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Old 30th May 2010, 11:33   #106
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Default Power steering kit

Finally i have the power steering kit completed and ready to ship, since there are some risk involved with sending these items through regular cargo service waiting for a safe source of transportation.
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Old 1st June 2010, 15:30   #107
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Default congrats

Anil,
You have collected a neat set of parts.
You can get high pressure hydraulic hose available locally for plumbing the lines.

Better split the cargo and send part by part through ur friends.I send mine as 2 hand baggages

The mounting hole pattern on PS is mirror image of what we have on Gypsy.
Adapter plate will be the easy solution. There is a picture of adapter plate in my thread)
You might need a wedge type insert plate also to ensure alignment of the box spindle & column.

In my 416, we drilled required hole pattern on chassis, inserted sleeves & welded them on both ends to the chassis. Finally stud bolts were inserted & welded.
It was little bit hectic job.
The machine shop guy who did it claimed that he develop one more joint in his arm.

I didn't opt the adapter plate as my mech had reservations on this idea.
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Old 1st June 2010, 17:42   #108
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Thanks Sreejith, definetly i will be bothering you while doing the installation.

We were searching for one particular design of alloy wheel, some what similar to what Khan Bhai has got on his Gypsy, finally found the same design and placed the order today. It is expected to arrive in another 45 days since the design & finish that we ordered has to produced. I am attaching the picture here, this is excatly what is ordered.
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Last edited by Jaggu : 1st June 2010 at 22:40. Reason: Back to back posts, EDIT the original post instead. Thanks
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Old 14th June 2010, 11:23   #109
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Default Photoshop trick

The alloy wheels will take again another 30 days to get delivered and i was anxious to see how it look like after installation. At last decided to do the installation in Photoshop first to see how it looks like ---
Attached Thumbnails
My Gypsy rebuild - Stage 2-dsc02399a.jpg  

My Gypsy rebuild - Stage 2-dsc02393.jpg  


Last edited by GTO : 14th June 2010 at 18:59. Reason: Please read our rules. No more than 2 smileys per post please
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Old 22nd July 2010, 11:28   #110
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Default Upgradation stage - 2

Finally after 6 months of garaged life Gypsy is moving to a workshop today for further upgradation mainly -
  • Power brakes installation
  • Power steering Installation
  • Suspension overhauling
  • Alloy wheel installation
  • Perfomance upgradation (Carb porting, FFE, K&N air intake)
Can any one help me with sourcing of PU bushing kits and 2 inch shackle kit for Gypsy.
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Old 15th August 2010, 13:44   #111
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The vehicle is now with very capable hands - Mr. Raju at EKM, for the stage 2 upgradations, alloys arrived at workshop, will be installed after all the works are completed.
Attached Thumbnails
My Gypsy rebuild - Stage 2-photo0079.jpg  

My Gypsy rebuild - Stage 2-photo0078.jpg  

My Gypsy rebuild - Stage 2-photo0077.jpg  

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Old 16th August 2010, 08:50   #112
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Looks awesome !!
chopping the rear over hang will be a killer.
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Old 19th August 2010, 17:57   #113
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Isnt that a Jonga in the background?
Where is this garage in EKM?
Shibu would be happy to see this
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Old 19th August 2010, 18:10   #114
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Quote:
Originally Posted by jeeva View Post
Isnt that a Jonga in the background?
Where is this garage in EKM?
Shibu would be happy to see this
jeeva, That Location was identified by JC long back. Thanks for your PM.
I spent maximum of my time searching for scrap 4x4's and also mechanics and garages to restore them.
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Old 22nd August 2010, 13:49   #115
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Hi Jeeva, Shibu is an Encyclopedia for everything related to 4x4's.
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My Gypsy rebuild - Stage 2-dscn0007a.jpg  


Last edited by Anil Vincent : 22nd August 2010 at 13:55. Reason: to add pic
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Old 6th September 2010, 12:38   #116
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Default Few more upgrades

Here are a few more upgrades done on the Gypsy, tried to squeeze the maximum out of the the 1ltr motor
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Old 15th September 2010, 11:52   #117
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Great work anil
after fitting the alloys the gypsy looks killer.
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Old 26th September 2010, 17:39   #118
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Default Gypsy on the full swing... still to go further.

Quote:
Great work anil
after fitting the alloys the gypsy looks killer.
--- Thanks Annu.

Almost all the intended repairs are completed but the non stop monsoon is not allowing to take the vehicle for an offroad test due as there are some leak issue on soft top, we dosent wanted the recaros to be spoilt by the rain. Here are some pics takes while a small drive done at the beach road.
  • The recambered leafs allowed resonable articulation & safe guarded tyres from touching the body even with the -ve offset wheels.
  • With all the body & suspension bishes replaced the ride is absoultely smooth & noise free, no more squeaks & rattle noise any where from the suspension.
  • There is no more free play of steering with the new power steering steup, more over the steering is soo precise & smooth that it can now be parked at a very tight spot with only one finger on steering wheel.
  • Brakebooster installation has totally changed the way it used to stop before, adding more confidence to the driving.
  • All the existing oils were changed including a complete over haul of the gear box & transfer case, a broken gear, main shaft, & bearing for the transfer case are replaced along with all the oil seals using SGP.
  • The free flow air filter seems to have bought a 10% increase in perfomance with a smooth idling & engine start.
  • A/C is fully functional and provides proper cooling in minutes, the soft top require upgradation to make best use of the A/C. In normal running conditions it seems that A/C is not putting any considerable load on engine.
Let the pictures explain further -
Attached Thumbnails
My Gypsy rebuild - Stage 2-photo0220.jpg  

My Gypsy rebuild - Stage 2-photo0217.jpg  

My Gypsy rebuild - Stage 2-photo0216.jpg  

My Gypsy rebuild - Stage 2-photo0200.jpg  

My Gypsy rebuild - Stage 2-photo0203.jpg  

My Gypsy rebuild - Stage 2-photo0202.jpg  

My Gypsy rebuild - Stage 2-photo0198.jpg  

My Gypsy rebuild - Stage 2-photo0201.jpg  

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Old 27th September 2010, 03:52   #119
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Hey Anil , thats a nicely worked gypsy that you have. What was the total cost of the project?
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Old 28th September 2010, 16:04   #120
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Quote:
Originally Posted by poojanayak View Post
Hey Anil , thats a nicely worked gypsy that you have. What was the total cost of the project?
Thanks Pooja, since all the repairs were affected over a period of time i haven't maintanied a proper expenditure figures but still altogether it is nothing less than 2.7 lacs including the vehicle.
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