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ajh last won the day on July 10 2014

ajh had the most liked content!

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About ajh

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    Old Hand

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  • Location
    Ottawa, Ontario, Canada

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  • Interests
    Expedition travel of all kinds, vehicle based, mountaineering, hiking, and backcountry exploration in general. I also teach rock and ice climbing in my "spare" time, do a little off-roading, and mostly work in the shop coming up with nutty inventions and improvements to things along the way.

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  1. ajh

    Rear Panels

    Upon second inspection, it looks like the change is actually on the inboard side of the panel and will just force a bit of trimming.
  2. ajh

    Rear Panels

    Did the Defender rear tub change shape at some point? I have a set of replacement rear panels sold by a well known aftermarket company and they really don't fit, they're not long enough and the curve of the side panel is entirely in the wrong place. The vehicle in question is a 1999 300TDI 90.
  3. One question though. Always used polys in the past.. with using the oe style one side of the tube sticks out more than the other, is this the inboard or outboard side? I assume inboard to allow more flex, but welcome correction.
  4. Not anymore. I suspect I removed about 1 to 1.5mm and they were still a tight fit, enough that I need to prep and repaint before installing tomorrow. I don't have anything precise enough at the moment, but the fact they don't seem perfectly round makes that harder too.
  5. I suspect they only ever fit polys, but this is a long travel setup and rubber is more suitable. They are clearly not even bored after welding as they don't even seem round when you look closely. The fact they are painted on the bushing surface would also contribute to the idea they never considered someone might want to install normal bushings. Machining a purpose build press die would probably also help.
  6. If anyone cares, the arms are not made to spec... it took quite a bit of time with a drum sander to get things fitting.
  7. One bushing deformed. 7 more chances to press in 4. Even 20 tonnes was insufficient.
  8. This is the new style arms, two halves centre welded vs I-beam like the old style.
  9. Has anyone had experience/issues pressing Allmakes metalastic axle end bushings into Terrafima Defender 3deg radius arms? Just looking it seems like the bushings are larger than the opening provided. After several press attempts I want to make sure I don't need to bore them out, I never thought of the bushing collar as something that would compress very much.
  10. ajh

    TF522 Sanity Check.

    and honestly, all they needed to do was stamp a small arrow on the top.
  11. ajh

    TF522 Sanity Check.

    Thanks, you'd think they would at least include a link to those instructions in the box. Didn't even know they had those available; Google didn't pull up anything on them. I was pretty sure they were correct, but wanted to be 100% sure.
  12. ajh

    TF522 Sanity Check.

    Anyone able to confirm that when installing the TF522 skeleton shock towers that the vertical portion is forward facing and the slanted portion rear facing? Just about to epoxy spray the assembly and having to take it apart later isn't in the cards, and they're being slow at responding.
  13. Indeed, when poorly placed or incorrectly flared they're not great. My plan was to actually do just the sides then probably put something over the holes and leave the top and bottom intact, but that also assumes the chassis is a basic one. Once you have an integrated safety cell/cage as well the rigidity goes way, way, up and the flex dynamics change entirely. Still, need to finish the first D2 Tomcat before I can look at making one lighter.
  14. Though really, I have tons of ideas, I'm more interested in seeing examples of things other people have done. Most seem to either go truck-cab trayback or stock bodywork, but there must be more people out there that've done really interesting custom work too. The guy who widened his Lightweight is a good example though; amazing work.
  15. Indeed, but isn't a lightweight bulkhead flat sided already? Not something you see up close over here.

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