[hisunil]

Yes Sir I have put the plates too.

Guys More updates:

Couple of updates done, Mostly Cosmetic:

1. Hi power 3w led strips (group of 6) in each indicators, connected to Parking lights.
2. Body Lines / stripes now have matching strips chrome/black strips

Long term Wish list:
1. PTO winch fitment.
a. If some one can post pics of VFJ PTO winch Drum & how it engages & disengages, that will help fabricate the Drum.
b. Can some one Source me a 5 Ton Nylon rope, I have bought a 12mm steel cable, but a rope will be more flexible & routable
c. More info on Electric / Manual Clutches needed.
d. What joint can be used to tap PTO output (saw a JCB one)

2. One PTO but Many Needs . How do we selectively drive many needs out of one input, Would love at lease 3 things.

3. High Pressure Piston Pulley Pumps (water pump) 10 to 40 Bar pressure 4,500 INR
This will be used to wash self, post OTR's & other vehicles at home too.
Planning to mount this just below & behind Navigator seat.

4. On board air compressor (but the once I saw were too bulky) is there a small & reasonably powerful one?
This will enable use of a Air Horn on board, like the ones in Trucks with long liver to operate them from a Air Tank
Inflate post OTR's (I have a small electric dual piston pump that does the job slowly)
May be later use it to inflate white water rafting boats!! I am getting ambitious I know.

5. Final Drive changed to 5.57 from 4.9
a. Can someone tell me what are the number of teeth in pinion & Crown that account for 4.9 is it 39 / 8?
b. Found a 39 / 7 Should I try this?
Planning to remove the rear assembly & check out the number of teeth, then take the sample to shop & get the higher ratio ones. cost 4500 to 5500 Rs

6. Ladder type Ramp to mount motorcycle (GT 250) & ferry it at the rear, I really miss it in Ghat sections!
Also need to make some custom mount points to fasten bike once mounted where rear seat now exists.

7. Custom Half Hard Top in Checker board in 2 seater configuration, have found the below:
a. checker board comes in MS (Main Steel) or Aluminum, The MS one in 2 mm to 3.5 mm thick costs 46 Rs per KG 4 feet wide only but up to 12 feet long
The Al one costs 280 Rs per KG & in MS for one Soft it takes about 2 to 2.5 kg, the AL one should be around 1Kg per Sq Ft
Aluminum 3mm thick sheet 8x4 feet costs 6250
Aluminum 2mm thick sheet 8x4 feet costs 4250
Planning to make a removable internally clamped 2 door Half Hard top in AL
b. Also planning to put checker board on the Top side panels ( not on the Bonnet ) but the area around indicators (front top) like in Defender 90's
this area has lots of scratches as many tools are kept on it while any repair work is done.
c. Also Need to put a Tool box in Checker board, may be use MS for this one.

8. Can I convert the rear Drum breaks to Disk?

9. ECU remapping or at least a Pete's Automotive Products Pvt Limited Petes Box?

After lot of walking around, showing may scrapyards the PTO unit I have, Video of PTO setup in Gurkha in iPhone & iPad have found the hidden treasure (at least from me).

People who needs the gear reduction gearbox that is the biggest component of a PTO winch, other than the Drum & Supports which can be easily fabricated.?
I have found a Place in Bangalore that has literally 100's of these units with varying reductions from 1:1 that change direction to 1:70.
the one I have is a 1:30 I guess. he also has electrically controlled clutch & break systems too.

Let the video speak:

YouTube - HoodandOtherGearReductions

YouTube - ElectronicClutchForPTO

YouTube - BigAirCompressor

YouTube - ClutchTestingForPTO

Guys this is the Python Hardware Adapter Part Number: DG-PYTHON-USB
used to diagnose Gurkhs or any BS3 engines.

* DG's Python *

Contact info from just dail:
+(91)-(80)-26531671, 22440404, 26531671, 22440025/35
www.deindia.com

A Very good White Paper Diagnostics for Automobiles – A Snapshot
by K Srirama Murthy, D A Satish from Dearborn Electronics is below:

http://www.deindia.com/images/downlo...A_Snapshot.pdf

I thought its worth sharing.


got a quotation for Garuda (newer version of Python) @ Rs 20,700 + 13% tax, but we need the company software to decode protocol & diagnose vehicle.

I also was able to load my Bike GT-250 in to the Gurkha with my cousin's help. Need to make proper mount & support points & secure it with straps.
Drove it for 2 to 3 kms at night it felt OK, need to do more testing. Was missing my bike in ghats, so this setup is to help reach ghats base (300- 350 kms from Bangalore ) with family & luggage, check-in to a resort & see the surrounding on the bike, load it back in & return to Bangalore, need to see how piratical it is.

The current Issue is that the seats need to be moved front, also the front wheel coming in necessitates the 4wd liver to be in 4H (in front), need to work around this issue

Some pics Enjoy











The quality suffers as its taken YTD night in a iphone4.

Cheers
Sunil

[Motocoorg]

Nice work in increasing the utility of your Gurkha.
About carrying your bike I thought I will chip in.
See the pics, we call it no mates trailer ( you can load it alone) but basically it is a bike carrier attached to the tow hitch. This may be of use to you and leave room in the Gurkha for more gear.

[14000rpm]

truck bed extenders like this could give you some space so you don't have to have the bike wheel brushing with your elbow.

[hisunil]

Thanks Motocoorg in fact that was the first thing I tried, but has 2 Issues
1. The GT-250 is much wider that the Gurkha, hence not sure if it will be safe
2. It weighs 180 Kgs dry & with all my mods 200+ now so really need STRONG mates trailer

Thanks 14000rpm but the Gurkha Door swing opens & carries the spare wheel which is quite heavy & hence cannot change the door to a flip open one as you have shown.
But surely something needs to be done.

Cheers
Sunil

[madhkris]

Superb thread Sunil. Just love your passion for the venerable Gurkha!! Indeed with all the mods your vehicle is aptly named TANK!! Thanks for sharing all the info. It makes a great guide for all of us planning on mods. Way to go and all the best.

[hisunil]

@ Dr Madhusudan / madhkris Thanks, Yes Sharing what I know & getting reviews from peers on approach taken or methods used is a win win for all.

More updates on PTO winch for the Gurkha:


Its almost ready,
New piece fabricated for

1. 1. Control shaft
2. 2. Lock / Release mechanism

Bearings Lubed & Hydraulically pressed in to the drum

Yet to fix & wind steel rope & test the setup before mounting

Mounting & Driving is yet an other beast
Planning for a Prism type enclosure to house the entire Heavy setup upside down below the navigator seat
Use a JCB shaft to couple PTO Transmission out to Winch in.

Let the pics speak.

YouTube - PtoFirstTimeRoll.MOV

Yet to fabricate its Mount to the body & route a Joint to couple PTO T-Case out to the winch.

Its almost impossible to route the PTO drive to front of the vehicle.
Rear is possible with some effort, Just hoping to see it work in a couple of weeks.

Cheers
Sunil

[roy_libran]

Apologies Sunil, for a slightly Off Topic question about the Gurkha, but there was no other thread alive on this vehicle!

Anyway, I have been told by the Force Motors Dealership in Gurgaon, that there are "confirmed" plans of re-launching both Gurkha and Gama with a 100 + BHP CRDI Engine, within the next 3 months. Has anyone else heard of this / can confirm or deny the same?

[4x4addict]

@roy:

Sear OM611 on this forum and you will see that this news has been floating around for over two years now.

Even if they do put it in the GAMA, we are not sure if the Gurkha will be relaunched given the very low volumes sold.

[roy_libran]

Originally Posted by 4x4addict

@roy:

Sear OM611 on this forum and you will see that this news has been floating around for over two years now.

Even if they do put it in the GAMA, we are not sure if the Gurkha will be relaunched given the very low volumes sold.

I specifically asked about OM611 to the dealer, and they emphatically said - No, it's not an OM Series engine. That got me very confused. Of course, like everyone else, I've also been following the discussion on OM611...

[hisunil]

@ roy, I would believe it if & when I see one in the showroom!! (the frustration is obviously due to previous viscous cycle of wait-disappoint-newNews-wait )
you know what it means right, No use waiting for the CRDE or The 611 version

The TDI does wonders too, Yes I understand that more is always welcome (BHP & NM), but I haven't personally felt the shortcoming in the TDI as yet.

All I know is that they have sold about 10 units of 611 Tempo travelers in Bangalore & That the 611 with G32 can be fitted on a Trax platform or chassis (based on a Military prototyping done info source: http://www.4wd4all.com/forums/showth...SHUL-Arriveth-!!).

If & When Force will do it has never been clear & not worth waiting upon.

Cheers
Sunil

[4x4addict]

@sunil:

I don't mean any disrespect mate, but the link you posted is a personal blog from a Gurkha owner who has been hanging around on this forum as well. So let us not confuse it with a news article.

Force motors has been trying for many years to break into the defence market, but I have never seen evidence of a picture or a news report with a Force Motors SUV actually deployed in any armed forces. Althought the OM616 and G16 gearbox manufactured by Force motors. has made it's way into the Army G-wagens.

[hisunil]

Dear 4x4addict Sir,

Firstly it's a link that I found which had 'any' info about Military prototyping at all, just wanted to share the info.
Its a personnel blog or otherwise is debatable, but will be OT & of no real value doing that too.

Secondly I surely don't want to get in to the loop of justifying about Gurkha or its use in Indian Army or other Army's, I have a Preowned one & I am loving it. thats is truth.

Ok back to updates:

The vehicle is now in Garage & is undergoing PTO Winch Fitment
Guys Wish me luck & pray that it works, I have put in a lot of Time, Energy & money to make the PTO thing work, now his is the last lap, The final leg






















Cheers
Sunil

[wanderernomad]

Hisunil, while all the best for your pto project, I ahve a small request to make. I am looking for a gurkha myself. In case you come to know about something of a deal please let me know.

[hisunil]

Thanks Wanderernomad,

More updates on the PTO Winch:

At first We tried to make a chassis mount & fit it in the front, connect the PTO to TCase via a vibrator cable. But that worked only to roll the cable at no-load, when it was asked to pull the Gurkha (with breaks applied) towards a tree, the cable cut near the braising point just after T-Case output. (Arka did warn about cable not the same as shaft! & I was not sure as-well), but was our only option to couple PTO to T-Case with no line of sight from T-Case to Front Bumper.

Later removed the mounts & welding from front, removed the diesel tank at rear & planning to put winch in its place & connect a propeller shaft (a thick fat one) from T-Case rear output to Winch. Rahul suggests that I get a plastic petrol tank that can be inside the cabin & possible larger in capacity too. I am worried about safety & smell if the tank comes inside the cabin.

We are yet to see if the rear setup works, fingers crossed, the Jeep has been in the garage for the past entire month :(

Lets the pics speak:





















































Cheers
Sunil

[sreejeshmp]

So you decided to kill your vehicle . Anyway its one of the best example for doing with out knowing and knowing from doing.