[jyobeb]

You will have a problem with the isuzu 4wd gearbox and your rear diff alignment since the isuzu gearbox rear drive is centered and your rear diff is right offset.

[sammyaulakh]

@ spike sir
adding the menon piston & head gasket pics.There are two
manufacturers suppyling gaskets to mahindra Banco & Miller.I have used miller
whereas the picture is of Banco.
@ jyobeb sir the last two pics are for you.

[SPIKE ARRESTOR]

Hi,

^^ That is a grade A piston with 4 notch gasket (4 cut wala), how did you decide which gasket to choose? There are actually 3 types (4 cut, 3 cut, 2 cut).

Spike

PS- Please do not call me Sir.

[sammyaulakh]

hi spike,
Since the head & block were machined and the piston topping done so to compensate for the gap,We decided to use the 4 notch gasket.

[SPIKE ARRESTOR]

^^ Hi, that is ok, can you share how much was the gap? I like your measured approach in doing things, would like to know if it is correct.

Spike

[sammyaulakh]

spike the word GAP should be read as reduction in the size of the combustion chamber due to machining which was undertaken to remove distortions (if any) on face of the head & block.Another factor was my father's decision to go in for a thicker gasket to nullify any chances of overheating and engine knocking which may occur due to the increase in compression because of the reduced combustion chamber.

[SPIKE ARRESTOR]

^^Ok, I understand what you are implying. The measured "gap" if available would have made things interesting with respect to selection of gasket size.

All the best with the rebuild, keep us updated.

Spike

[TurboDiesel]

Aulakh Saab,

Any updates so far?

[sammyaulakh]

Hi
My apologies to all my fellow jeepers who were following this thread for not updating it.
As I was busy with my work and wedding which happened in November last year,I was out of touch with my jeeps and team bhp.BTW the 550 project was completed and it ran beautifully for a year before I decided to plonk in a bigger engine.i bought an Isuzu 2.8 TC intercooled engine mated to a 5spd 4wd gear.pictures will follow soon.
@ turbo diesel
I just brought the jeep home today after the above mentioned conversion.will keep you posted.

[sammyaulakh]

Pictures of the engine mated to the gearbox and body conversions.i chope dof the pillar and moved the door locks a little lower so that whenever needed i would be able to fit the doors also.As the initial idea was to keep it open with the windscreen folded.

[sammyaulakh]

these are the only pictures i can post as i lost rest of them due to a corrupt memory card.

[spawnofsatan]

Originally Posted by sammyaulakh

these are the only pictures i can post as i lost rest of them due to a corrupt memory card.

Corruption has affected our country in so many ways !!


On a serious note absolutely love the looks so far, you have now got me considering converting my mm550 to a 2 door !!!

[drsamuelk]

Hi Sammyaulakh, nice project, is that the isuzu gearbox, did you weld the mating surface of the KMT90 to the new gearbox. I can see a circumferential weld. if u did then its an amazing work to centre the PTO shaft to the centre point of the clutch.
Whats the paint shade number and what brand paint did u use for the body and chassis.
I can never ceased to be amazed by the passion we Indians have to improve the jeep, that too with the limited resources we have. keep it up.

[sammyaulakh]

Thank you for your appreciation Dr. Samuel,my apologies for a late reply. the housing is Isuzu mated to the mounting surface of the Isuzu gearbox which came in the bolero and not of kmt 90.kudos to the mechanic and the welder who did a thorough job.
The shade is the darkest green available in Aspa paints.dont really remember the exact name.will find and let you know.
The last modification I undertook on this jeep was replacing the mechanical cooling fan and the copper radiator with twin electronic fans and an aluminium radiator.this helped to run the engine cooler and never did it overheat even when pushed hard.