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Old 30th March 2024, 13:52   #1
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Project Maximus - A Decade old Jeep Story!

So.. this... is about a Jeep I own for over a decade now. Over the last ~10+ years, this Jeep has undergone countless part replacements (eg: Atleast 10 axle swaps), Numerous Changes to its body structure, different tyre rim combinations, different steering and suspension set ups and what not. All this has imparted me with tremendous learnings and knowledge which I will cherish for the rest of my life. This Jeep is also probably one of the reasons my Career and Life has taken a U-Turn to from being a Villager to a Corporate Employee (Apart from my personal reasons)

I will not be getting too deep into how this build, but, I will try to share some pics of the entire lifetime of this Jeep.

This is probably few of the first pics after when I bought the Jeep. With the alloys and tyres it came with. I may have only added the canopy to it.

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Further which I changed the steering to RCBT and Upgraded the tyres rims and rear axle, IIRC.

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Further into the build, I put a proper door, windshield, some lights here and there, some changes to the suspension and some other functional modifications.

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Then came a time when I wanted a closed cabin, some music.. nice comfy seats..


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Then came a winch, Hi Lift Jack.. some more mechanical mods like the LSD, New Axle, Better steering, Suspension etc...


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And a Full page feature in the Local News paper.

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Then came MT tyres into the picture.. Some body lift.. Minor mechanical mods..

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Last edited by dhanushs : 30th March 2024 at 17:13.
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Old 30th March 2024, 14:39   #2
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Re: Project Maximus - A Decade old Jeep Story!

Now, it was a few years into the ownership and parts started giving away.. And it was time for a major overhaul. Did a full patchwork of the Jeep, and most important change was an Engine Swap to a Nissan SD25, a wider stance (wide axles and off-set offroad rims)! .

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During this time, the Jeep also went through major Cooling system change, Roll Cage changes, Electrical changes and more..

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Then came even bigger tyres and more mods for tougher off-roading and tougher competitions. Oh. yea.. I had a nice Air Conditioning too

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Next phase was the weight reduction phase.. Removing all the unwanted stuff, that weighs the vehicle down.

Project Maximus - A Decade old Jeep Story!-11.jpg

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And some trophies to add to the collection..

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Next phase of the Jeep was further complicated. Gave it a new paintjob, New bits and pieces of body, I relocated the radiator to the rear to check for cooling efficiency, more mods on suspension and engine. More mods on the FIP for more power..

More functional mods and some more lights here and there..


Project Maximus - A Decade old Jeep Story!-1.jpg

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Next comes even bigger tyres and some engine mods like better turbo.. Different Fuel Injection Pump.. and some more mods.. Honestly, i dont rememeber them all.

Along with this, I had some more mods done on the body, like a different kind of lift. A different steering set up. Ah.. yeah, I had a different axle too.. One with a chromoly build.


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And.. Some more recognitions along the way!



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Last edited by dhanushs : 30th March 2024 at 14:47.
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Old 30th March 2024, 15:22   #3
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Re: Project Maximus - A Decade old Jeep Story!

Now, the next phase of the Jeep is probably the most advanced, before the current set up. Everything was changed again. The engine was changed to Nissan BD30T, The suspension to Longer Travel Ironman, Pajero seats, New & better winch.. oh yeah.. even bigger tyres and a custom made PTO winch.. and more..

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And.. some more recognitions and some media coverage... Including the prestegious Club Challenge Award of India's best Club & 5 Lac Rupee Cash.

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After that, I again go ahead and strip and change the Jeep. This time for more weight reduction and in the process make it look good too.. Numerus mechanical changes too come, some of them include pneumatic fiddle brake system, air lockers, changes to the PTO winch, Engine etc.. which I'm not getting in detail.

Project Maximus - A Decade old Jeep Story!-135568674_10159059121516963_4655559382586457605_n.jpg


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Old 30th March 2024, 16:56   #4
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Re: Project Maximus - A Decade old Jeep Story!

Now, for the final episode of this thread, and for the final iteration of my Jeep! After the numerous iterations the Jeep has gone through, I think, I can safely say that this would be one of the last.

In this last iteration or this current rebuild I have tried to incorporate my decade old experience in the design and for build, I have replaced every old part and with brand new ones wherever available, and good condition ones if not available. This new re-build of mine would be the 'newest' a re-built jeep can become.

Since now it's relevant, and very much present. The Current Specs of the Jeep would be:
  • Nissan BD30Ti Engine
  • Custom built Zextel Japan inline fuel pump with bigger elements and higher rpm.
  • Turbocharged with K03 (TEL) Oil Cooled Turbo Charger
  • Electronic Fuel Pump to assist smooth idling and fuel flow at steep angles.
  • Performance exhaust
  • High Idle Switch
  • Raised and Custom Made driveline beds for Clean Underbody. No gearbox, or prop shafts hanging under.
  • Custom built and mounted radiator, with high-speed bldc fan.
  • Hydraulic clutch with heavy duty friction plates. For that aggressive clutch dumps...
  • 57-inch Open Knuckle Ball Joint Type Dana 44 Front Axle with 4.88 (44/9) Diff ratio extended breathers
  • Custom made Chromoly Axle shafts
  • 53 inch Fully Floating Dana 44 Rear Axle with 1.5" spacers on either side. Also, includes differential guards and extended breathers
  • Again, custom made axle shafts
  • Rear Disc Brakes.
  • 19 spline Lambda Pneumatic Diff-Lockers front and rear. Switch Operated.
  • Individual Pneumatic Fiddle brakes for each rear wheel, for tight turns.
  • ARB Twin Piston Compressor
  • Longer Travel Ironman Nitro Gas Filled Shock Absorbers.
  • Custom Made Leaf beds. Shackle at the back.
  • Power steering with Probably the best steering pitman arm angle on a lifted Jeep.
  • Custom made stronger steering rods & Heavy Duty Ball Joints.
  • 38 x 12.5 x 15 Maxxis CST Extreme Mud Tyres.
  • 8000 lbs high speed winch in front.
  • India’s first PTO winch with 16mm 175 feet rope.
  • PTO winch with free spool & brakes.
  • 30 meters, 22000 lbs rated synthetic winch rope
  • 48" T-Max hi lift Jack
  • 6 point FMSCI Approved roll cage (Seamless pipes with 4.5mm thickness and 48mm outer dia)
  • 4 point Sparco Rally Seatbelts.
  • Custom Stainless Steel Snorkel plumbing. Approx wading height more than 1500 mm of water wading
  • 2mm thick 5 feet x 3 feet metal plate on top of the front cabin, protection in case of roll on’s
  • Raised Fuel Tank
  • Full RFC Specified Safety equipment.
  • Full RFC Specified Electrical Equipment.
  • 100ah Dual Battery,
  • 90 ah Dual Alternator set up.
  • Electric Master Cut Off Switch, sealed for water wading
  • All terminals and joints waterproofed
  • 48" inch 240W cree led bar & 24 inch 120W cree led bar
  • Front Offroad Bumper
  • Rear Off-Road bumper and Tow Hitch


Presenting MAXIMUS with a Brand New Body, New Chassis, New Axles, New Compressors, New Fiddle Brake Boosters, Rebuilt Engine, New Clutch, New everything..


Project Maximus - A Decade old Jeep Story!-maximus45.jpg


Some Paint Booth Pics from night.


Project Maximus - A Decade old Jeep Story!-maximus41.jpg

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Now some Paint Booth Pics in Day Light.


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Some pics to drool on the paint finish.


Project Maximus - A Decade old Jeep Story!-maximus39.jpg

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Now some outdoor pics:


Project Maximus - A Decade old Jeep Story!-maximus15.jpg

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Project Maximus - A Decade old Jeep Story!-maximus31.jpg

Project Maximus - A Decade old Jeep Story!-maximus32.jpg



Now for some action pics:


Project Maximus - A Decade old Jeep Story!-maximus1.jpg

Project Maximus - A Decade old Jeep Story!-maximus8.jpg

Project Maximus - A Decade old Jeep Story!-maximus9.jpg

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Project Maximus - A Decade old Jeep Story!-maximus11.jpg

Project Maximus - A Decade old Jeep Story!-maximus13.jpg

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Project Maximus - A Decade old Jeep Story!-maximus16.jpg



I hope I have done justice to Maximus in summarizing it's lifetime. This is particularly important as this guy is now out of action. Cos of the current career path I have taken, I have decided to retire Maximus out of action and keep it home. Parked. Safe. Like a Trophy Truck. Hence the fancy paint job and attention to detail.

I also hope you guys have enjoyed a decade of transition of my Jeep - which started out its life as a humble MM540XD.

Last edited by dhanushs : 30th March 2024 at 17:15.
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Old 30th March 2024, 19:37   #5
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Re: Project Maximus - A Decade old Jeep Story!

Thread moved out from the Assembly Line. Thanks for sharing!
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Old 31st March 2024, 09:55   #6
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Re: Project Maximus - A Decade old Jeep Story!

Given what Maximus Reborn (You should consider the name plate) is, it's not going to be long before it tempts you back into the rough stuff should your occupation keeps you behind a computer screen at some point of time in future, hope not.

Thanks for the awesome Easter Sunday morning read

My daughter has already given me notice about my Jeep, that it's going to be hers soon, It's a tradition one should preserve because they have many lives, reborn.
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Old 31st March 2024, 10:44   #7
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Re: Project Maximus - A Decade old Jeep Story!

Dhanush, craziest build ever.
Thanks for sharing your journey with lovely Jeep. Very informative.
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Old 31st March 2024, 12:40   #8
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Re: Project Maximus - A Decade old Jeep Story!

Hats off to your dedication, patience, knowledge, will power and the time and money you have invested into this beautiful machine!!
Add to that you've used it to it's potential and some more and not made it a mall crawler/ garage queen.
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Old 31st March 2024, 13:13   #9
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Re: Project Maximus - A Decade old Jeep Story!

Quote:
Originally Posted by dhanushs View Post
Now, for the final episode of this thread, and for the final iteration of my Jeep! After the numerous iterations the Jeep has gone through, I think, I can safely say that this would be one of the last.

In this last iteration or this current rebuild I have tried to incorporate my decade old experience in the design and for build, I have replaced every old part and with brand new ones wherever available, and good condition ones if not available. This new re-build of mine would be the 'newest' a re-built jeep can become.

Since now it's relevant, and very much present. The Current Specs of the Jeep would be:
[*] Indiaís first PTO winch with 16mm 175 feet rope.[*] PTO winch with free spool & brakes.


[b]Presenting MAXIMUS with a Brand New Body, New Chassis, New Axles, New Compressors, New Fiddle Brake Boosters, Rebuilt Engine, New Clutch, New everything..
Congratulations on the "superbuild" if I may call your vehicle that!

From the pictures it looks like you have an electric winch installed currently, what happened to the PTO winch? Is it a traditional PTO or a high speed one (apparently in Malaysia they have one called the "god winch", something similar?).

Any specific reason why you have not done a suspension upgrade/change from the original leaf sprung set up despite the engine upgrade?
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Old 31st March 2024, 16:27   #10
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Re: Project Maximus - A Decade old Jeep Story!

Quote:
Originally Posted by Kosfactor View Post
Given what Maximus Reborn (You should consider the name plate) is, it's not going to be long before it tempts you back into the rough stuff should your occupation keeps you behind a computer screen at some point of time in future, hope not.
I do take it out for a spin whenever I'm home. But for the serious stuff now I'm planning to have a different body shape.

Quote:
My daughter has already given me notice about my Jeep, that it's going to be hers soon, It's a tradition one should preserve because they have many lives, reborn.
All the best to your Daughter!
Quote:
Originally Posted by BlackBeard View Post
Congratulations on the "superbuild" if I may call your vehicle that!
Thank you.

Quote:
From the pictures it looks like you have an electric winch installed currently, what happened to the PTO winch? Is it a traditional PTO or a high speed one (apparently in Malaysia they have one called the "god winch", something similar?).
Yes, I have an electric winch and a PTO Winch. The PTO winch is not installed with a cable in the pics, hence not shown. The PTO winch is the "ring and pinion" type one. Like the God Winches in Malaysia.

Quote:
Any specific reason why you have not done a suspension upgrade/change from the original leaf sprung set up despite the engine upgrade?
I like the simplicity of the leaf springs. Also, apart from the approach angle advantage, I still haven't really found a really good advantage of coils. If ever I move to coils, it will be with proper ORI Strut set up.
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Old 31st March 2024, 17:44   #11
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Re: Project Maximus - A Decade old Jeep Story!

Congrats on the build! The learnings that you have taken from these rebuilds again and again would have been unimaginable.

This read definitely inspired me to go out there and buy an 4x4. Easier said than done.

Fantastic thread. Kudos to your dedication
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Old 31st March 2024, 19:34   #12
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Re: Project Maximus - A Decade old Jeep Story!

Amazing journey and post. This reminded me of the "Ship of Theseus" thought experiment - if all parts of the Jeep has been changed, it is still the same Jeep?
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Old 31st March 2024, 19:45   #13
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Re: Project Maximus - A Decade old Jeep Story!

Wow wow wow what a journey. Of both you and your jeep.Huge respect.
I also drove a jeep (1988model) around year 2001-02. But had to part ways due to some Land deal of my dad where it was demanded as gift to complete the deal. Same fate for my lovely TVS shogun.
After that changed many cars like zen,micra,verna,innova, seltos. But my heart always goes out to jeep
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Old 31st March 2024, 23:45   #14
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Re: Project Maximus - A Decade old Jeep Story!

Amazing care and dedication shown for Maximus by you Dhanush. I can't begin to imagine how much of a labor of love this is.

Quote:
Originally Posted by bhp-obsessed View Post
Amazing journey and post. This reminded me of the "Ship of Theseus" thought experiment - if all parts of the Jeep has been changed, it is still the same Jeep?
One could even say its the Jeep of Theseus
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Old 1st April 2024, 10:04   #15
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Re: Project Maximus - A Decade old Jeep Story!

@OP thatís quite the mud plugger youíve built, congrats !! Btw, am I seeing things or is there slight negative camber on your front wheels ?
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