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Originally Posted by kryogesh I have one question which I had asked earlier to DB sir. Guess he missed it. Is there a possibility to change the existing windshield (on the CRDe) to the one that comes in the DI? I so badly need the openable windshield. All i want to know is if the provisions exist. I would like to do it after market. Please point out if there are any disadvantages/potential risks? Thanks in advance. |
Dear kryogesh - I remember your query very well but I had chosen to keep quiet because there is a lot of explaining to do from my side and a lot of understanding to do from your side. Now that you have asked the same query for the second time, I guess I need to reply in totality. As the answer is going to be very long, I had typed this at home yesterday night, I am just copying and pasting now.
Well, here goes:
Thar CRDe uses the Bolero VLX base IP (Instrument Panel). Why? Bolero VLX is the only vehicle which uses a black IP, all others are either grey or biege. Thar CRDe uses black theme interiors (naturally!). For these volumes, no manufacturer will go for a new injection molding tool costing in excess of 1 crore rupees, so that option is out (it's a no-brainer). Also, as Thar CRDe is BS4 /
M1 (not N1) category vehicle (passenger car category so most stringent CMVR norms apply), it needed to meet EMI / EMC as also the very stringent front seat passenger "head impact test" as per CMVR. Only Bolero VLX instrument cluster meets this EMI / EMC, so using it "without changing its part number" (HaHa) becomes a foregone conclusion, because no other instrument cluster (barring Scorpio / Xylo) meets EMI / EMC. Also, as Bolero body tub is a derivative of the MM540 body tub which the Thar CRDe also uses, we needed to use the Bolero aggregate and not the Scorpio / Xylo one to provide for platform commonality. Just for the record, we physically tested and we complied with the severe requirements of the front passenger head impact test which was a huge achievement by any standards, considering the body tub's and the IP's pedigree. This test was conducted on 19 July 2010. It "surprised" many persons, eyebrows got raised! The core team did what needed to be done to progress the project. 19 July 2010 was the positive turnaround date for the Thar CRDe project. It is after this result that things really moved, culminating in the launch on 21 December 2010.
With all this as the background, the rest is still more simple. The Bolero VLX uses a curved windshield glass whereas the MM540 uses a flat windshield glass, so the IP would needed to be cut at its top to match the MM540 body profile. There was a huge discussion on "hydro erosion" and this and that and finally, for the prototype, we took a simple hacksaw and we cut it.
. For production, we designed a locating / cutting fixture. The IP is only 3 mm thick all round. When we cut it, as we had expected, it lost it's profile shape as seen in the Bolero. It buckled inwards. It had to be supported properly. So, we designed and manufactured a "U" sectioned strip and incorporated it on top of the IP to hide the cut and to provide a uniform appearance. This "U" section was made on a press brake (so no specific tool) to provide sufficient section modulus (measure of strength). Now, how to hold this "U" section? We used the existing 4 nos M6*1.0 projection welded nuts, which came with each windshield as it was shown on the original MM540 drawing, to hold it. These 4 locations perfectly defined the IP position in CAD and also on the car. This also solved a major assembly line issue, the operator could now "hang" the IP perfectly on the line before using the power tool to tighten the four bolts. The two small brackets have an obtuse angle of 173 degrees built into them to match the windshield frame angle with the IP angle. Now, in order to cover this "U" section, we have provided a rubber cover, which is not cosmetic. It's shore hardness determined the successful result of the front passenger head impact test.
These 4 bracket locations were originally for the latch supports of the "openable windshield". I think now you will be very clear. Now come to Thar DI. It uses the Bolero Maxi Truck IP (as also many other parts including floor panel, tool box and seats). As it is BS3, it does not need to meet EMI / EMC although it also meets head impact. So, it still uses the round instruments and gets away. As it progresses towards BS4, using Thar CRDe IP on Thar DI is a natural / foregone conclusion. There is no rocket science here.
So, you want to do this aftermarket on one car? It is so very simple. Use the existing four holes to locate the latch supports taken from the Thar DI and make four more holes for the "U" strip. Change the bracket locations on the "U" strip.
Everything is openly seen on the respective IPs, just look at them critically, that's all. Boundary dimensions are common.
Whew!
Best regards,
Behram Dhabhar