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Old 17th April 2013, 11:11   #1
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Default Wickedly Radical - Mahindra Bolero Build

Its been a long time searching for a 4wd bolero. I even tried to buy a new 4wd bolero but had a bad experience hence I thought of building myself one.
You may say I am crazy yes but what makes you crazy is when you buy one new 2wd and you come to know that the 4wd was available with the company, and you get guys telling you that there are around 3 boleros 4wd for sale in the second hand market too.
OK its all settled I sell off the new bolero and everythings gone no new no old.
Now I pick up a lx 2wd 2004 model and about to start work and again there are about 4 Boleros all 4wd for sale up again
Now thats it I have made up my mind on the conversion so no looking back now.

P.S:- Guys please dont advice me not to go ahead with the conversion as I have made up my mind and you are going to waste your time.

Got a 2004 lx 2wd bolero going to convert it to a 4wd.
Parts that I have collected till date the most priced an open knuckle differential of the bolero, a 4wd divorced transfer case with PTO (i think its off a tata 407), a borg warner manual shift transfer case with adaptor, and tyres 245/75-16 maxxiss bighorns 764 (thanks Subendhra)and steel army NGCS rims 160pcd 5.5j 16'' (thanks Sudarshan).

Its gonna be a slow thread as I have yet to get some more things sorted and more parts picked up and fabricated.
Now for some pics
Attached Thumbnails
Wickedly Radical - Mahindra Bolero Build-1.jpg  

Wickedly Radical - Mahindra Bolero Build-2.jpg  

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Wickedly Radical - Mahindra Bolero Build-8.jpg  

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Wickedly Radical - Mahindra Bolero Build-10.jpg  


Last edited by moralfibre : 17th April 2013 at 12:28. Reason: Please use "you" instead of "u"
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Old 17th April 2013, 11:21   #2
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Default re: Wickedly Radical - Mahindra Bolero Build

Woah ! Congrats for your Bolero

Those BIG HORNS look real good on the Bolero, & a perfect start to the Build.

BTW, looking at the last picture it seems your going with an all BLACK paintjob on this car & I tell you what this gives me a feeling this will turn out to be one of the hottest Boleros on our forum

Last edited by karan561 : 17th April 2013 at 11:23.
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Old 17th April 2013, 11:43   #3
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Default re: Wickedly Radical - Mahindra Bolero Build

hi,

I would like to congratulate you for the bold step.Im converting a bolero 2wd which is having a dead axle and a rigid suspension in the front to 4wd.

Would be using 16inches 160pcd steel rims, ISZ 4jg2 3.1ltr + ISZ 5spd 4wd gear box with AC & PS.

3.1 L in-line 4-cylinder intercooled turbodiesel (designated 4JG2) producing 114 PS (84 kW; 112 hp) at 3,600 rpm, and 260 N•m (192 lb•ft) at 2000 rpm. It was offered as an alternative to the 3.2-litre petrol, as a more rugged and fuel-efficient option for towing and heavy-duty operation.

The 2.283:1 low range can be selected on the move, providing the front hubs are engaged, at up to 15 km/h 1st gear, 25 km/h 2nd gear and 40 km/h 3rd to 5th gears

I would recomend to go for more powerfull engine than XDP or DIT as you have to perform in a 4wd terrain with solid shell weight on head..

Last edited by Rajith : 17th April 2013 at 11:48.
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Old 17th April 2013, 12:04   #4
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Default re: Wickedly Radical - Mahindra Bolero Build

Hi WW,
I like the black paint job but have seen a BOLERO with similar black job done with MATT CARBON FIBER sheets including the side (black) patties. IMO it looked nice.
That way you can covert it to anything else by just pulling out the older sheets.

Raab rakha.
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Old 17th April 2013, 12:23   #5
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Talking re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by whicked wheels View Post

a 4wd divorced transfer case with PTO (i think its off a tata 407), a borg warner manual shift transfer case with adaptor,
You have been quite clearly & wickedly seem to continue to confuse me then & now here .

Please for gods sake tell me how & why you are using TWO transfer cases ?

Looks like I will be raiding your place soon for few parts, if you avoid to answer & continue to confuse me now on .

BTW this thread is going to be a worth to keep watch on .

Best of Luck & any help from my side will always be there .

Best Regards
Sudarshan
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Old 18th April 2013, 08:22   #6
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Hi Rajith
Thats a nice build you got going. Do you have a thread here on team-bhp will love to see the updates and the progress on your bolero build.

Hi Sudarshan
I see your still confused once its done ill let u drive it. This season it might be just a simple 4x4 conversion.

Last edited by whicked wheels : 18th April 2013 at 08:23.
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Old 18th April 2013, 10:48   #7
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Hi guys

Need some help regarding LSD. I just want to know if the scorpio LSD will fit the bolero differential and where can i get them.
I also wanted to know if lockers are available and where can i get them.
What would be the cost of the lockers and LSD.
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Old 18th April 2013, 12:43   #8
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by whicked wheels View Post
Hi guys

Need some help regarding LSD. I just want to know if the scorpio LSD will fit the bolero differential and where can i get them.
I also wanted to know if lockers are available and where can i get them.
What would be the cost of the lockers and LSD.
As far as i remember we dont have an option of LSD or LOCKERS from M&M for a BOLERO.

There is Lockright Auto-Lockers available for Dana 44 with 19 spline and 30 spline.
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Old 18th April 2013, 15:41   #9
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by whicked wheels View Post
Hi guys

Need some help regarding LSD. I just want to know if the scorpio LSD will fit the bolero differential and where can i get them.
I also wanted to know if lockers are available and where can i get them.
What would be the cost of the lockers and LSD.
Hey wicked wheels,

Congrats on the buy, and all the best for the build. Its nice to have a lockable offroader to drive around!

AFAIK, with the borg warner TC and a center aligned scopio rear differential and 30 spline axles, you can try these for lockers. http://www.team-bhp.com/forum/long-t...ml#post2745881

IMO, they are great VFM and you can get it done from M&M ASS!

Last edited by dhanushs : 18th April 2013 at 15:43.
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Old 18th April 2013, 20:29   #10
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by Rajith View Post
Im converting a bolero 2wd which is having a dead axle and a rigid suspension in the front to 4wd.
Hi,
Which vehicle is this? I thought 2WD Boleros always had IFS.

Regards
Sutripta
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Old 18th April 2013, 23:15   #11
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by Sutripta View Post
Hi,
Which vehicle is this? I thought 2WD Boleros always had IFS.

Regards
Sutripta
A version called BOLERO DI , my handle in TBHP is having same pics and another one is Bolero LX , gone mostly to govt. Also Armada grand or std with NGCS got a rigid front with 2wd setup
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Old 19th April 2013, 07:58   #12
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by whicked wheels View Post
Hi Sudarshan
I see your still confused once its done ill let u drive it. This season it might be just a simple 4x4 conversion.
I can guess the plan. But yes with two TC in row you are going to produce some menacing torque. Now which Jeep axle is going to handle that ?

Perhaps you are going for 407 axles ? & then a 407 chassis to keep them in control ?

God bless, not you but me, with few parts


Sudarshan
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Old 19th April 2013, 13:12   #13
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Default T-Case

Hi Wicked Wheels,

Are you sure the T-Case is from a Tata 407?

AFAIK the Tata 407 T-Case has a front left output (LHS Front Differential).

Regards,

Arka
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Old 19th April 2013, 14:16   #14
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Hi Sudarshan

God please bless him with parts or else he may want mine.
On a serious note i am sure the axles of the jeep will hold that kind of torque, as for the chassis its a box type one so it should hold.

Hi Arka
I am really not sure about the transfer case if its of a 407, ill post some close up pics of the same. It will be nice if you could identify it for me . I too feel the front out put is to the left.

Regards James

Last edited by whicked wheels : 19th April 2013 at 14:18.
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Old 19th April 2013, 20:12   #15
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Default Re: Wickedly Radical - Mahindra Bolero Build

Quote:
Originally Posted by Rajith View Post
A version called BOLERO DI , my handle in TBHP is having same pics and another one is Bolero LX , gone mostly to govt. Also Armada grand or std with NGCS got a rigid front with 2wd setup
Would be great if someone could compile a timeline-variant list for the Bolero.
What was the timeframe for this DI variant. Is this the one without PS or AC?

The AG always had a rigid front axle, 2wd or 4wd. When the Bolero was introduced (with XD3 engine) it was essentially distinguished from the AG by the slight styling changes (esp. curved windshield) and IFS (for the 2wd).

Regards
Sutripta
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