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Old 4th May 2011, 10:35   #16
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

madhu Sir,

So decided to live with a Very Big Marker enjoy the restoration. Please update the current status of jeep. are you changed the gearbox ? (it a 3 speed gearbox right ?).

- Sreejesh
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Old 4th May 2011, 14:05   #17
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Hey Doc,

Congrats! Thats a surprisingly neat vehicle that you've got from govt. auction. And the best part is that it has apparently got a working 4X4 which otherwise is one thing that is severed from most of the govt vehicles for FE. Hopefully, all other aspects of the vehicle is more or less okay. Definitely, a great "less headache" vehicle you have got. Congrats once again.

PS: Most of us here are Jekyll and Hyde.
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Old 4th May 2011, 14:30   #18
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

That was a nice write up doc. Congrats.
For its age, the 540 appears to be in a decent shape.
Looking forward to see the final outcome which I am sure is going to be a sweet one.
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Old 4th May 2011, 14:54   #19
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Nice write up Madhu. Please upload all pics and details of the work going on.
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Old 5th May 2011, 05:52   #20
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Quote:
Originally Posted by trammway View Post
Doc,

Welcome to the Jeeper's world, I'm glad finally you hooked to a Jeep. I was expecting this to happen bit earlier

Congratulations!
Hi Siva,
Thanks for the wishes. Especially after we had that awesome OTR in your Jeep, am now hooked line and sinker to Jeeps!!

Quote:
Originally Posted by jeepster View Post
congrats !!

540 is best platform for offroader as its small & parts are available almost every where. (new/old)
also many alternate options are available too. (Engines, GB's, TC's)

are you kipping it stock or some modifying?

wishing best luck for project.

rgds,
Nikhil
Hi Nikhil,
Thanks for the wishes and you are right. 540 is a great platform to make a good offroader, although I did think of playing with the gear ratios.
The engine and gear box were in good condition and was advised not to change them.

Quote:
Originally Posted by sreejeshmp View Post
madhu Sir,

So decided to live with a Very Big Marker enjoy the restoration. Please update the current status of jeep. are you changed the gearbox ? (it a 3 speed gearbox right ?).

- Sreejesh
Hi Sreejesh,
If you remember I had called a year ago and asked many doubts when even basics of 4x4 was greek and latin! Thanks for helping out. No, I did not change the gearbox. (It's the OE 4+1)

Quote:
Originally Posted by wanderer4x4 View Post
Hey Doc,

Congrats! Thats a surprisingly neat vehicle that you've got from govt. auction. And the best part is that it has apparently got a working 4X4 which otherwise is one thing that is severed from most of the govt vehicles for FE. Hopefully, all other aspects of the vehicle is more or less okay. Definitely, a great "less headache" vehicle you have got. Congrats once again.

PS: Most of us here are Jekyll and Hyde.
Hi Wanderer,
Thanks for the compliments. I guess that since the vehicle was serving the Geological Dept they had use for the 4WD. In fact the mechanicals were in decent condition.

Quote:
Originally Posted by jeeva View Post
That was a nice write up doc. Congrats.
For its age, the 540 appears to be in a decent shape.
Looking forward to see the final outcome which I am sure is going to be a sweet one.
Hi Jeeva,
Thanks and yes the body looks good but finally had to change the rear floorboard as it had a lot of rust pockets. Chassis though has not taken my abuse.

Quote:
Originally Posted by mohang_j View Post
Nice write up Madhu. Please upload all pics and details of the work going on.
Hi Mohan,
Surely I will update all the work done stage wise with photos. Thanks for the help during build-up.
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Old 5th May 2011, 23:22   #21
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Some pics of Work in Progress.
The steering assembly had gone bust and got it changed it to CV joint type.
Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4149-large.jpg

Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4150-large.jpg

Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4151adj-large.jpg

Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4152-large.jpg

The radiator was also conked. Got a new one from JC Road for Rs. 3300/-
Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4153-large.jpg

Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4162-large.jpg

Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4163-large.jpg
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Old 6th May 2011, 07:09   #22
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Nice buy Doc. if money permits get an all syncromesh gearbox. you will love the difference over your currant one. further possible, get the front breaks changed to disc breaks also. you can get both these from army scrap vendors.

wish you a speedy recovery!!

cheers ..
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Old 6th May 2011, 13:42   #23
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Default Air-Filter

Hi Doc,

Do consider Upgrading your Air-Filter to the paper element type.

You can fit the older Bolero Type or the new Plastic Drum used with the MDI3200TC.

Regards,

Arka
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Old 6th May 2011, 15:36   #24
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

You will be amazed at how well she handles with some good rubber underneath her.

A couple of downsides:

1.) Jeeps can go anywhere. Your house calls will increase as will patient expectations
of same.

2.) Your patients see you pull up in a jeep instead of a Pajero? There
goes your fat fee.
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Old 6th May 2011, 19:36   #25
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Dr sir,
I am Still not clear with the restoration plan !! are you planning to do the tinkering without removing the body from chassis ? I can see the mechanical works also started on the jeep I think its better completely disassemble the jeep and then assemble it in a systematic way other wise it won't be a reliable one .
- Sreejesh
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Old 7th May 2011, 08:18   #26
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Is the radiator 3 core or 4 core? I'm sure you didn't buy a 3 core radiator.
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Old 7th May 2011, 09:11   #27
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Arka - done, this is a flashback write up - jeep is ready to get out in a few weeks

DD - 1/2 LOL -- Btw- She got rubber, lots of it and some nice socks too

Sree - other than the tub (10 bolts?) - coming off the chassis, everything was taken apart. All 3 floor panels and lot of sheet metal went out.

Doc, just to get your story going, here are some tips. Things we did were...

All 4 axles O/H'd
Full brake system OHed
All 4 leaf sets Re-Camb
GB OH'ed
Clutch Pressure Plate changed
COMPLETE Electrical redone
All plastic parts/lights/fittings new
Tinkering and painting - underbody channels were OK so didnt remove tub for now
New Tyres and Alloyz
New Steering assy
Engine flushed and new oils everywhere
FIP & Nozzles OH'd and recaliberated

Anything else missing?

-------EDIT ---- ^^ New 4 core radiator

Last edited by svsantosh : 7th May 2011 at 09:14.
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Old 7th May 2011, 18:25   #28
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

@Toms, Arka, Dan, Sreejesh, Siva I guess Santosh has answered for me. Thanks all for the wishes.
Santosh, Thank you for filling in those updates. Along with these the front Windshield was also changed as well as the window glass assembly.
Tinkering work going on.
Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4236-large.jpg


Driver-side floor-board
Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4238-large.jpg





Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4239-large.jpg

This is where the battery used to sit. Got it removed and now made a compartment in the engine bay.
Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4241-large.jpg


Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper-img_4243-large.jpg

Rear floor-board full changed
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Old 7th May 2011, 22:05   #29
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

WoW Looks like its being fixed inside out. Nice to know you got your cure Hope to see you join in some OTR soon.

Cheers
Sunil
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Old 7th May 2011, 22:41   #30
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Default Re: Dr. Jekyll and Mr. Hyde- From Doctor to Jeeper

Quote:
Originally Posted by svsantosh View Post

All 4 axles O/H'd
@SVS, did I miss something here?? Axle shafts I presume.

@Madhkris- please check if there is a reinforcement on the fender near the headlamp (underside), if not available reinforce it, otherwise your fender will crack after some time. Also use big washers which seal the bolt head (M8 x 1.25 size) with the fender inner panel, this will help.

Spike
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