Looking good.

PS how did the diff change from a drum to a disc rear end?? OLr am I losing it?

PPS like the battle scars - makes me less worried about scratching our Disco Dave!

Hooray! Go the Jungle Trekkers!

[quote="RangingRover"]Hooray! Go the Jungle Trekkers! [/quote]

yea i like em but there a bit small (33") i want 35"


[quote]Looking good.

PS how did the diff change from a drum to a disc rear end?? OLr am I losing it?

PPS like the battle scars - makes me less worried about scratching our Disco Dave![/quote]

Nissan diffs are disc's allround .....yea most of those battle scars came with the truck, but i did put a few on it you cant be worried about that kinda thing i reckon.....if your worried about scratching your truck this isnt the sport for you

yeah - I was confused by this picture - but now I see what you have done.

http://i93.photobucket.com/albums/l60/t ... C_0084.jpg


35's will be good on the Nissan diffs given the lower gearing than Rover standard 3.54, and strong enough too.