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Old 21st June 2014, 18:36   #61
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The work is progressing well and the entire front end is complete in respect of axles, bushes, spring leafs, brake shoes and brake linings. Work is now on the rear axles. Only the front two shockers have been changed with Escorts make as Gabriel were not available. Some body work will also be required at the rear panels and on the metal plate beneath the diesel tank. The pedals have come from the lathe and have been fitted. An extra tube has been fitted around the ball of the front axles which according to the mechanic eliminates the death wobble. Gurus?
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_170333695.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_170341753.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_171528461.jpg  

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Old 21st June 2014, 19:28   #62
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Sorry but the connection went off before I could edit the previous post.
The radiator has some markings of madras heat transfer. Maybe its the original radiator still doing the duty? The remaining pictures:
PS: I just noted that the mechanic has got the rear shockers for fitting up front. Are they all same or different?
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_165824998.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_165216533.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_165304747.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_170018797.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_163211882.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_164451242.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_164240170.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_164249059.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140621_164600542.jpg  


Last edited by wanderernomad : 21st June 2014 at 19:30.
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Old 22nd June 2014, 08:49   #63
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Quote:
Originally Posted by wanderernomad View Post
PS: I just noted that the mechanic has got the rear shockers for fitting up front. Are they all same or different?
They are slightly longer shocks, but, should do the job better.
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Old 25th June 2014, 17:42   #64
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The mechanical works are almost over and now electrical works have started. Also some tinkering work that needs to be done are to be started. The points here are:
1. To retain the half doors but the frame is higher than the tub body line. Suggestions?
2. How to frame a spare tyre carrier separate from the rear door so that even the rear door is functional? Or we weld the frame to the chassis and do away with the rear door functionality?
The pictures:
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140625_165022688.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140625_165032811.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140625_165106991.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140625_165919745.jpg  

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Old 25th June 2014, 18:33   #65
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The few rough hand drawings that I have in mind are as follows:
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-cs.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-df1.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-df2.jpg  


Last edited by wanderernomad : 25th June 2014 at 18:37.
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Old 26th June 2014, 14:50   #66
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The brake master cylinder service kit cannot be sourced and the mechanic says it has to be changed. Should we change it to the newer double cylinder one? What are the pros and cons? Will the change require any more adaptations to be made to the brake pipes and lines?
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Old 28th June 2014, 18:09   #67
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Purchased the double master cylinder for brakes. But then decided to explore the servo assisted brake cylinder. Got an old one from the Marshall but the mechanic says cannot be done on my jeep for two reasons:
1. There is not enough space in the engine bay and the foot well to accommodate the servo booster mechanism.
2. It requires a hanging pedal and won't work with the floor one. Any adaptation is bound to be unreliable plus the entire brake system is designed for the low pressure mechanical type while with the servo assist, it becomes high pressure hydraulic?
So have to let go. Here are the pictures of the old master cylinder and the new one purchased. Also the mounting rack in the foot well required for the hanging pedals and the firewall which is supposed to hold the assembly and cylinder.
Also in the picture the rear seat is removed to be set further ahead and lower to accommodate the swing canopy bars.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_121303294.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_121310525.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_163050387.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_163101721.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_163120338.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_163018650.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140628_163037548.jpg  

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Old 28th June 2014, 22:02   #68
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

If you stick to drum brakes, you don't need the servo. In fact, I would strongly recommend against a servo if the other components are (drums -> discs) are not changed as well. Servo will also mean an alternator with a vacuum pump.

Something about your tailgate picture is bothering me. Can't put my finger on it.

Check the battery support, and spare wheel mounting bracket for cracks.

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Old 28th June 2014, 22:59   #69
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Quote:
Originally Posted by Sutripta View Post
If you stick to drum brakes, you don't need the servo. In fact, I would strongly recommend against a servo if the other components are (drums -> discs) are not changed as well. Servo will also mean an alternator with a vacuum pump.

Something about your tailgate picture is bothering me. Can't put my finger on it.

Check the battery support, and spare wheel mounting bracket for cracks.

Regards
Sutripta
Dada, we have the alternator with vacuum pump but its the matter of changing everything right upto the lines that has stopped us from being so adventurous for now. The sag towards the right side in the tail gate or the upturned rear bench in the background? In any case the battery support is being done afresh as adding the alternator has changed the space dynamics in the engine bay.

Last edited by wanderernomad : 28th June 2014 at 23:04.
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Old 29th June 2014, 22:03   #70
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Dada, we have the alternator with vacuum pump but its the matter of changing everything right upto the lines that has stopped us from being so adventurous for now.
In my opinion the vehicle would have become almost undrivable. Walking on eggshells all the time.

Quote:
The sag towards the right side in the tail gate or the upturned rear bench in the background?
Neither.

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Old 29th June 2014, 23:10   #71
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Do we get bed liners in the local market like monstaliner? Details at www.monstaliner.com. If not, can we have it brought in baggage from US. One gallon would be suffice for the 500 body tub? Any body having an experience of a similar product here?
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Old 30th June 2014, 10:52   #72
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Do we get bed liners in the local market like monstaliner? Details at www.monstaliner.com. If not, can we have it brought in baggage from US. One gallon would be suffice for the 500 body tub? Any body having an experience of a similar product here?
I have bought few cans of Rust'O'leum bed liner and anty rust coating on few occasions from US of A. I have no idea about monstaliner but Rust'O'Leum are not so good.

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Old 30th June 2014, 15:30   #73
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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I have bought few cans of Rust'O'leum bed liner and anty rust coating on few occasions from US of A. I have no idea about monstaliner but Rust'O'Leum are not so good.

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Thanks mate, so it was not worth the effort? Should I just get the tub and chassis spray painted then?

Any ideas about the paint scheme? Desert Tan is what I am leaning towards or a deep shade of blue like in the polo.
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Old 30th June 2014, 15:47   #74
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Thanks mate, so it was not worth the effort? Should I just get the tub and chassis spray painted then?

Any ideas about the paint scheme? Desert Tan is what I am leaning towards or a deep shade of blue like in the polo.
Why dont you try Wurth products, i have heard good reviews about them.
You can even think of reusing existing color scheme, IMO it would look good.

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Old 30th June 2014, 19:43   #75
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Why dont you try Wurth products, i have heard good reviews about them.
You can even think of reusing existing color scheme, IMO it would look good.

Shubhendra
But it keeps reminding of the sarkaari ancestry and I would like to look it a bit more personal. tough I know that a darker shade would mask its longer looks while a lighter shade would make it look even larger.
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