Turning an L300 into an overland vehicle

Kellyn said:
WOAH! Did you make that exo skeleton?!
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I wish! I helped, and the design was largely mine, but I didn't do the fabrication. I did make the custom engine mount. The engine, when I sold it, was a 1.9l VW turbo diesel built from a (and this where it gets fun) Mexican second. I had a leftover AAZ head from the wormed out original 1.4l diesel that I bought it with, then bored and built from there. The guy in that picture melted that power plant and then replaced it with a 2.4 l VW TDI. Most of the under carriage is still my handy work. Two inch GoWesty lift with custom Burley A-arms. He replaced the South African VW 15" rims I worked on bringing to the US for two years with what appears to be KLS rims painted black :rolleyes:. The CVs are from a recent Porche 911 salvage. The transaxle was stood up by Daryl from AA Transaxle. It was a fun bus.
 
Totally sounds like it. That, and it to have certainly been a labor of love.... Why'd you let her go? Found a REAL van? :p
 
Kellyn said:
Totally sounds like it. That, and it to have certainly been a labor of love.... Why'd you let her go? Found a REAL van? :p
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I have a seizure disorder that reared its ugly head right about when I got things rolling. For about two years starting in 2011 I wasn't able to drive at all and had mounting hospital costs. Zeno paid for some of that. The good news is that I've been seizure free since 2013 and, yes, I'm loving my Delica. Lots of work, lots of projects ahead of me.
 
So happy to hear that you're doing better medically. I look forward to being of any assistance to any of your Delica projects if I can. Cheers to your health!

K
 
im curious about the thule feet you used. when i had the 12" thules on my crystal lite it sat WAY above the roof. are the roof heights different? i want to put a roof rack on again but want something with a more snug fit like you got
 
Kellyn said:
The issue is the design of the Delica exhaust. The downpipe has a tough flange to find on the turbine side, making it difficult to create a true 2.5 inch exhaust. Most will start the increased diameter exhaust at the downpipe outlet flange which is the first jspec joint closest to the engine.
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is it possible to source just the flange? if so is the part number and supplier info available?
 
@coop74 @Kellyn
In case you're both still interested, I'll be throwing together a true turbo-back 2.5 kit with a stainless flange/downpipe I'm 3D printing with Shapeways.com and I'll throw the part up for free download on here so others can make the kit with their local shop and Shapeways. I figure that flange/downpipe is the only missing piece to a true 2.5 inch.
 
Rad, I'll throw up a STEP file to CNC just the flange too incase any DIYers prefer to weld. Tearing intake/exhaust apart this week to take measurements.
I guess this is the place for wild ideas... I'm also playing with a design for an air-to-water direct to manifold intercooler, with a bolt up electric water pump. All open source of course. Thermo-electric exhaust harvester is on the mind too, but that'll be another year of research.
 
@Kellyn - after all this time, are you still enjoying the Rigid lights? I am thinking of getting these to mount in the same place on the lower bar... or maybe contemplating the SAE version instead for regular driving. do you use the 10" bar more often or less? i have never had/used one so i don't really know the difference in light output. any changes you'd now make in the mounting location? Any special welding/additional mounting required in your setup for the square lights?
 
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