jad Posted June 23, 2012 Share Posted June 23, 2012 Evening everyone, After having rebuilt 2 defenders (mine and my dads) I fancied a project that was just a little different. The last couple of years I have been to Le Mans with a few friends. One with a 6.0L Monaro and one soon to buy a 3200GT Masserati, before Le Mans 2013. Hevcurrently owns a boring diesel BMW. I therefore wanted my own fast car to go in and since I am into landys I decided to build a fast(er) one. So I bought a 1978 Series 3 109 with a 6 cylinder engine for £350 Then came the question of which engine. A 4.6 Rover V8 would have been far too easy/sensible and a yank V8 has been done and isn’t great on fuel, not that this will be although I am quietly hoping it won’t be disastrous…. Bowie69 put an advert for a friend up for a 1UZ-FE Lexus V8 engine from a LS400 (http://forums.lr4x4....us&fromsearch=1). At a standard 250BHP and 260lbft (across most of the rev range) and more after de-catting and megasquirting it seemed to fit the bill nicely. So after a days long round trip to somerset it was all mine! My dad and I then set about dismantling the 109. It quickly came apart revealing a suspected amount of rust. Some parts such as the steering relay requiring a little more effort than others! The 1UZ-FE comes in a few different vehicles and therefore a few different sump configurations. The engine I had bought was from a LS400 with a “front sump” I therefore bought a knackered engine from a soarer that has a “rear sump” allowing me to not have it sit where the front axle is… I then hung this engine in the 109 chassis to see how much of a problem I was going to have making it fit. The V8 is a big wide engine and even with the rear sump will be close to the propshaft as the sumps are about 36cm wide! Obviously this didn’t show all of the problems as it was a bare block with no engine mounts, exhaust headers and everything that adds to its overall size. I contemplated making and designing my own exhaust manifold and engine mount for the left hand side of the engine to place the engine to the left side but I do not really have the expertise for this so eventually decided the engine basically has to sit centrally in the chassis as was apparent when hanging the full engine gbox and tbox in the chassis. What also came apparent at this point was that due to the high central output from the tbox, the rear propshaft angle was far too high to be useable and it would also require a P38 axle to be used. Within a very short period I therefore decided to go to a manual land rover gbox with an LT230 to bring the tbox outputs down into a good location. This solved and created a number of of problems as you can well imagine. Some problems it solved were the prop angle, controlling the auto gbox, having props made to go from Toyota Tbox to landy axles as well as some others I cant remember. Some problems it created were, joining the short R380 gbox, and engine together, what flywheel to use as the 1UZ-FE is a solely auto gbox and whether or not the gbox can handle the engine…... Yet to be determined, but am hoping that as the 350Nm of the engine is less than the 380Nm of the gearbox it should ok with care. I then started trying to make an engine adaptor using some MDF templates. This however didn’t seem to be going well at all, I am not sure why but I eventually turned to CAD instead relying on someone else to do the machining for me. I also discovered that the 2/300 flywheel had a very similar (overlapping) PCD of the holes. I therefore decided to get one machined to fit the Lexus engine. A company called Milbor engineering in Hemel Hempstead turned the flywheel down to accept the ring gear and slightly enlarge the central hole to fit over the crank. They also shaved some of the thickness off in order to position the ring gear the correct distance from the engine. Next I needed to find someone to machine the adaptor. I was originally going to get a friend in the landy club to waterjet cut it for me. But unfortunately this was not going to be ideal and I therefore needed someone to CNC machine it for me. In another topic VulcanBomber had offered to machine some plate flat for me for the adaptor. I however went one further and asked if he was willing to machine the complete adaptor. I was pleasantly surprised when he agreed to and a while later he had finished…. After his boss found out at one point and was not too pleased but eventually took pictures of the end product for their webpage! I then today, offered it up to the engine and gearbox. Unfortunately, 2 of the 10mm holes that bolt into the structure that make up the sump construction were in completely the wrong place! (But that’s not too surprising since I got the dimensions off of the internet…..) However with six 12mm bolts and two 10mm bolts in the correct places I am not too concerned. I may however use the bellhousing to re-drill these holes in the correct place. I then bolted the gearbox to the adaptor and voila! Hoping its all lined up centrally…. So tomorrow I will be hanging it in the chassis to position the gbox cross member and make engine mounts (new chassis, forgot to mention that but wanted a good base to build the car on, yet to be galved and going a bit rusty in the garage ) In the meantime throughout this a couple of other bits were also completed. That’s about it for now. The project is at my parents house so work is only being done on the weekends I’m not busy so progress is currently slow. Shortly Ill have my own house though so it will move over there. Unfortunately into a single garage but it should hopefully be in less pieces by then! I look forward to any opinions you have to share unless it involves 3 certain little letters…… Jad Quote Link to comment Share on other sites More sharing options...
Paul Woodward Posted June 23, 2012 Share Posted June 23, 2012 This is going to be an interesting build. Keep up the good work! What axles do you plan on using? Quote Link to comment Share on other sites More sharing options...
jad Posted June 23, 2012 Author Share Posted June 23, 2012 Putting it on leaf sprung 24 spline disco axles. Gonna see how well they last. Would like ashcroft ATB's at some point... Jad Quote Link to comment Share on other sites More sharing options...
ToyRoverlander Posted June 24, 2012 Share Posted June 24, 2012 Awesome build! I can really appreciate this sort of builds. It's nice to see something different. Good luck with the project! Quote Link to comment Share on other sites More sharing options...
mickeyw Posted June 24, 2012 Share Posted June 24, 2012 Nice project, I'll be watching with interest. Nice machining from Vulcan Vomber too Quote Link to comment Share on other sites More sharing options...
stuck Posted June 24, 2012 Share Posted June 24, 2012 Looks fun. What are the Lexus lumps like for parts? Quote Link to comment Share on other sites More sharing options...
gavin. Posted June 24, 2012 Share Posted June 24, 2012 Wow, this is going to be an epic build! That adapter plate is a lovely piece of work, too. Quote Link to comment Share on other sites More sharing options...
jad Posted June 24, 2012 Author Share Posted June 24, 2012 Cheers Everyone. Vulcan Bomber did a very good job and I am very pleased with the result. Im not sure how his boss would react to him doing more work though. Would definitely have to ask for his permission beforehand.... I havent tried asking lexus for parts yet. The engine is actually toyota who seem to be better with parts. I need to get 8 flywheel bolts at about £3.50 a pop. On ebay a timing belt kit is 135 and a waterpump is 80. Im sure (crosses fingers) there must be a better source for parts....... On the other hand i bought a complete car for under £500 with an lpg kit..... A few updates. After quite a long time of deciding where to put the engine this morning we knocked up some engine mounts. We hung the engine in and then tacked the mounts into their final resting place. Which put the engine in its position! Gbox cross member supported by axle stand as I want to modify it.... Just to show you how much clearance there is around the engine/gbox/tbox here are a few pics. And a picture from the Tbox output the front diff. Not as much room as I would like under the sump but I think it should be fine.... Would like the get one of the "skinny halfshaft" type props you sometimes find under defender and RRC V8s to be sure. Anyway time for bed! Night all. Jad Quote Link to comment Share on other sites More sharing options...
FridgeFreezer Posted June 24, 2012 Share Posted June 24, 2012 That's all very tidy, top work there fella. Always good to see a Series getting some attention I reckon the R380 should last OK, V8's are pretty smooth, it seems to be big diesel lumps that kill them. Obviously that's subject to your right foot... Quote Link to comment Share on other sites More sharing options...
ejparrott Posted June 26, 2012 Share Posted June 26, 2012 Looks like its going to be quite a truck! Quote Link to comment Share on other sites More sharing options...
Soren Frimodt Posted June 26, 2012 Share Posted June 26, 2012 Great project! Nice with a proper tech thread on here again! Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted June 26, 2012 Share Posted June 26, 2012 Cant really take the credit for the machining...... the programming came directly from the CAD model James made me. A pic here of the adaptor up on my Lathe: Good luck with the project. David. Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted June 26, 2012 Share Posted June 26, 2012 Nice!! A mate and I had been looking in to using one of these Lexus v8s, but keeping the auto box and mating it to a LT230 to sort out 4wd and output flanges etc. Nice work on the adapter plate, smart. Looking forward to seeing this come together. Luke Quote Link to comment Share on other sites More sharing options...
jad Posted July 2, 2012 Author Share Posted July 2, 2012 Bit more of an update. Turned the spigot bush up. Also put the gearbox cross member brackets in and modded the cross member to suit. As you can see there are a couple of spare mountings further back. They are there just n case I need a stronger gearbox in the form of a very expensive R380 from ashcroft! with a longer bellhousing. Also took off the brackets for the series steering relay. Originally I wanted to use the series steering relay box but the engine put engine got in the way of everything! Also moved one of the permanent cross members back further to allow a longer gbox to be fitted if needed. Thats it for now. Not as much as I wanted to acheive over the weekend but isnt that always the way! Jad Quote Link to comment Share on other sites More sharing options...
Michele Posted July 2, 2012 Share Posted July 2, 2012 Very cool, and the adapter is sooo nice...good luck P.S. What happened to the old inline-6? Quote Link to comment Share on other sites More sharing options...
ejparrott Posted July 2, 2012 Share Posted July 2, 2012 Proper Lathe.... Quote Link to comment Share on other sites More sharing options...
jad Posted July 2, 2012 Author Share Posted July 2, 2012 Very cool, and the adapter is sooo nice...good luck P.S. What happened to the old inline-6? Cheers and it was advertised, unwanted and weighed in! It hadnt been used in a number of years and only seemed to run at a few thousand RPM or not at all. I have no experience with them or carbs so didnt fancy trying to fix it. Was beautifully smooth though! Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted July 3, 2012 Share Posted July 3, 2012 Proper Lathe.... A myford super 7!!! First Lathe i ever used, I was about 10. Quote Link to comment Share on other sites More sharing options...
Michele Posted July 4, 2012 Share Posted July 4, 2012 "Cheers and it was advertised, unwanted and weighed in! It hadnt been used in a number of years and only seemed to run at a few thousand RPM or not at all. I have no experience with them or carbs so didnt fancy trying to fix it. Was beautifully smooth though!" Forum is playing silly this evening... Shame to hear, I wouldn't have had the chance to pick it up for mine, but would have loved to... :-) Michele Quote Link to comment Share on other sites More sharing options...
fozsug Posted July 4, 2012 Share Posted July 4, 2012 "Cheers and it was advertised, unwanted and weighed in! It hadnt been used in a number of years and only seemed to run at a few thousand RPM or not at all. I have no experience with them or carbs so didnt fancy trying to fix it. Was beautifully smooth though!" Forum is playing silly this evening... Shame to hear, I wouldn't have had the chance to pick it up for mine, but would have loved to... :-) Michele I know of one that purrrrrrs if you are interested? Quote Link to comment Share on other sites More sharing options...
jad Posted July 9, 2012 Author Share Posted July 9, 2012 Just a brief update. The chassis is now ready! Made a few more mods. Strengthened up the rear outriggers just a little for some rock sliders to act as SIPS and for when people open car doors into it.... and made mounts for the remote oil filter, an extra exhaust mount and some to attach the seat belt brackets to. Here it is finished (with the rear axle still attached so my mum and dad can get it on the trailor while im not there....) Also drilled some holes for brake pipes and to mount the radiator on the front cross member. Next will probably be of it all shiny Jad Quote Link to comment Share on other sites More sharing options...
jad Posted August 4, 2012 Author Share Posted August 4, 2012 Bit more of an update today. Took the engine etc apart today fitted the clutch and including slave cylinder. The engine adaptor and engine needed grinding away slightly for it to fit though. Also changed the seal between the Gbox and Tbox and fitted the cross drilled input gear. Also fitted the engine etc into the shiny chassis! Also fitted the fuel tank using some modified shock abosorber bushes after being told by dingocroft I could by PART of a 109 fuel tank mounting kit for fifty something quid! And finally another job not high on the list of things to do is making a guard to stop anything from spraying into the bellhousing. More to come tomorrow Jad Quote Link to comment Share on other sites More sharing options...
Soren Frimodt Posted August 4, 2012 Share Posted August 4, 2012 Very nice looking indeed! Over here in Denmark, the Lexus bug has been raging throughout the 4x4 world too, so far though, none has found its way into a Landy.. But will happen I'm sure as it is very good value. Keep up the good work! Quote Link to comment Share on other sites More sharing options...
jad Posted August 4, 2012 Author Share Posted August 4, 2012 Thank you Soren. The only other landy I have seen it in is the discovery below, but is currently only running 2WD. Would be nice to find some more info on it, Will have to ask him if he has a build thread.... Jad Quote Link to comment Share on other sites More sharing options...
jad Posted August 5, 2012 Author Share Posted August 5, 2012 Today we redrilled the brake like holes and put some clips in. The first peice of bodywork went on! Also put the seatbox on and started modifying it to fit around the gearbox. Doesnt seem like a lot but its taken all day! Jad Quote Link to comment Share on other sites More sharing options...
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