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-   -   Mahindra 540 - Making (https://www.team-bhp.com/forum/4x4-vehicles/93722-mahindra-540-making.html)

Hi,
This is my first message onto BHP community, while i have been reading the threads very ofen.... the making of my MM540 gave birth from one of the threads i read a year back... i have drawn an outline to my ideas in the last 8 months..
I picked this vehicle from Belgaum scap yard, the engine was in good condition & documents were mostly pleasing.. went on a deal with the garage owner, if the vehicle can be driven from belgaum to bangalore in as it is condition, it would be worth investing.. Hired a driver to drop the vehicle in bangalore, he managed to deliver the vehicle in 12 Hrs which built the confidence in me..
Started working on the mechanical & allied parts <clutch plate, clutch, brakes, brake liner, axle, ignition..... etc etc > bring them to normalcy, tinker & painting actually took a long time, replaced the tyres without modification on the suspensions with CEAT F78-15 as i was running out of time for a long drive to kanyakumari... Replaced the long seats with bucket seats in the front beore i started my journey.... I could sense the power of the vehicle all along...
Now i take to beat the bangalore traffic on weekends...
Wish to complete the interiors before getting into the conversion of HP & suspensions..
Would like many to read the post & comments with their view... it would help me do it right first time...

Regards
Nishand R

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Nishand first and foremost get rid of that CRASH GUARD IMMEDIATELY
every other things comes next.

Please remove the crash guard first! Makes it look bad.

Other than internals let me guess some work and tell us if its done.

The roof
Lighting as in check the entire wiring
If you want you could install some fog lamps instead of the crash guard
Tires could be changed to better ones. These will not help in offroads.
Entire body check for rusting

Dear Nishand R - please post photographs of the bavk of the Jeep. Fenders seem out of place, I would want to know if its an original MM540 or a body of the MM has been fitted on the CL.

Best regards,

Behram Dhabhar

@ Dhabhar Behram: Its an original MM540 with the fenders cut in this shape. I shall post a photo of backside of the Jeep.

@ Maddy: I;ve fixed the Windshield frame and so are the doors.. Roof on the back is open while front remains fixed with a soft top covering only the front 2 seats...
The soft top can be extended to the back to cover it up completely..
Have got the complete wiring of the vehicle done... planning to fix four Fog lamps at the top... looking for a fixture to hold the stepney on chasis which i would replace the crash guard...
The vehicle has leaf spring suspension which needs to be replaced with coil spring or spacer for fixing Off-road tyres..
Have redone the vehicle body so there is no fear of Rust ...

HOLY CRASHGUARD BATMAN!!! I am sorry but that is the WORST looking front end to ever disgrace a Jeep :)

Sorry to say, but your Jeep will look much better with the fenders in the original shape and 16 inch rims and tyres.Also throw that bullbar to some #@# as soon as possible!

Yes, the fenders look really out of place. Pls put in the originals, otherwise the 540 is losing its character.

I think the fenders were modified to allow for extreme articulation under severe off-road conditions.