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bova

Member Since: 29 Aug 2015
Location: Dubai
Posts: 6

2004 Range Rover HSE 4.4 V8 Chawton White

Fantastic thread, I found it today and have read it all.

Can't wait for more

29th Aug 2015 5:39pm

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

2014 Range Rover Autobiography SDV8 Loire Blue

Glad you enjoyed it, should be doing some more this coming week so watch this space.... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

29th Aug 2015 6:19pm

bova

Member Since: 29 Aug 2015
Location: Dubai
Posts: 6

I'll be waiting, I'm reading your other threads right now.

I just picked up a 2004 L322 2 days ago and it has a long way to go to make it bullet proof.
As you can see suspension is first on the list, then making it a bit more rugged.

29th Aug 2015 6:41pm

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

They do seem to suffer from rubber bits perishing in the hotter climates... good luck with it... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

29th Aug 2015 7:00pm

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

Hi,

(Just keeping this build thread up to date...)

Been meaning to do these for ages but haven't been able to because of various bit's of me needing welding up and repairing, only one joint left to go and a mate offered to help with the big stuff so have started on them, doing the rear first as mine is on LPG and I've been pushing my luck green laning for a year with no spare wheel...

With a spare wheel carrier two thirds of the rear drop down tailgate is covered and you would see one reversing light and a bit of the old numberplate suround... not that attractive so I decided to sort out a smoothed out tailgate..

First job, cut out the whole numberplate surround

Cut out several pieces of plate I used 1.2mm to give it plenty of strength, the bootlid is made up of three skins anyway so is pretty tough.. Tack welded them in all round the edge, moving from place to place to reduce the heat build up and possible warping, carrying on until it's all done

Ground it all down

Then just a bit of filler work, got it to the primer stage and then dropped it off at the painters... came back looking very nice...

Next job was to remove he back box from the exhaust, mines been hit several times and wasn't far off falling off anyway and I wanted to see 1. how loud it was and 2 how high I could get the new bumper ... well the answer to 1. is VERY LOUD, it makes small children cry and sets off car alarms... it really is too loud to live with so I will be putting in a couple of smaller rear boxes when the bumper is finally in place and I know how much room there is... I just cut the tailpipes off the rear box and joined them to the pipes with some 60mm ID flexi exhaust pipe, welded on some brackets and used the rear pair of exhaust mounts.. then sprayed it all black after this picture....

Then onto the bumper, started yesterday and took off the old one, out with the corrugated plastic and knock up a template... radius was done by hand, wanted the bumper to stick out a bit further than the original to help protect the rear wings..

Drilled out a piece of 8mm x 200mm plate for a rear support for the bumper, this will give a massive amount of strength to the rear of the FF and the bumper...

Cut the bumper top from the template, did two so the sides were the same shape, then the sides as well, tack it all up and used the piece of angle to ensure it is flat...

Offer it up into place and do a bit of head scratching and lots of measuring....

Top and front made out of 4mm plate, next job to bend the front piece around the top, tacking it as you go, takes a fare bit of effort to bend it around the corner.... we cut it a few feet longer than needed to get a good pull around the bend..

Put a few good tacks either side to give it some strength...

Click image to enlarge

Welded a Winch plate into the bottom and cut a hole for the fare lead, a hole will be cut in the top for the Winch to go in...

Offered it back to the car and checked the fit, do have to say it looks like a dodgem car!!!!

Fit was very good though

Then dropped a line from the rear wing and light onto the top of the bumper for the fill in...

Click image to enlarge

Cut the fill in, again out of 4mm plate and contoured it to fit the gap...

Both sides done, drivers side needs trimming back a bit, also working out the bottom profile of the bumper to give better clearance and some aesthetics...

Tack a return on the top edge..

Click image to enlarge

Then weld it up and grind it off smooth....

Click image to enlarge

Checked it one last time and it is looking good, fit's very nicely and I think will look great when painted..

Click image to enlarge

Then started welding all the seams, put a return on the bottom edge for strength and added some webs inside for more strength..

The reason the bit below the rear light is pulled back in and not sticking out like the original bumper is so the spare wheel carrier has room to mount out the way of the tailgate and make the rear lights visible...

Last few bits of welding finished, bent up some recovery points out of 18mm bar, cut holes in the front face of the bumper, welded them through and onto a piece of 8mm plate welded to the rear 8mm plate (should be able to pull just about anything with them

)

Click image to enlarge

Then welded in some strengthening webs with 6mm plate...

Click image to enlarge

Stonechipped it then topcoated in body colour, needs a better bit of adjustment but it's a bit hard on your own, going to have to come off again to fit the winch so will sort it then..

This is one of the things I was after, far more room here to get the rear wheel off an obstacle...

Well pleased with the result, strong as an Ox and not that bad looking...

Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

Last edited by Haylands on 4th Jun 2022 2:04pm. Edited 3 times in total

8th Sep 2015 5:20pm

Dean

Member Since: 23 Mar 2014
Location: Glasgow
Posts: 51

I'll honest and say that bumper looked a horrible monstrosity part way through the build, but the end result is fabulous. It looks very well integrated. You certainly have a lot of skill, and a great eye for the design and the detail.

I'm very impressed with the end result - I hope you are too 👌👌👌

Dean 2006 FFRR TDV8 Vogue
2012 Discovery 4 SDV6 GS

9th Sep 2015 6:28am

johnboyairey

Member Since: 11 Jan 2013
Location: surrey
Posts: 2032

2012 Range Rover Westminster TDV8 Orkney Grey

all ready for a good night of RAM-RAIDING then.....

9th Sep 2015 7:55am

mzplcg

Member Since: 26 May 2010
Location: Warwickshire. England. The Commonwealth.
Posts: 4029

2014 Range Rover Vogue SE SDV8 Corris Grey

Perfect Pete. Now, how much to make me one of those?

Actually, could you not make some fixed exhaust sections in a bit of stainless? Might look nicer.

9th Sep 2015 9:12am

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

Thanks chaps, exhaust will be done again, this was just a quick cheap bodge to get rid of the rear box... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

9th Sep 2015 9:31am

Cam-Tech-Craig

Member Since: 03 Aug 2011
Location: Gloucestershire
Posts: 16284

2015 Range Rover SVAutobiography SDV8 Loire Blue

Just realised Pete... What about the PDC? You not putting them back in for norman road use?

9th Sep 2015 9:49am

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

Going to have a play with the PDC when the spare wheel carrier is done, it may pick it up so may not bother.... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

9th Sep 2015 9:56am

Cam-Tech-Craig

Member Since: 03 Aug 2011
Location: Gloucestershire
Posts: 16284

9th Sep 2015 9:59am

Cam-Tech-Craig

Member Since: 03 Aug 2011
Location: Gloucestershire
Posts: 16284

Just a thought... You maybe able to use the inserts from your old rest bumper pete?

9th Sep 2015 10:04am

mjdronfield

Member Since: 04 Nov 2011
Location: Derbyshire
Posts: 7793

2011 Range Rover Vogue SE TDV8 Buckingham Blue

Do you need the rear red reflectors back on it to comply with some regulation or other ?

Just a thought..... 2011 Range Rover Vogue SE 4.4 TDV8

Previous cars :
2003 Range Rover Vogue TD6
1999 Discovery Td5 ES
1995 BMW M5 3.8 6 speed
1992 Range Rover 3.9 Efi Vogue
1992 BMW M5 3.8
1988 BMW 735i SE
1989 Ford Sierra XR4x4 2.9i
1981 Ford Fiesta Supersport

9th Sep 2015 5:36pm

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8190

Yes Mark, I'm looking into that.... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

9th Sep 2015 5:43pm

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