LT77 conversion

[AlexB]

Just thought I would share what John and I have been doing on my blue Dormobile to be, regarding the LT77 conversion. The Blue Dormobile to be refers to the rotten series 3 Dormobiel I bought from scotland recently which will be re-incarnated into what was going to be a standard 2a 109 pick up (allbeit on a station wagon chassis)
It is in a 6 pot repaired and galvanised chassis, using the standard 6 pot engine mounts, ie further forwards than “normal”. This will give some challenges when sorting radiator etc, but at the moment, makes the route for the prop shafts easier – no cutting of chassis required. It looks like the rear prop will have to be shortened by an inch and probably another rear cut up to use as a front prop.
engine and box conjoined and lifted up out of the way

Cutting off the existing gearbox cross member

New metal for removeable cross member brackets fabricated and tacked into place

Both sides welded and painted -outside only – I have yet to gob some paint inside the chassis to offset the damage caused by welding.

Disco gearbox cross member with new ends fabricated and welded on to fit brackets on bottom of chassis.
Still a bit to do – inside painting and waxoiling, but I reckon it is a fairly neat solution. Using the 6 pot mounts might just make it possible to get at the starter motor when the bulkhead is back!

I have used 200 tdi rubber engine mounts – a lot bigger than 2 1/4 ones.

[ant]

Wow Alex – you’re truly a brave man – and a glutton for punishment! Is this chassis going to become a pick-up or a Dormobile? I suppose the the LT77 gearbox is to take the extra torque of a TDi engine – will you keep the full-time 4WD drive-train?

[AlexB]

It will be a Dormobile – with some refinements from our existing Dormobile – quieter, 5 speed box, slidy front windows (both of them). I have been informed that I have a stage one front axle, which will be deployed so as to have permanent 4 wheel drive.

Time will tell how much of an improvement it will turn out to be! and yes, it is tdi powered

Hopefully be ready for a trip down the Pyrenees next year.

[jerryd]

Hi alex,
Watching with interest as I’m going to put a 300tdi defender motor into mine, although I’m going to keep the series gearbox. Does your gearbox cross member sit in the brackets that you’ve welded on ?? and then get bolted together 😕

It’s something I’m planning to do on mine when I start the conversion, trouble is it goes extremely well with the six cylinder fitted and I love using it 😆 I just have to get tough with myself and start the conversion !!

[AlexB]

Yes it does Jerry. Not sure I will ever be able to drop it as in change the gearbox from underneath, as it is so heavy by the thought is there

[dieselhen]

That is a truly impressive bit of work, and glutton for punishment definitely comes to mind. Good luck with her!
Sheila

[Author]

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