1972 Series III 88"
- Thread starter proper4wd
- Start date
proper4wd
Expedition Leader
An update here.
As I progressed with the small details of the project it became obvious that the P38 power steering conversion was the right thing to do. The column is installed, and the bracket for the box is welded to the frame. A few things to button up with that tomorrow (Thursdays are my only project day) and I can post some photos.
It has also become evident that using a 200Tdi radiator with a 300Tdi intercooler is also the right thing to do. This is the next step.
As I progressed with the small details of the project it became obvious that the P38 power steering conversion was the right thing to do. The column is installed, and the bracket for the box is welded to the frame. A few things to button up with that tomorrow (Thursdays are my only project day) and I can post some photos.
It has also become evident that using a 200Tdi radiator with a 300Tdi intercooler is also the right thing to do. This is the next step.
Is this mounted to the stock gearbox?
I've contemplated this swap a number of times, but the steering turbo issue, and the fact that the stock tranny wasnt strong enough and the 5 speed was going to make it too long for such a short wheelbase, i always came to the conclusion to just buy an import 90 20tdi and drive that.
I've contemplated this swap a number of times, but the steering turbo issue, and the fact that the stock tranny wasnt strong enough and the 5 speed was going to make it too long for such a short wheelbase, i always came to the conclusion to just buy an import 90 20tdi and drive that.
junkyddog11
Oil Soaked Filter
Adam, a DII steering shaft is the right spline for the p38 box and the right spline at the other end for the D90 column......and it is the right length. Can even use all the stock Defender brackets to hold the column if such were lying around (I try to get all the brackets if it is out of a wreck). I'm basicly building this same rig over and over it seems. The disc brakes were a big item for a bit (when you could get them) but I honestly feel they are the last upgrade I'd do on my own rig. The improved driving safety (no more wandering all over) of the PAS is by far the most attractive mod IMO. Even power upgrades are secondary to that. I have actually removed more diesels and replaced with petrol than vice versa last couple of years now that people are figuring out what diesels really are lol (no offense intended.....I still have a couple)
I have 2 SIII's that are that exact same faded red color. I call it "parked too long in Fla red"
I have 2 SIII's that are that exact same faded red color. I call it "parked too long in Fla red"
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proper4wd
Expedition Leader
Hey Matt, good info on the steering shaft. I will yank one out of a junkyard this week.
How do you like to do the hoses for the P/S system? I have the stock 200tdi pump and the P38 box with banjo fittings. I have some old 200tdi P/S hoses but no "donor" P38 hoses for fittings...
How do you like to do the hoses for the P/S system? I have the stock 200tdi pump and the P38 box with banjo fittings. I have some old 200tdi P/S hoses but no "donor" P38 hoses for fittings...
I Leak Oil
Expedition Leader
After seeing some of Matt's handy work I'm kinda jones'n for a 200tdi and I've always wanted PS. Once my new garage is up pehaps it can happen....someday...
junkyddog11
Oil Soaked Filter
convert the p38 fittings to JIC / An. Same with the pump. Make your own hoses. Sounds excessive but is field serviceable and you get what you want.
proper4wd
Expedition Leader
I messed around with that a few years ago swapping a 2006 Range Rover ps pump into a 95 Discovery (standard ps box). I spent hours on hydraulic websites, in hydraulic stores, talking to hydraulic people, looking for the right fittings.
I might have to make a trip up to Berwick to see what you've got. Or you could spare yourself my trip if you know offhand what fittings you use (or at least where to look)
I might have to make a trip up to Berwick to see what you've got. Or you could spare yourself my trip if you know offhand what fittings you use (or at least where to look)
junkyddog11
Oil Soaked Filter
It's very easy. All standard stuff I get from Pegasus racing supply. The Rover system only runs at 750 psi so you can actually use regular aluminum fittings that would be used for fuel etc that is rated at 1500 psi. I can get you all the part #'s and a plan. The only rig I have at the shop under construction and relevant has a 2.25 petrol with an adapted RR pump so the plumbing is a tad different. You are welcome to come look. I moved, but the shop is still in Eliot.
junkyddog11
Oil Soaked Filter
Lots of options. I have done several SIIIs with 4 wheel discs, power steering and turbo diesel conversions with 5 speed fully synchro trans. Also have done them with V8's / coil springs for those that really want to have some fun. And yes, you could by a Defender for what that all costs, but it would just be another Defender now wouldnt it?
RMP&O
Expedition Leader
This project has been progressing at the rate of about 1 day of work per week.
Frame plated for new engine bracket:
New engine bracket installed:
200Tdi finally installed (apologies for the blurry photo, this was immediately following 5 hours of wrestling the 600 pound diesel in there, in 100* heat, and photo quality was not at the front of my mind)
Your welding looks good but you really should "fish plate" that. The way you have welded the plate to the frame is prone to failure. If you don't know what a fish plate is, search google.
proper4wd
Expedition Leader
Yes I considered that approach, however I am not too worried about it considering how these frames are manufactured from 4 individual pieces of steel welded at the corners. The engine mount plate spans the full height of the frame rail from top corner weld to bottom corner weld. This frame design is inherently stiffer being large cross section, fully welded 3-dimensional shape versus mandrel bent rectangle tube as seem on most other 4wd frames.
RMP&O
Expedition Leader
I am no Rover guy, never had my hands on a Rover frame but most manufacturers build a boxed frame with the inside rail being the thinnest. I see you have it at least half way welded to the top rail, again not a Rover guy so not familiar with their frames.
The problem is when you do a straight weld like that it weakens the steel. With the inner frame rail being the weakest it is even more of a concern. There are many examples of a person out there in 4wd world doing it like you have only to have a frame buckle or break. Will that happen to you!? Beats me, may happen to the next guy or a dude 15yrs down the road. Or it may never happen.
My point is simply, fish plating is the correct way to do it and ensure you won't have a weak point or create a weak point in the frame. Myself, I would have not only fish plated it but also perhaps wrapped the mount (weld) around both the top and bottom frame rails.
Take this only as constructive criticism and carry on man, I like old IRON!
Cheers
The problem is when you do a straight weld like that it weakens the steel. With the inner frame rail being the weakest it is even more of a concern. There are many examples of a person out there in 4wd world doing it like you have only to have a frame buckle or break. Will that happen to you!? Beats me, may happen to the next guy or a dude 15yrs down the road. Or it may never happen.
My point is simply, fish plating is the correct way to do it and ensure you won't have a weak point or create a weak point in the frame. Myself, I would have not only fish plated it but also perhaps wrapped the mount (weld) around both the top and bottom frame rails.
Take this only as constructive criticism and carry on man, I like old IRON!
Cheers