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Old 24th July 2011, 17:40   #1
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Default My MM540 4X4 Build: new shell, SOA, PS etc

After letting my Jeep, rust in isolation for almost 2 years I have finally put aside some money to Bring her back to life. Here are the To Dos:
Body Shell
Power Steering
Spring Over Axles
Hanging pedals
Brake Booster & New Alternator
Windshield Frame.
hard top for the cabin ( I like the Mahindra Invader roof)
new set of alloys (hopefully 3 spoke rally 10J 15")
31" to 35" tires ( maxis?) Mudzilla? Trepador? $$??
bucket seats
So far I have bought an export class body shell and a power steering kit. The windshield frame had to be replaced since the older one had a nasty hole in it. My original front grill and fenders will remain.
For a long time I have pondered and researched on whether to or not to increase the ground clearance. Well finally I said chuck it and decided raise the height with the SOA. I hope I'm not gonna regret this.
My friend at the workshop here has done the SOA conversion for me.
We still have to get the shock absorb er mounts corrected. The body shell that I got was for a left hand drive vehicle. So here there are a few mods to be done.
The PS has been fitted too. temporarily to get the holes in the chassis right.
I will try and update the status of this project as and when I can. Hope to hear some comments from the experienced Team BHPians.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-before.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-body-off.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-before-soa.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-springs-removed.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-after-soa.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-after-soa1.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-aftersoa2.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-shell-front-left.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-shell-front.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-shell-rear.jpg  

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Old 27th July 2011, 16:59   #2
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

sorry for the offtopic, but posting here because I can't PM you
could you reply to this query here
http://www.team-bhp.com/forum/techni...ml#post2234164 (OBD (On-board diagnostics) for Indian Cars)
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Old 15th February 2012, 17:30   #3
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Ok so my workshop guy went away for a long holiday and is finally back and has started work on my baby. Here are some more pics of the work in progress. SPOA is done but we still have to figure out the mounting of the front shocks. PS fitted. Suspended pedals and brake booster also installed. factrory reject bonet and fenders fitted too.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-28082011298.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-28082011301.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-28082011306.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-28082011313.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-110220121245.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-110220121248.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-300120121143.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-300120121144.jpg  

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Old 15th February 2012, 20:38   #4
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Interesting thread! Please do keep update. This workshope looks like specialized in jeep modifications.

Why new alloy? The current one looks nice with jeep

Sali.
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Old 28th February 2012, 19:08   #5
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Yes This guy only does MM jeeps. He has a very good team of ex-MM mechanics, denters and painters.
Here are some more pics,
Due to the SPOA the drag link angle appears rather steep.
might have to mod that too.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-20120220032.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-20120220036.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-20120220033.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-20120220030.jpg  

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Old 1st March 2012, 11:26   #6
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Quote:
Originally Posted by 4x4Roadie View Post
Hanging pedals
Brake Booster & New Alternator
Are you planning for disc brakes? Please can you tell me how much did the hanging pedal cost you?

Quote:
Originally Posted by 4x4Roadie View Post
new set of alloys (hopefully 3 spoke rally 10J 15")
31" to 35" tires ( maxis?) Mudzilla? Trepador? $$??
bucket seats
So far I have bought an export class body shell and a power steering kit. .
If you are really planning for a change I would be interested in buying the old alloy that you have in now

What gauge is the export class body shell, and is the PS a new one? which make.

Looks like you are building a mean machine, do let me know when you part the alloys...
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Old 7th March 2012, 15:00   #7
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Default

Since I decided to go all the way with this build I thought why not a new engine???
And since all the Team BHP gurus have put it up on a pedestal I decided to get one. My babys new powerplant: The XD3P. Just came in yesterday from Mumbai cost me 36K plus transport... dunno if i got ripped off. Looks in good condition. will know the truth once it is started up. Pics below.

Im very curious to know what this connector is for. It seems to be connected to a sensor or switch on top of the throttle lever. Can anyone tell me what it is for. throttle position sensor maybe? and what does it connect to in a Bolero? I was told this engine was removed from a 2005 Bolero.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-20120306015.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-20120306016.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-20120306024.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-201203060171.jpg  


Last edited by Jaggu : 7th March 2012 at 16:17. Reason: Back to back post, please use EDIT once the posts are approved. Thank
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Old 8th March 2012, 14:53   #8
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Quote:
Originally Posted by Twinn View Post
Are you planning for disc brakes? Please can you tell me how much did the hanging pedal cost you?
If you are really planning for a change I would be interested in buying the old alloy that you have in now
What gauge is the export class body shell, and is the PS a new one? which make.
Looks like you are building a mean machine, do let me know when you part the alloys...
Hanging Pedals: cost around Rs.2600

Disk Brakes: No I wont be putting in disk brakes now, If budget permits, may be later.

Alloys: Might keep the old set of alloys for a regular driving set of wheels, and the new ones for offroading. Time will tell if I make up my mind to sell I will let you know.

Body shell: My guy at the workshop says its a Mahindra Thar original shell. dunno the gauge though. Meant for export vehicles ie: it had the drivers side on the left.

Power S. Rane make meant for the Bolero
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Old 8th March 2012, 15:58   #9
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Thumbs up Re: My MM540 4X4 Build: new shell, SOA, PS etc

Buddy

My Questions in Bold Italics
Quote:
Originally Posted by 4x4Roadie View Post
Hanging Pedals: cost around Rs.2600

Disk Brakes: No I wont be putting in disk brakes now, If budget permits, may be later.

Alloys: Might keep the old set of alloys for a regular driving set of wheels, and the new ones for offroading. Time will tell if I make up my mind to sell I will let you know.

Body shell: My guy at the workshop says its a Mahindra Thar original shell. dunno the gauge though. Meant for export vehicles ie: it had the drivers side on the left.

Please share the cost of your new body shell as well as the place from where you got it.

Power S. Rane make meant for the Bolero

Do post detailed pics of how the PS is being installed because one of my friend to has plans for a PS in his 540.

Last edited by crazyjeeperk : 8th March 2012 at 15:59. Reason: formatting error
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Old 8th March 2012, 17:32   #10
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

The body shell cos me around 40K plus 3k in transport. It was a year back.
My friend who runs the garage ordered it. He has a contact somewhere. most probably Mumbai or Nasik. Cant remember where it was bought from. Will ask him and confirm exactly where it was bought from. They are factory rejects of some sort. The shell comes in 4 pieces. Cut through and through with a gas cutter. We then assemble the shell back and weld it carefully. He has bought quiet a few of them here in Goa. All the vehicles have turned out real good.

Anyways here are pics of the PS install on the chassis. please forgive that they are not in proper order. Will put more pics once the rest of the kit is installed.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-ps5.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps2.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps1.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps6.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps7.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps4.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-ps3.jpg  

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Old 8th March 2012, 18:47   #11
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Quote:
Originally Posted by 4x4Roadie View Post
The body shell cos me around 40K plus 3k in transport. It was a year back.
My friend who runs the garage ordered it. He has a contact somewhere. most probably Mumbai or Nasik. Cant remember where it was bought from. Will ask him and confirm exactly where it was bought from. They are factory rejects of some sort. The shell comes in 4 pieces. Cut through and through with a gas cutter. We then assemble the shell back and weld it carefully. He has bought quiet a few of them here in Goa. All the vehicles have turned out real good.

Anyways here are pics of the PS install on the chassis. please forgive that they are not in proper order. Will put more pics once the rest of the kit is installed.
Hi

Those Pics were really informative and i am sure it will help many during their P.S installation , Waiting for the next set of pics and also your feed back about the newly installed P.S both ON & OFF the Road.

Thanks again for your prompt reply with the pics .

Last edited by crazyjeeperk : 8th March 2012 at 19:07.
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Old 9th March 2012, 11:24   #12
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Here are pics of the body shell when we got it before it was fitted on the jeep.
Notice the fuse box mount on the right and steering and pedal holes on the left. And the cut lines.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-shell1.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-shell2.jpg  

My MM540 4X4 Build: new shell, SOA, PS etc-shell3.jpg  

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Old 10th March 2012, 14:36   #13
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Angry Re: My MM540 4X4 Build: new shell, SOA, PS etc

Update: this XD3p engine wont fit on the current bell housing and starter location is on the left side of the vehicle. So i need a new bell housing and a thinner flywheel. so now another wait till I get the new bell housing.
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Old 10th March 2012, 15:03   #14
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Here is another hurdle I knew I would have to overcome. This is because of the SPOA conversion.

The drag link angle is very steep and it will definitely hamper steering operation.
Also the tie rod is now very much exposed to damage from front impact.

I am going to go for a HIGH STEER ARM mod. I need to make these arms that mount on the king pin cap bolts. Google search brought up these pics which have given me a very good idea of what I need.
The prices are very steep for these aftermarket mods and then the cost of shipping and probably customs.
Has anyone made these already? it would be awsome if some one has and I could buy them within India.
I might get a lathe guy to mill them.
I will have to do this on both sides. I think if i achieve this it will put both the drag link and the tie rod safely above the spring leaves and it will look a lot neater too. PICS attached.
Attached Thumbnails
My MM540 4X4 Build: new shell, SOA, PS etc-high-steer.jpg  

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Old 10th March 2012, 22:59   #15
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Default Re: My MM540 4X4 Build: new shell, SOA, PS etc

Ahhh, just noticed that Im a BHPian now. 25 posts up...
Thanks a lot my fellow BHPians for your support.
Its been a pleasure visiting and posting in this community. Im sure there will be a lot more posts from me. It is really good to share with everyone what we learn everyday with our machines.
I can now put on the Team Bhp stickers I bought almost a year back.
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