1120 AF Build in Norway

[Geo.Lander]

OK, so lots of stuff happening behind the scenes, but we have been a little delayed in getting the fire department stuff removed, we had originally planned to use a tractor forklift to hold the cab up and drive the truck out from under it. On closer inspection we found a number of intersecting air lines running through the FD frame and disappearing up into the cab. I know one is for the light tower but I am not sure about the others. There are also warming cables for the water tank running the length of the truck, so probably a couple of hundred KGs of extra weight to shed in the dept.

Our new plan for removing the FD cab and pump. We have hired a truck shop mechanic and his gantry lift and taken the time and expense to do this correctly, we will be there of course lifting the cab slightly and disconnecting all the Tekalan lines in order and sealing up the superfluous ones..

Also:

• We have been in contact with various firm in Norway that build workers cabins or "arbeidsbrakke" and found at least on that want the project, details coming on a separate post because we are still deciding on what box we want. The "German plan" we feel is going to take far too long as we are now being told June at the earliest. So we are also looking into having subframes and boxes built elsewhere and shipped over to us. 4wheel24 GmbH are stating at least one year waiting time for "any" work.
• We also have a quote from a Chinese manufacturer for a DIY kit, running to about 7000 euros with shipping for a 5m*3.4m box with departure angle cutout. I have not yet taken this further as I'm a little concerned with this blind approach.
• Performance: I have been in contact with 4wheel24 GmbH and they have a performance package which seems interesting, but maybe not for us right now as I have no issues as yet with the truck and our one has the 6 speed gearbox which might make things more tolerable)

Now, I feel a bit foolish for going against almost all the senior members' advice here and waiting till I know my final weight before fitting new springs, but let me explain a bit. My rear springs are totally shot, 3 long leafs are broken in half and both rear axle ends are totally dependent on the helpers. Not a good situation to be in I am told. About rear springs I ordered, they are 4 + 1 parabolic leafs , 4 leafs are main spring , perfect and scoped for a 4,5 to 5 to rear axle load (which is the absolute heaviest build I have estimated in my parts list including a rear mounted CRF250l). I am told the 5th leaf is a helper leaf only working for "extreme situation". I have been assured I can remove one leaf and use a 3+1 setup if the default setup is too hard. But he advised me to drive for 1000kms first. The kit we have assembled will also lift the truck about 600-850mm. We decided on the shocks lengths below for this setup:

Front 483 mm to 773 mm. Rear 530mm to 880 mm.



That is basically it, they only have 2 setups possible from DFF for a 1120, and their service and expertise is amazing considering they had to deal with someone as clueless as myself. Of course, this all comes at a price.



In other news we have sold out much loved Land Rover Discovery 4 and it is the first time in many years I have not been a LR owner. Instead we opted for a base model Mitsubishi Pajero gen IV with a full service history (3.2l common rail DI-D).

 

[Geo.Lander]

Just for visual purposes these "arbeidsbrakke" are very common in Norway due to outside workers regulations, something about workers not being allowed to freeze to death ?

If we go this route we will need to find a firm that can build us a torsion free subframe (paperwork is important for our recertification dreams). We have engaged a few firms and only one got back to us and agreed to build one to our specifications. Which actually great news for being Norway! The alternative route is still military Cabins or buying something below on the 2nd hand market.. But, like I mentioned above, we are feeling like waiting for min 6 months for the German contingent isn't going to work for us..

 

[DiploStrat]

... regulations, something about workers not being allowed to freeze to death ?
...

Communists! Socialists! It's about FREEZEDOM!"

 

[palebluewanders]

Which Chinese manufacturer gave you that quote? I read a bit of Chinese so I can see if there are some reviews or people talking about them.

 

[VerMonsterRV]

On thing about your rear leaf springs. We have the same ones and to get the rear low enough we had to remove the factory spacer blocks and use just a single 25mm one that we got from DFF. Also the front spring hanger will require a custom washer as the front of the spring is narrower than the hanger mount. I am still waiting on the shocks as I feel I need to do some measurements myself in regards to extended and compressed length. Oh, and MB used the helpers as the bump stop. With these new springs there is no limit to up travel (well except for the compressed shock right now...), so in my opinion a bump stop needs to be added. I will be working on this project in the next few weeks.

 

[Geo.Lander]

Which Chinese manufacturer gave you that quote? I read a bit of Chinese so I can see if there are some reviews or people talking about them.

Nice! GENERAL EAST CO.,LTD but I found them on www.TrailerBull.com

I've had very good experiences ordering from Aliexpress and alike but I have also been ripped off... This just seems like too big of a risk and I couldn't find much on the net about their site/customers...

 

[Geo.Lander]

On thing about your rear leaf springs. We have the same ones and to get the rear low enough we had to remove the factory spacer blocks and use just a single 25mm one that we got from DFF. Also the front spring hanger will require a custom washer as the front of the spring is narrower than the hanger mount. I am still waiting on the shocks as I feel I need to do some measurements myself in regards to extended and compressed length. Oh, and MB used the helpers as the bump stop. With these new springs there is no limit to up travel (well except for the compressed shock right now...), so in my opinion a bump stop needs to be added. I will be working on this project in the next few weeks.

Do you happen to have a picture of the custom washer? I suppose in the picture below the chassis mount and upper part of the hanger is what you are referring to and not where it intersects directly onto the leaf?

I had not thought about the "bump stops" to be honest.. Although my truck mechanic did seem eager to fit some aftermarket airbags to the rear I need to go over the details with him next week.. Other than bump stops airbags just sound like expensive bump stops to me at this point.. This time next week I should be a little wiser to the whole situation for better or worse ? ?



While we are looking at this picture i noticed we had some small leaks in the tanks (constant 8 bar, down to about 6 after a week or so). A lot of the tanks and "parts" are rusted but all the other connectors and piping upstream of the tanks appears to be brand new. looking around the LN2 forum I noticed a lot of projects concerning relocation air tanks to the central chassis. This has always been really appealing to me to free that entire side for a gear shed box. This can get really expensive if you start looking at modern air dryers etc but 2 30L tanks at 70 euro each makes this whole idea seem tempting. I am now thinking of traverse mounting them with factory consoles..

 

[palebluewanders]

Nice! GENERAL EAST CO.,LTD but I found them on www.TrailerBull.com

I've had very good experiences ordering from Aliexpress and alike but I have also been ripped off... This just seems like too big of a risk and I couldn't find much on the net about their site/customers...

Looks like they are part of CIMC which is quite a big company. They mainly do commercial truck bodies so not sure how much people are talking about their overland bodies. It's 1am here so I'll try to dig a bit more tomorrow!

 

[VerMonsterRV]

Looks like they are part of CIMC which is quite a big company. They mainly do commercial truck bodies so not sure how much people are talking about their overland bodies. It's 1am here so I'll try to dig a bit more tomorrow!

Not sure but the fast assemble frp/grp box looks very much like our total composite box. So much so I think they use the same pictures and adhesives. Might just be the same manufacturer?

Fast Assemble FRP / GRP TruckBody, Fast Assemble FRP / GRP TruckBody Products, Fast Assemble FRP / GRP TruckBody Manufacturers, Fast Assemble FRP / GRP TruckBody Suppliers and Exporters - GENEAL EAST CO.,LTD | Flatbed Trailers | Tanker Trucks

Fast Assemble FRP / GRP TruckBody, find quality Fast Assemble FRP / GRP TruckBody products,Fast Assemble FRP / GRP TruckBody Manufacturers, Fast Assemble FRP / GRP TruckBody Suppliers and Exporters at GENEAL EAST CO.,LTD | Flatbed Trailers | Tanker Trucks.

www.trailerbull.com

 

[Geo.Lander]

So Gertrude has found her home for the winter, or at least a few weeks while the heavy chassis optimisation is done, I'll post some details in the coming weeks. But for now here's the truck heaven where tired souls go to rest and recover:

 

[Geo.Lander]

On thing about your rear leaf springs. We have the same ones and to get the rear low enough we had to remove the factory spacer blocks and use just a single 25mm one that we got from DFF. Also the front spring hanger will require a custom washer as the front of the spring is narrower than the hanger mount. I am still waiting on the shocks as I feel I need to do some measurements myself in regards to extended and compressed length. Oh, and MB used the helpers as the bump stop. With these new springs there is no limit to up travel (well except for the compressed shock right now...), so in my opinion a bump stop needs to be added. I will be working on this project in the next few weeks.

Thanks for the heads up. Our were shipped on the 15th (all four corners springs and dampers). I managed to get hold on Henrik first thou and he assured me these ones would fit exactly. Time will tell ??

 

[Geo.Lander]

Not sure but the fast assemble frp/grp box looks very much like our total composite box. So much so I think they use the same pictures and adhesives. Might just be the same manufacturer?

Fast Assemble FRP / GRP TruckBody, Fast Assemble FRP / GRP TruckBody Products, Fast Assemble FRP / GRP TruckBody Manufacturers, Fast Assemble FRP / GRP TruckBody Suppliers and Exporters - GENEAL EAST CO.,LTD | Flatbed Trailers | Tanker Trucks

Fast Assemble FRP / GRP TruckBody, find quality Fast Assemble FRP / GRP TruckBody products,Fast Assemble FRP / GRP TruckBody Manufacturers, Fast Assemble FRP / GRP TruckBody Suppliers and Exporters at GENEAL EAST CO.,LTD | Flatbed Trailers | Tanker Trucks.

www.trailerbull.com

Jon, Can I ask the price you paid for your box from TC?

 

[VerMonsterRV]

Do you happen to have a picture of the custom washer? I suppose in the picture below the chassis mount and upper part of the hanger is what you are referring to and not where it intersects directly onto the leaf?

I had not thought about the "bump stops" to be honest.. Although my truck mechanic did seem eager to fit some aftermarket airbags to the rear I need to go over the details with him next week.. Other than bump stops airbags just sound like expensive bump stops to me at this point.. This time next week I should be a little wiser to the whole situation for better or worse ? ?

View attachment 630830

While we are looking at this picture i noticed we had some small leaks in the tanks (constant 8 bar, down to about 6 after a week or so). A lot of the tanks and "parts" are rusted but all the other connectors and piping upstream of the tanks appears to be brand new. looking around the LN2 forum I noticed a lot of projects concerning relocation air tanks to the central chassis. This has always been really appealing to me to free that entire side for a gear shed box. This can get really expensive if you start looking at modern air dryers etc but 2 30L tanks at 70 euro each makes this whole idea seem tempting. I am now thinking of traverse mounting them with factory consoles..

That looks to be the rear hanger on the front spring. What I am talking about is the front hanger on the rear spring. You will see the post that the front of the spring attaches to. The post is a larger diameter than the threaded end. So when you tighten the nut the washer (very thick washer) comes in contact with the end of the post. With the original springs this snugged up against the spring bushing not allowing movement. With the replacement springs the bushing is a bit narrower so there is some play on the shaft. This is what the custom washer needs to be (and might even be best with 2 thinner washers, one inside and one outside). I have asked Harald about this and he has made us a single 13mm thick one as putting one inside/outside means removing the springs. Wish we would have done this when the springs were installed. With the parabolic springs I don't think you will need to worry about an air suspension. I would think bump stops will be way less expensive and simpler to install. Hard rubber ones would require a steel mount to be fabricated, there are already holes in the chassis to bolt them up as they were installed by MB depending on which springs were originally installed. An example it the bump stops already installed for your front springs.

 

[Geo.Lander]

Hi!

Does anyone know where I can source chassis drawings for my particular truck (similar to the one attached), I have contracted an engineering firm to plan our intermediate frame (including finite element analysis) and they are asking me to contact the Norwegian dealer to obtain these but I am not having a positive response yet on that side..

 

[Sitec]

I'd think you'd be better supplying a basic engineering drawing of 'your' truck... Mine had been modified since it left the factory, and then I shifted and changed stuff again to suit our build... Different diesel tank, batteries and air tanks relocated, spare wheel carrier shifted, tail of chassis shortened etc etc... If you are mounting your Hab Box 'rail on rail', they'll need the rail width's, rear axle position in relation to the back face of the cab and rear end of the chassis. They'll need the side view plan (showing how much to cut out to allow for the front splash guards) etc. Those factory drawings might complicate the job. I'd do 3 basic scale plans. Side view (showing wheelbase, wheel size, cab and mudguard positions and height, chassis overhang), aerial view (showing rail width, tyre width, cab width, overhang, fuel tank, batteries and air tanks, leaf springs etc) and rear view (again showing rail widths, wheel widths etc). If they have any questions, they can always ask.

I'd also be prepared to shift stuff on the chassis to suit your build... We have used every available piece of free chassis space for lockers, water tanks, fuel tank, box type muffler etc. Early scale drawings/plans are worth their weight in gold. You get to see your finished truck, see what will and won't work, and what you can fit into it!