Outer Limits 4x4 Board

this is C&P'ed from another forum so it might seem a bit odd as its all in one long post

i used to have a D90 that i used for winch challenges & offroading, king cabbed it, cage, 35" simex, ARbs etc etc all the "right" bits for uk competitons, However @ the end of the day it was still a "heavy" 90 & had soft bodywork when it was being rubbed against trees, rocks, the ground etc so over a brew @ work we decided to build a different take on the tube buggys we offer for customers,

So i went from this






to building a buggy like this


but with a few differances

Any how everyone likes a spec, so in no real order here goes

Engine
2.5 TD5 from a D2 with VNT turbo & Bell auto services remap & boost box
will be sticking with the standard DM flywheel till it breaks then going for a solid one

Transmission
Standard 5 speed manual from same D2 doner vehicle, nowt trick

Axles
24 spline axles front & rear fitted with ARB lockers, Rover tracks front shafts & cvs, GKN rear shafts, standard 3.54 ratio, may change gear ratio if required & peg them if they explode, located with D2 radius arms front n rear,

Suspension
fox 2.0 7/8 coilovers non reserviour in 12" travel, simple solution instead of going for air shocks, if needs be can squeeze 14"s in or go to ORi's

Chassis/ Frame
Whitbread offroad standard challenge frame built with a door on drivers side & hop over bar on pass side,takes a standard defender bonnet & remaining panelwork is flat ali sheet
mounted on a tubular chassis with inbuilt winch trays front, middle & rear,

Wheels & tyres
37/12.5/15 maxxis creepy crawlers on 10x15 modulars with weld on beadlocks (still to be done )

anyway, everyone likes pictures so here goes, ill say now if you have 56k gtf,











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first time out to give it a thrapping prior to its first event








goes really well, suspension is nice & supple just needs tweeking to stop it touching the bumpstops,
overall very impressed & chuffed to bits

more pics thanks to nobby

& then first time out

td5 power



only downside is clutch didnt like it so solid flywheel & paddle clutch next,







also managed to stab a tree through the windscreen & the rad at the same time,

overall considering we only got it finished in time for taking it for scrutineering on friday, needs a fair few tweaks to get it sorted but overall its brill, has sooooo much power so its point n squirt, have loooooads of pictures to upload but not quite finished checking them yet,

& also some vidio
http://youtu.be/VyX5SK51WmU" onclick="window.open(this.href);return false;

http://youtu.be/u38nIuP_CFo" onclick="window.open(this.href);return false;

Some more pics

thats a awesome build there ,i would still peg your diffs just so much stronger a lot off us here do the toyota diff conversion here once again making the diffs so much stronger ,what weight is the finished unit i reckon it would be fairly light with that kind of weight you should be able to thrash the pegged diffs and not break them ,how does all those D2 electrics go in the mud and water

pegging the diffs is on the to do list, just not got there yet

it weighs roughly 1780kg, was 1680kg when i initially weighed it but have since added 2 more winches & waffle boards to give me 100kg more weight, its not a definet weight but close enough,

the elctrics have been good sofar, the wiring has been converted from a D2 to a defender loom so is much more simplified but still has quite a bit of wiring in it,

impossible!!! the guys on pirate said your chassis/frame would fail....so how is it possible you made it out the garage...hahahahah

great work...very nicely done

uninformed wrote:impossible!!! the guys on pirate said your chassis/frame would fail....so how is it possible you made it out the garage...hahahahah

great work...very nicely done

prime example of if you listen to all the people on forums you will not get anything done.

as serg said awesome.... practical basic functional manufacturing always works

cheers guys,

glad you like it, thought i would show it off as im pretty chuffed with how it turned out

what did you use to locate the rear axle? A frame or watts?

how do your find the RA's in the rear? Im guessing it has quite high Anti Squat, which seems to be a negative in high traction steep ledgey climbs....but it may be better in loose surface climbs as it would lift the rear a little and load up the front more?????????????

just thinking out loud

i used a standard A frame & then made up a crossmember to take it at the chassis end,

roll angle & antisquat, i have no idea of the numbers, we built it up to be similar to the standard geometry & so far it works, need to get out in it more to get the suspension set up how i want it

That's cool.
But tell me, in those pics above are you trying to winch it through a tree?

no, you can see the punch on the white square on the tree, the card was attatcthed to the top of the windscreen frame on the passenger side, was trying to get the front of the buggy to climb up the tree so i could get closer in, in the end had to abandon it as i couldnt get the last few inches to punch the card