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Old 5th July 2010, 17:08   #271
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Default Phase II: Engine overhaul

After using the jeep for around a year and making few memorable trips, it was time for the Phase II build-up. The first and the foremost was to pay attention to the engine which was not overhauled during the 1st phase.

Though the engine must have run for quite a good amount of kms before being put in the jeep, even without any overhaul it just kept going. There was no black smoke or no overheating or any similar problems. However after the Corbett trip, the consumption of engine oil increased drastically and finally Mandeep & me decided to get the engine completely overhauled in the hands of his trusted mechanic.
Fortunately almost all original Japanese parts of the engine is available brand new and we replaced pretty much everything with new parts. And we were pleasantly surprised looking at the cost of the parts, much much lesser than the usual figures we are habituated to see with jeep engine overhaul. As always, Mandeep took all the pain to get the work done on the head and the block from the area of Delhi famous & specialized for these jobs.

Posting few pics:

The story of my jeep: MM 440-l.jpg

The story of my jeep: MM 440-dsc06441.jpg

The story of my jeep: MM 440-dsc06445.jpg

The story of my jeep: MM 440-l0.jpg

The story of my jeep: MM 440-l1.jpg

The story of my jeep: MM 440-dsc06406.jpg

The story of my jeep: MM 440-dsc06407.jpg

The story of my jeep: MM 440-dsc06410.jpg

The story of my jeep: MM 440-dsc06414.jpg

The story of my jeep: MM 440-dsc06417.jpg

The story of my jeep: MM 440-dsc06419.jpg

The story of my jeep: MM 440-dsc06421.jpg

The story of my jeep: MM 440-dsc06425.jpg
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Old 5th July 2010, 17:13   #272
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Somen - post some of the latest pics of your jeep with the MT tyres!! It looks KILLER!!

Cheers
Ankit
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Old 5th July 2010, 17:57   #273
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The engine overhaul was done and the initial impression was that the engine did regain good amount of power showing a hint of isuzu's prowess. But the 'fast moving soul' inside mandeep and his right foot was still not satisfied and after some thoughts it was decided to switch back to the original bigger carb of the engine (the one we 've been running was the smaller one, more fuel efficient but underpowered). So a trip to mayapuri & we managed to find the carb at a throwaway price because most of the parts were not functional. However our mechanic was convinced to put back everything into working order with newer parts, so we picked it up. Some days of wait and it was put back in proper functional order and the change was visibly impressive, the real isuzu power started showing up.

The run-in went on smoothly and the engine didn't throw any tantrums. So now the engine was done it was time to concentrate on the other upgrades. The list goes like this:

1. Front new OKBJ: To improve turning & steering response, eliminate the occasional wobbling, suitability of tyre upgrade & escape form any kingpin related issues cropping up once in a while.
2. Upgrade to front disk brake
3. Complete internal roll cage fabrication
4. Installation of handbrake assembly
5. Installation of wipers
6. New seat mounts as the older ones done in mayapuri were pathetic!
7. New fender flares to cover up the increased front track due to OKBJ upgrade
8. Change of body mounts
9. Fabrication & stiching of soft doors: Since the jeep is usually used for touring purpose, it was a necessity.
10. Some work done on wheel bearings, rear axle, hub spindles, change of cross in front drive shaft

In between procured a hi-lift jack and installed at the rear for the time being. Here are some pics, excuse the poor quality as most of these were clicked in mobile cam

The story of my jeep: MM 440-image013.jpg

The story of my jeep: MM 440-image019.jpg

The story of my jeep: MM 440-image023.jpg

The story of my jeep: MM 440-image026.jpg

The story of my jeep: MM 440-image027.jpg

The story of my jeep: MM 440-image032.jpg

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The story of my jeep: MM 440-disk2.jpg

The story of my jeep: MM 440-doors.jpg

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The story of my jeep: MM 440-okbj.jpg

The story of my jeep: MM 440-hilift.jpg


Ankit, will post the latest pics by tomorrow.
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Old 5th July 2010, 19:06   #274
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Quote:
Originally Posted by Kandisa View Post
The engine overhaul was done and the initial impression was that the engine did regain good amount of power showing a hint of isuzu's prowess.
Congrats Soumen!!

Quote:
Originally Posted by Kandisa View Post
So a trip to mayapuri & we managed to find the carb at a throwaway price because most of the parts were not functional. the real isuzu power started showing up.
Cool Man... this shows the Jeep rebuild process is never ending.

Quote:
Originally Posted by Kandisa View Post
The list goes like this:

1. Front new OKBJ: To improve turning & steering response, eliminate the occasional wobbling, suitability of tyre upgrade & escape form any kingpin related issues cropping up once in a while.
2. Upgrade to front disk brake
3. Complete internal roll cage fabrication
4. Installation of handbrake assembly
5. Installation of wipers
6. New seat mounts as the older ones done in mayapuri were pathetic!
7. New fender flares to cover up the increased front track due to OKBJ upgrade
8. Change of body mounts
9. Fabrication & stiching of soft doors: Since the jeep is usually used for touring purpose, it was a necessity.
10. Some work done on wheel bearings, rear axle, hub spindles, change of cross in front drive shaft

In between procured a hi-lift jack and installed at the rear for the time being. Here are some pics, excuse the poor quality as most of these were clicked in mobile cam

Ankit, will post the latest pics by tomorrow.
I can see from your pics that many of your planned upgrades are done. But please confirm which ones are completed from your above list.

I love the rollcage! Mandeep, Can I also get one??

Man,your Jeep has turned out be a mean machine now.
Now waiting for the killer pics.
JC
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Old 5th July 2010, 21:47   #275
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mandeep is the upgrade done in authorized service station?

how much does those front diff with disc cost you

A wonderful jeep you'e got dude
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Old 6th July 2010, 09:35   #276
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Quote:
Originally Posted by JeepCaptain View Post
....Cool Man... this shows the Jeep rebuild process is never ending.
Thanks Shibu. Who else than jeepers know that the rebuild process never ends. We already 've in mind what upgrades to do in Phase III & IV


Quote:
..I can see from your pics that many of your planned upgrades are done. But please confirm which ones are completed from your above list.
Actually all those mentioned in the list have already been done. The complete pics will roll in soon.

Quote:
Originally Posted by joshguy View Post
mandeep is the upgrade done in authorized service station?
Yes, in fact this is probably the only authorized Mahindra workshop in this zone having experience of working on Jeeps.
Quote:
...how much does those front diff with disc cost you
A wonderful jeep you'e got dude
Thanks a lot. The new front OKBJ (along with new steering linkages e.g. tie rod, drag link etc) and new disk together have cost around 42k including everything.
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Old 6th July 2010, 10:06   #277
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In between i managed to grab a CJ7 type mirror for the left side quite accidentally after a long wait! Installed some basic ICE set-up with an old Sony USB enabled HU and a pair of decent speakers. Custom fender flares were made to cover the wider front track. Minor alterations were done in the soft top for a better fitting. A 12v lighter socket was fitted. So couple of weeks of patient wait and the jeep came out in this form:

The story of my jeep: MM 440-dsc06483.jpg

The story of my jeep: MM 440-dsc06484.jpg

The story of my jeep: MM 440-dsc06488.jpg

The story of my jeep: MM 440-dsc06490.jpg

The story of my jeep: MM 440-dsc06492.jpg

The story of my jeep: MM 440-dsc06494.jpg

The story of my jeep: MM 440-dsc06498.jpg

The story of my jeep: MM 440-dsc06500.jpg

The story of my jeep: MM 440-handbrake.jpg

The story of my jeep: MM 440-hu.jpg

The story of my jeep: MM 440-speakers.jpg
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Old 6th July 2010, 10:12   #278
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Default Good job

Your Jeep looks good. Please share the cost of Roll cage.

What is the thickness of the Pipe used?

How much did the hi-lift jack cost you?

Regards,
Krishna Thanthri
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Old 6th July 2010, 10:26   #279
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Wow your jeep has progressed really well. Looking butch as usual. Can you post some more detailed pics of the roll cage and how its mounted, please.
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Old 7th July 2010, 09:52   #280
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Quote:
Originally Posted by krishnathanthri View Post
..Please share the cost of Roll cage.
...What is the thickness of the Pipe used?
...How much did the hi-lift jack cost you?..
The roll cage part (total) costs around 8-9k. Thickness is 2". Hi-lift jack (from hi-lift) is around 7.2k.

Quote:
Originally Posted by Jaggu View Post
Wow your jeep has progressed really well. Looking butch as usual. Can you post some more detailed pics of the roll cage and how its mounted, please.
Thanks Jaggu. Give me some time, i will definitely post some detailed pics. As per mounts, two heavy duty brackets have been fabricated for each of the mounting points, one above & one below the body.
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Old 7th July 2010, 10:40   #281
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The front wider track made a HUGE difference in the driving behaviour of the jeep, particularly ease of steering and even more importantly the turning radius. Taking tight turns is much much easier now. Howver it was distinctly visible that the Jeep desperately needs some tyre upsize with that kind of an width. After a lot of searching here and there finally managed to grab a good deal on a new set of 31X10.5 R 15 Maxxis Bighorn MT 762 tyres The good thing is apart from being a tough tyre on offroad situations, these are pretty good on the tarmacs as well. Much quiter than the usual M/Ts, slight change in braking performance but nothing substantial.

Name:  bighorns.jpg
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So with the new mechanical components and new shoes the Jeep was taken to an NIOC OTR. Here are some pics.

The story of my jeep: MM 440-dsc06512.jpg

The story of my jeep: MM 440-dsc06519.jpg

The story of my jeep: MM 440-dsc06527.jpg

The story of my jeep: MM 440-dsc06528.jpg

The story of my jeep: MM 440-dsc06532.jpg

The story of my jeep: MM 440-dsc06537.jpg

The story of my jeep: MM 440-dsc06551.jpg

The story of my jeep: MM 440-dsc06560.jpg

The story of my jeep: MM 440-dsc06594.jpg

The story of my jeep: MM 440-dsc06595.jpg

The story of my jeep: MM 440-dsc06598.jpg

Name:  vlcsnap99653.png
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Views: 1248
Size:  592.1 KB
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Old 7th July 2010, 10:49   #282
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Somen - great job man! I remember when you had got this first and what it is today. It is a real head turner and a very functional and reliable jeep.

Kudos to you and Mandeep.

Cheers
Ankit
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Old 7th July 2010, 11:41   #283
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Quote:
Originally Posted by Kandisa View Post
The roll cage part (total) costs around 8-9k. Thickness is 2". Hi-lift jack (from hi-lift) is around 7.2k.


Thanks Jaggu. Give me some time, i will definitely post some detailed pics. As per mounts, two heavy duty brackets have been fabricated for each of the mounting points, one above & one below the body.
Pipe circumference is 2 inches. What is the thickness of the metal (in mm)?
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Old 7th July 2010, 14:15   #284
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Quote:
Originally Posted by GoSlow View Post
Somen - great job man! I remember when you had got this first and what it is today. It is a real head turner and a very functional and reliable jeep....
Ankit, thanks a lot. Just to remember this was the initial condition:
Name:  Image077.jpg
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Yes the functionality & reliability have always been of utmost importance than anything else. Thats why i 've always put brand new genuine parts even if they cost much higher.

Quote:
Originally Posted by Red Liner View Post
Pipe circumference is 2 inches. What is the thickness of the metal (in mm)?
Ideally that should be the diameter & not circumference. Thickness as per as i know is around quarter inch which in mm is around 6.3

Last edited by Kandisa : 7th July 2010 at 14:28.
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Old 7th July 2010, 14:55   #285
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hello kandisa ji

when i look at this picture i can only think of thar.


but your 440 looks better!
wanted more info on the fabric doors .
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