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Old 9th June 2014, 18:43   #46
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Dear wanderernomad - spend your money only on value-add activities. Don't go overboard!

Best regards,

Behram Dhabhar
Sir, absolutely planning to stick to functional basics but a few changes just to remove the sarkaari look and to make the boot a bit more useable. Nothing bling.
Sir, one clarification the space on either side of the front grill will host reflectors or clear lens lights? A person here in Jorhat, who claims to have been around jeeps since WWII claims that I should not put clear lens lights but only white reflectors there. As in the Major.
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A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140609_123021274.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140609_123026826.jpg  

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Last edited by wanderernomad : 9th June 2014 at 18:47.
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Old 9th June 2014, 20:46   #47
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Another option is to mount a double scissor to hold the canopy when in use. Otherwise it gets folded down along the side, behind the rear seat. A rough estimation:
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Old 14th June 2014, 15:39   #48
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Nothing much progress to report. Hopefully next week should see some considerable progress. Only the roof is completely removed now and we took measurements for the scissor arms for the canopy. 3ft of what seems to be required to form a V frame for supporting the canopy when required. Otherwise they will fold down nicely inside the body tub behind the rear seats. Now 2 queries:-
1. Will rims of a Marshal DI fit my jeep or is the pcd different?
2. How to mount seat belts? Is it legal to drive without ones if the original vehicle did not have any provisions for mounting the seat belts?

And please some suggestions on how to mount the rear tyre on a frame separate from the rear gate, while retaining the rear gate usability as well.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140614_131604557.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140614_131940254_hdr.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140614_131953509.jpg  


Last edited by wanderernomad : 14th June 2014 at 15:41.
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Old 14th June 2014, 19:29   #49
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by wanderernomad View Post
Nothing much progress to report. Hopefully next week should see some considerable progress. Only the roof is completely removed now and we took measurements for the scissor arms for the canopy. 3ft of what seems to be required to form a V frame for supporting the canopy when required. Otherwise they will fold down nicely inside the body tub behind the rear seats. Now 2 queries:-
1. Will rims of a Marshal DI fit my jeep or is the pcd different?
2. How to mount seat belts? Is it legal to drive without ones if the original vehicle did not have any provisions for mounting the seat belts?

And please some suggestions on how to mount the rear tyre on a frame separate from the rear gate, while retaining the rear gate usability as well.
**** all non Ngcs rims will fit also old and new major rims / gypsy Rims also will fit.
**** it's legal to drive vehicles came from factory with out seat belts as is,but for your safety it's good install one.i suggest Ngcs major roll cage as it has seat belt points for front.
**** for spare wheel please instal new majors tail door.
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Old 14th June 2014, 22:52   #50
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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**** for spare wheel please instal new majors tail door.
What is different in it? If it has a separate mounting bar, can I not just use it? Or I need to use the entire rear gate?
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Old 15th June 2014, 09:57   #51
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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What is different in it? If it has a separate mounting bar, can I not just use it? Or I need to use the entire rear gate?
New Major rear door is having proper reinforcement channels on the back side of the door like new Thars.
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Old 15th June 2014, 18:20   #52
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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1. Will rims of a Marshal DI fit my jeep or is the pcd different?
The wide track marshal PCD is 160
Narrow track Marshal PCD is 139.7
Your Jeep PCD is 139.7
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Old 15th June 2014, 22:12   #53
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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The wide track marshal PCD is 160
Narrow track Marshal PCD is 139.7
Your Jeep PCD is 139.7
How do I determine which Marshal is the wide track and which is the narrow track? Anything to do with the model year or any indication on the VIN plate?
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Old 16th June 2014, 10:26   #54
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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How do I determine which Marshal is the wide track and which is the narrow track? Anything to do with the model year or any indication on the VIN plate?
hey,
wider track marshal is NGCS and Narrow one in NON NGCS. Else take a tape and measure.
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Old 16th June 2014, 11:34   #55
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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hey,
wider track marshal is NGCS and Narrow one in NON NGCS. Else take a tape and measure.
Hi Rajith, If you get the vehicles side by side you can differentiate, if not, might be little confusing for non familiar people. As, both chassis are box, IIRC
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How do I determine which Marshal is the wide track and which is the narrow track? Anything to do with the model year or any indication on the VIN plate?
Hi,

Look if the steering box is up front, just behind the front bumper, below the MAHINDRA Cover plate, bolted on to the driver side long member. If you can find the steering box there, its the 160 PCD Marshal.

If the steering location is like old 540's/your current jeep. Its the old narrow track Marshal.
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Old 16th June 2014, 12:06   #56
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by dhanushs View Post

Look if the steering box is up front, just behind the front bumper, below the MAHINDRA Cover plate, bolted on to the driver side long member. If you can find the steering box there, its the 160 PCD Marshal.

If the steering location is like old 540's/your current jeep. Its the old narrow track Marshal.
Checked. The steering box is right after the steering column towards the firewall and not the chassis long member. So its the narrow track and will fit. Thanks Dhanushs. Moreover, it has a front shunt so a little difficult to check visually, as both the front axles are broken and the wheels totally at an unnatural angle.
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Old 16th June 2014, 12:56   #57
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by dhanushs View Post
Hi Rajith, If you get the vehicles side by side you can differentiate, if not, might be little confusing for non familiar people. As, both chassis are box, IIRC
Hi,

Look if the steering box is up front, just behind the front bumper, below the MAHINDRA Cover plate, bolted on to the driver side long member. If you can find the steering box there, its the 160 PCD Marshal.

If the steering location is like old 540's/your current jeep. Its the old narrow track Marshal.
Yes Dhanush your right.Both are box with different width of springs for front and rear.
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Old 17th June 2014, 15:29   #58
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The following items need to be replaced:
1. King Pin bearings, small.
2. Both cross.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_124824090.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_124907314.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_124926554.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_124932924.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_125955531.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140617_125946848_hdr.jpg  

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Old 17th June 2014, 23:06   #59
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

In case I have to replace the shockers, what should I buy? The shackles have been found to be ok and need no work so are the tie rods. Up front the mechanic suggests to replace only what is purely needed and then get the jeep on road. After running for a month or so then all the irritants would be addressed in one go. It is at that stage that I would get it repainted.
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Old 18th June 2014, 11:51   #60
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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In case I have to replace the shockers, what should I buy? The shackles have been found to be ok and need no work so are the tie rods.
Gabriel (blue color), costs around 1800 INR for set of four. Does the duty pretty well. In local market they are know as 'jeep ka shockup'. on top corner of box i think jeep is mentioned.
Please make sure hole in shackles are not circular and not distorted.

Regards,
Shubhendra Singh
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