109 Expedition rig build

[DCH109]

Did you have a plan of the mounting for the battery and wiring under the seatbox? Have you looked at how the Military rovers are setup?
My 109 has the batteries (2 for the 24 volt but 1 when i am done as i will be back to 12 volt) in the middle (no middle seat in mine), in a heavy duty battery box. All cables are run from there to the engine compartment via flexible conduit that is attached to the frame.

Not sure i would use conduit again (maybe a galvanized would be better) as mine was badly rusted, but the idea is there.

 

[Mercedesrover]

I’ve never really looked at the military ones but I have a good idea of what I need.

The four headlight will be wired through relays for each one, there’s a starter relay to run the glow plugs, a 12-place fuse block and a few other relays to run things like the cooling fan, etc.

There will be four loomed harnesses running from the box. One up to the engine, one running up to the dash, one for the front lights and one for the rear lights. The looms will be regular split plastic ones. They seem to hold up pretty well and I can add to them as needed.

 

[Yorker]

Jim what battery(ies?) are you using?

 

[Mercedesrover]

NAPA 75XDT800. Dual terminals, good guarantee. I've had three go-arounds with Optima and haven't had much luck. These have been good for me so far.

 

[Mercedesrover]

It's been a few days since I've posted any new photos....

Got the inside of the bulkhead is lined with "Soundcoat". Starting to run some wires up to the dash and back to where the seat box goes.

Last pictures before the wings go on. Got the heater box rebuilt and painted and the new fan motor mounted. I got the air cleaner assm. last night and just need to paint that too. About all that's left under the hood after that is to plumb the heater core and install the heat valve. That should be here today. The wings will get paint tonight and installed tomorrow. From there I can start wiring the lights.

jim

 

[Michael Slade]

Looking good. I would add a second layer of that sound coat on the engine side of the bulkhead.

 

[frans]

Jim, are you going to stick with the stock air cleaner? It seems like I replace alot of those rubber mounts for folks and always thought that re-routing the air cleaner to a K&N set up would be longer lasting... Of course your engine is tuned so should not shake too much but still as a off road vehicle everything will get jostled alot.
?

 

[Mercedesrover]

Looking good. I would add a second layer of that sound coat on the engine side of the bulkhead.

I think I'll get away with just this layer on the inside. These engines are remarkably civilized. The 5-cylinder turbos are even smoother than the 4-cylinder ones. In the 88" at highway speeds the sound of the wind rushing by is louder than anything you can hear from the engine.

 

[Mercedesrover]

Jim, are you going to stick with the stock air cleaner? It seems like I replace alot of those rubber mounts for folks and always thought that re-routing the air cleaner to a K&N set up would be longer lasting... Of course your engine is tuned so should not shake too much but still as a off road vehicle everything will get jostled alot.
?

Yeah, those rubber isolators have always been a problem. I ordered some different ones from McMaster Carr and hope they'll hold up better than the stock ones. Funner Mercedes hasn't come up with a cure for those mounts yet.

 

[Scott Brady]

That looks so awesome. Great job!

 

[Michael Slade]

I think I'll get away with just this layer on the inside. These engines are remarkably civilized.

You would know better than I.

 

[KingSlug]

Jim,

How are you shutting off the engine? I have and electric EGR valve that I am playing with on the 240D that will open up vaccuum to the stock cut-off on the IP when the key is in the off position. I was just wondering how you were doing it besides pushing the lever.

Jared

 

[Mercedesrover]

How are you shutting off the engine?

Simple momentary air switch plumbed into the brake booster circuit. Again, McMaster Carr. It would be impossible to do any of this without McMaster Carr.

Part # is 62475K21

jim

 

[James86004]

It would be impossible to do any of this without McMaster Carr.

When I started my mechanical engineering career, my boss told me there were really only two things I needed to know. F=ma, and McMaster-Carr's phone number.

 

[Mercedesrover]

When I started my mechanical engineering career, my boss told me there were really only two things I needed to know. F=ma, and McMaster-Carr's phone number.

I used to know it....Now it's just entered into the speed-dial on my phone.

Man, shoulda bought stock in that company before this build started....

jim