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Old 5th August 2014, 21:21   #91
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by DHABHAR.BEHRAM View Post
Dear wanderernomad - tired from now only? "abhi to shuruwaat hai, aage aage dekh kya hota hai". This frustration with mechanics, electricians, tinkers and painters is a part and parcel of trying to restore a Jeep! .

Best regards,

Behram Dhabhar
Dear Sir, am not tired but rather feeling angry because I have so many ideas in my head and the tinker has not even started the basic work yet. Haha. Guess am tired. Lol. But the reason am in that particular workshop is primarily the quality of mechanical work. Once its done ill move the jeep out for body work either to the Mahindra workshop or the workshop I intend to get it repainted.
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Old 9th August 2014, 22:15   #92
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Finally some progress. The bigger alternator has been fixed but now the battery needs to be repositioned. One suggestion is to keep a bigger battery beneath the rear seats. Suggestions please?
The scissor work has started and it seems my rants the other day have worked. Today changed the rubber headings around the windshield as well and the rubber mounts for holding the folded windshield are next on the agenda.
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Old 13th August 2014, 10:00   #93
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The latest pictures. The right side fender has been removed to make way for a battery holder as after the larger alternator there is no space on the original location to fit a larger battery. Any suggestions on alternate locations will be very welcome.
Rough work for the scissors along with the proposed position and working mechanism is being tried out.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140812_162049264-1.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140812_162121446.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140812_162551758-1.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140812_162600883.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140812_163007190.jpg  

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Old 6th September 2014, 22:48   #94
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The much awaited battery holder bracket has finally been fixed today and the jeep is ready to be rolled out on road for trial runs on Monday. Some pictures of the battery holder tray and the mods done in order to keep it clear of the steering rod.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140906_155050801_hdr.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140906_155058219_hdr.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140905_170504870_hdr.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140906_155035323.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-img_20140906_155043556.jpg  

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Old 14th September 2014, 22:03   #95
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Took the jeep out and have made it safely back too, twice now. Here are the observations:
1. There is a lot of smoke at present. Mech says it will reduce after a few hundred kms.
2. There are vibrations that shake the entire body while in neutral and standing still.
3. Engine is missing slightly.
4. Clutch gets disengaged quite late.
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Old 25th September 2014, 17:40   #96
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The jeep is running fine on road tests now, engine sounds sweet and the pull is also quite good. The noise has also died slightly after repairing the exhaust pipe. The steering does not feel vague either and braking is decent. However, the 4X4 engaging lever gets stuck and becomes difficult to engage or disengage.
Am so happy with it running that I need advise on what all things to keep an eye on or check at this stage itself before it goes for paint and final finishing up.
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Old 26th September 2014, 13:50   #97
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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
.
Am so happy with it running that I need advise on what all things to keep an eye on or check at this stage itself before it goes for paint and final finishing up.
Dear wanderernomad Ji,
I will suggest to use it for thousand Kms at least before you send it for painting. this includes intended offroading sessions as well.
It will be worth solving everything now than getting your new pain scratched by mechanics, who will climb to side fenders to work on your engine bay. These fenders also serve them as table to keep all their tools, battery or sometime jack..........


Shubhendra
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Old 7th October 2014, 15:51   #98
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by Shubhendra View Post
Dear wanderernomad Ji,
I will suggest to use it for thousand Kms at least before you send it for painting. this includes intended offroading sessions as well.
It will be worth solving everything now than getting your new pain scratched by mechanics, who will climb to side fenders to work on your engine bay. These fenders also serve them as table to keep all their tools, battery or sometime jack..........


Shubhendra
Shubhendra jee, I was intending to drive for about 500 kms or so and make a list of what all I find discerning. But 1000 kms means I will get it repainted only next summer. But advise taken and shall stick to it unless the bitter half threatens divorce.
4X4 transfer case was opened and cleaned. One ball bearing was changed along with 2 small springs and now every thing is smooth.
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Old 7th October 2014, 16:02   #99
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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
But 1000 kms means I will get it repainted only next summer.
I know covering 1000 kms in hilly area is a task in itself. Idea is to stress test the vehicle before you get it painted.
I made this mistake with my recently done up diesel CJ3B, during its maiden OTR, gearbox gave way and i had to tow my jeep across the city in maddening evening traffic. We had to open Gearbox to find that one bolt was not tightened enough leading to this failure.


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Shubhendra
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Old 7th October 2014, 16:17   #100
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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Originally Posted by Shubhendra View Post
I know covering 1000 kms in hilly area is a task in itself. Idea is to stress test the vehicle before you get it painted.

Regards,
Shubhendra
Jorhat is all plains though I intend to take it to the Naga hills for real stress tests with a back up vehicle. I had planned to do it this long weekend that we had but parents came down for Diwali and took them to Shillong etc. But with the forthcoming weekends I will try to spend as much time as I can with the Jeep to understand her.
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Old 8th October 2014, 15:30   #101
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The rear tailgate has been converted to a drop down by adding hinges on the sides. The Jeep is ready to be brought home for stress tests and having fun. Presently a coat of primer shall be made over all the exposed metal parts. The design for the swing type tyre carrier is on. Suggestions please. Also I request jeep gurus to kindly post some detailed pictures of how they anchor the folding canopy rods on the body tub.
Attached Thumbnails
A Mahindra CJ500 DP and a custom made Expedition Trailer-camerazoom20141008113342186.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-camerazoom20141008113435146.jpg  

A Mahindra CJ500 DP and a custom made Expedition Trailer-camerazoom20141008114718018.jpg  

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Old 16th October 2014, 11:47   #102
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

The Jeep is running well and still ahs the following issues:
1. There is smoke coming to the passenger foot well area from the exhaust pipe. Though the pipe from the manifold to the silencer has been replaced but I think the joint at the silencer may not be adequately sealed.
2. The speedo needle wont go above 20 even at the time when the engine is screaming its lungs out.
3. The temperature is still around 60 so I think the cooling system is functioning well. Though the fan shroud is still to be put in.
4. The Fuel needle and the charging needle refuse to work for the last 2 days. Not sure if the alternator is charging the battery or not.
5. Most of the mechs here say there is no alignment on the jeep. is it true?
6. Still has smoke issues though the intensity fo the fumes has gone down. Should i again refill the engine oil and change the filter?
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A Mahindra CJ500 DP and a custom made Expedition Trailer-camerazoom20141015163301503.jpg  

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Old 18th October 2014, 23:01   #103
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

What to do about the smoke? Should I change the piston rings?
Shubhendra jee is your smoke issue sorted out?
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Old 19th October 2014, 19:24   #104
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

Took the jeep out for a longish run of about 75 kms. Enjoyed through the tea gardens and it ran well without any issues except that at low rpms and idle the smoke is as if we are on a fumigation drive. Gurus, please advise on the smoke part.
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Old 20th October 2014, 16:07   #105
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Default re: A Mahindra CJ500 DP and a custom made Expedition Trailer

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What to do about the smoke? Should I change the piston rings?
Shubhendra jee is your smoke issue sorted out?
wanderernomad Ji,
I am not eligible to comment due to limited knowledge but suggestion made by DB sir is applicable to your case as well. Ideally XDP engines should not emit much smoke.
One question though - is it black smoke or white smoke. I am yet to perform steps suggested by DB sir, i wanted to complete 1000 kms in as is condition and wanted to do those steps along with oil change.
May be in a months time, i will reach 1000 kms mark.

Regards,
Shubhendra
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