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Old 18th February 2015, 12:49   #46
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by caged_nomad View Post
Hi Antihero. Could you please share some photographs of the spare wheel carrier? I have had to keep the spare wheel inside the gypsy as the hinges on my car are unable to take the weight of the tire.
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Originally Posted by antihero View Post
I will post photographs when I am back in Jammu. Cheers!
Here's an illustrative version of what I did.

1. Got a custom roof carrier made with 1/2 inch hollow pipes. Cost 2300 Rs.
1996 Maruti Gypsy MG410W - Going places-img_0326.jpg


2. Moved the wheel to the roof carrier. No Cost.
1996 Maruti Gypsy MG410W - Going places-img_0325.jpg

3. The wheel is held down by U bolt that is used to hold the leaf springs in a Gypsy. The U bolt fits the gypsy tyre holes without any modification. The U bold goes below the pipe tubes for the carrier and comes out through the rim holes. Cost 10 Rs.
1996 Maruti Gypsy MG410W - Going places-image-1.jpg

4. Tightened size 19 nuts (also used in Gypsy wheels) over the u bolt. Cost 10 Rs.
1996 Maruti Gypsy MG410W - Going places-img_0322.jpg
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Old 18th February 2015, 14:12   #47
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by antihero View Post
Here's an illustrative version of what I did.

1. Got a custom roof carrier made with 1/2 inch hollow pipes. Cost 2300 Rs.
Attachment 1341213.......
A pretty novel way of keeping the spare. Is that a Bridgestone dueler?

Now this may sound stupid but how do u manage to mount/ dismount the tire?

Do you climb onto the roof each time ? or do you carry a ladder ?

Must be pretty physically demanding? (from an average joe's perspective?)

How has she been doing ?
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Old 19th February 2015, 07:34   #48
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by caged_nomad View Post
A pretty novel way of keeping the spare. Is that a Bridgestone dueler?

Now this may sound stupid but how do u manage to mount/ dismount the tire?

Do you climb onto the roof each time ? or do you carry a ladder ?

Must be pretty physically demanding? (from an average joe's perspective?)

How has she been doing ?
  1. The spare is a Goodyear Wrangler RT/S. The tyres are Michelin 4x4 A/T
  2. My Gypsy has a custom hardtop with a side door. This makes the access a bit easier. However, it does require climbing on the door-well or on the roof to access the spare. I do not carry a ladder. The carrier fabricator can build me a ladder ala a Ford Endeavour. But I do not require it. I have had just one flat since I have owned the Gypsy.
  3. I trek for a living. These pages will give you a better idea of the kind of terrain the Gypsy has to get me to. I prefer the rooftop arrangement because I need the space in the back to sleep in. Therefore, the wheel cannot be carried inside the cab or behind the driver's seat as seen in most army vehicles. This leaves the rear door or the rooftop as the only mounting options. The rear door is out of the question with the poor roads that I ride on 80% of the time. Thus, the final answer: rooftop. Yes its physically demanding and time consuming, But I have the flexibility to carry 2 tire with no rattles and squeaks, which comes in handy.

I hope this clarifies the unusual wheel carry arrangement.

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Old 4th March 2015, 22:20   #49
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Default Re: 1996 Maruti Gypsy MG410W - Going places

Updates:
  1. Gypsy has been doing winter time in J&K and Himachal. Most trek accessible roads are still closed due to heavy snowfall in the past couple of weeks. The gypsy has been used to get as close as possible to a trek starting point and as a base camp.
  2. The tire on roof arrangement has been a success. Door rattles are negligible.
  3. The Gypsy leaks in numerous places. Below the dash (as referred to by many in similar threads), from numerous bolt holes in the rear body tub floor pan and through the custom windows. This has made living in the Gypsy a bit of a wet blanket. I am working on improving the waterproofing, in a cost effective way. Any ideas on whats the best way to plug small bolt holes in the floor pan?
  4. The exhaust is knackered due to poor maintenance by the previous owner and the harsh terrain plus snow trudging is not helping. I have had the exhaust welded to seal off some bad resonance but eventually it needs to be replaced. A new exhaust is Rs. 2400, which is reasonable. My question is, with my extreme bad road usage, how long can I expect a new exhaust to last? Is the MGP exhaust a stainless steel exhaust? if not, is there an option to get a stainless steel exhaust for the MG410W? I do not mind spending more, if a better option is available.
  5. In situation where the terrain alternates between tarmac and ice, is it ok to have the gypsy running for long periods (> 20 kms) in 4H? I understand transmission windup but 4H gives me more confidence on ice and if I choose to use 2H then I usually lose momentum on turns. This usually means restarting in 4L to make up for lost momentum. Any tips on this kind of scenario?

In the meantime here are some pics from recent excursions and some trek reports, just to give you an idea about the terrain that the Gypsy has to deal with.

cheers
Attached Thumbnails
1996 Maruti Gypsy MG410W - Going places-img_0350.jpg  

1996 Maruti Gypsy MG410W - Going places-img_0359.jpg  

1996 Maruti Gypsy MG410W - Going places-img_0379.jpg  

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Old 6th March 2015, 08:46   #50
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Default Re: 1996 Maruti Gypsy MG410W - Going places

4H over very longer distance is not a problem as long as you do not have hard tarmac. Most of the rally guys run Gypsy's over mountain roads at high speeds in 4H or even 4L !!
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Old 6th March 2015, 09:21   #51
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by sudev View Post
4H over very longer distance is not a problem as long as you do not have hard tarmac. Most of the rally guys run Gypsy's over mountain roads at high speeds in 4H or even 4L !!
On a related note, is there a maximum "safe" speed under which one should shift from 2H to 4H? I understand that for 4L you need to come to a complete stop and shift.
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Old 9th March 2015, 12:42   #52
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Default Re: 1996 Maruti Gypsy MG410W - Going places

Quote:
Originally Posted by antihero View Post
Updates:
  1. The Gypsy leaks in numerous places. Below the dash (as referred to by many in similar threads), from numerous bolt holes in the rear body tub floor pan and through the custom windows. This has made living in the Gypsy a bit of a wet blanket. I am working on improving the waterproofing, in a cost effective way. Any ideas on whats the best way to plug small bolt holes in the floor pan?
INEXPENSIVE WAY WILL BE TO BUY A PACKET OF PLASTIC PLUGS WHICH ARE EASILY AND CHEAPLY AVAILABLE AT M.A.S.S.
ALSO BUY A ROLL OF RAMNEK TAPE (BROAD BROWN COLORED TAPE WITH BITUMNE COAT ON ONE SIDE).
  1. The exhaust is knackered due to poor maintenance by the previous owner and the harsh terrain plus snow trudging is not helping. I have had the exhaust welded to seal off some bad resonance but eventually it needs to be replaced. I do not mind spending more, if a better option is available.
ONE WORD - SNORKEL
Have answered your queris in quote itself. Hope it helps.
Ramnek tape should be easy to find as I saw few military trucks using them during my Srinagar visit in Oct 2014.

Rgds-Sonu
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Old 9th March 2015, 13:48   #53
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by ariesonu View Post
RAMNEK TAPE (BROAD BROWN COLORED TAPE WITH BITUMNE COAT ON ONE SIDE).
Ramnek tape should be easy to find as I saw few military trucks using them during my Srinagar visit in Oct 2014.
Rgds-Sonu
An excellent idea, Thank you. I will try this solution and post pictures if this solution holds up.
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Originally Posted by ariesonu View Post
ONE WORD - SNORKEL
I do not understand this. As I understand it, a snorkel is made to suck in air into the air filter. How does this fix a rusty, knackered exhaust pipe? Could you please elaborate on your solution?
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Old 9th March 2015, 14:46   #54
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by antihero View Post
a snorkel is made to suck in air into the air filter. How does this fix a rusty, knackered exhaust pipe? Could you please elaborate on your solution?
My bad. I proabably was thinking through my EXHAUST pipe.
Sorry snorkel is not the answer to your exhaust problem.

Rgds-Sonu

Last edited by ariesonu : 9th March 2015 at 14:47.
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Old 14th March 2015, 14:06   #55
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by antihero View Post
On a related note, is there a maximum "safe" speed under which one should shift from 2H to 4H? I understand that for 4L you need to come to a complete stop and shift.
Yes you should stop and shift. The reason is more to do with the way gear are cut. They are straight cut instead of helical and hence do not lend themselves to shift on the fly. Though anecdotal inputs I have many guys in rallies do this on the fly.

Last edited by sudev : 14th March 2015 at 14:08.
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Old 16th March 2015, 11:52   #56
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Default Future proofing a roof mounted rack or on how to waste a weekend

Future proofing a roof mounted rack or on how to waste a weekend.

The Why: The roof mounted rack that had had custom built was finished off in poor black paint buy a lad with a rag and a non descriptor black paint. The welded pipes were rusted and they were quickly dabbed on with paint.

Rationale: Since I plan to keep the rack for a few years to come, I reckon it needed a better finish

Time: One and a half day

Prerequisites and cost:
  1. Paint brush 2.5 inches = 50 rs
  2. Asian paint Red oxide Primer 0.5 lt. = 80 rs
  3. Asian paint black enamel 0.4 lt. = 80 rs
  4. 80 grit sandpaper 1.5 meter = 40 rs
  5. 600 grit sand paper 2 sheets = 20 rs
  6. Paint thinner = 35 rs
Process:
Sandpaper the rack to bare metal. Ensure all paint and rust falls off. Start with 80 grit and then finish the surface with 600 grit. Time Half day.

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Clean the rack thoroughly with cloth and thinner
Coat one with red oxide primer
Coat two with red oxide primer, ensuring all metal is covered. Time half day

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Coat three with black paint. Time half day.

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Old 17th March 2015, 20:36   #57
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Lightbulb Identifying MG410W's age

Tip: another way of judging a Gypsy's (MG410W) age. The rims have the month and year of manufacture stamped on them

1996 Maruti Gypsy MG410W - Going places-img_0434.jpg

From my Gypsy. Rims stamped 96-05 which means a manufacture date of 1996 May. It states the kind of rim (6 1/2 J x 15)
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Old 19th March 2015, 00:59   #58
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by antihero View Post
...
2. A new front windshield, custom hardtop needed a custom windshield
....
You are a lucky man- doing what you are doing with that beautiful vehicle. Just one query- what sort of glass is that? Laminated or simple toughened glass? Or windowpane stuff?
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Old 19th March 2015, 08:40   #59
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Default Re: 1996 Maruti Gypsy MG410W - Going places

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Originally Posted by fighterace View Post
Just one query- what sort of glass is that? Laminated or simple toughened glass? Or windowpane stuff?
Short Answer - Laminated glass.

Long Answer - Most automotive shops in the "transport section" of your town will have a shop or two that deal with bus / truck glass. The trick is finding the best quality laminated glass. Busses and truck drivers don't seem to care much for glass quality.Laminated glass quality can be empirically measured on
  1. glass clarity
  2. plastic sheet thickness and adhesive in laminated glass and
  3. whether the glass sheets (2 in laminated glass) have been toughened or not
In most cases asking the shop owner for information will just lead to irrational "gyan". So inspect the sheets yourself and try to decipher the thickness and other features based on an accurate ruler and packaging material.

1996 Maruti Gypsy MG410W - Going places-img_0448.jpg
glass clarity

Shop around for best results. In Jammu, the price for gypsy's laminated glass ranged between Rs. 1200 and Rs. 2500.

Last edited by antihero : 19th March 2015 at 08:45. Reason: grammar
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Old 22nd April 2015, 22:18   #60
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Default Re: 1996 Maruti Gypsy MG410W - Going places

The gypsy is being worked on. The rear cab has been been put through a DIY rust proof refurbishment. Catch the complete story on this thread
http://www.team-bhp.com/forum/techni...ent-gypsy.html

for the quick story here it is
1996 Maruti Gypsy MG410W - Going places-desktop1-copy.jpg
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