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VVS210



Member Since: 12 Nov 2016
Location: Hampshire
Posts: 946

United Kingdom 
Photoshop Whistle
Post #833809 28th May 2020 6:20am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Ouch! Rolling with laughter Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia
Post #833816 28th May 2020 7:02am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Rear Step 2
When I fitted my receiver hitch I had to remove the folding step that I'd fitted some time earlier, as the hitch clashed with one of the step mounting points. Not having a step has been a real nuisance though and I've been considering all sorts of cunning plans to resolve it. This has included butchering a standard step to make it fit and fabricating something from scratch that could utilise some of the hitch mounting bolts. In the end though, I've gone for the really simple solution of bolting a step to the drop plate that came with the hitch Rolling Eyes


Click image to enlarge

Because the drop plate sticks out quite a long way, I've mounted the step on its' rear, which necessitated hacking around a couple of tow ball spacers to clear a vertical brace on the rear face. It makes for a much better position for the step, though:


Click image to enlarge

The whole lot is secured to the hitch with a lockable pin like this one from eBay:


Click image to enlarge

I'm not sure that I'd want to tow anything with this pin given it's dubious provenance, but it's perfectly adequate as a means to stop casual theft. Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia
Post #836672 11th Jun 2020 9:08pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Rear Load Deck
Something that I’ve been working on for a few weeks is a shelf or deck to span between the rear wheel boxes. What started out as a simple idea turned into quite a complicated task, though!

I wanted to take advantage of the stepped wheel boxes in the rear of my USW to create a full width flat floor and avoid permanently fixing anything to the vehicle. I also wanted it to be easy to remove and incorporate some cargo rails to provide fixing points.

In simple terms, it’s a sheet of 18mm thick plywood. After some careful measuring, I established that two layers of 18mm ply would make up the level between the lower part of the wheel boxes and the upper, so I cut the main sheet to size and then glued and screwed two strips to the underside, spaced to match the width of the floor (910mm). Then came the tricky part. I worked out that my circular saw set on its’ most acute mitre angle would just about match the slope of the wheel box sections between the lower and upper levels. After much measuring and several test cuts on some scraps, I cut a mitre along the full length of both edges such that the deck would drop into place on the wheel box cut outs.


Click image to enlarge



Click image to enlarge

As I wanted to secure the deck in place to prevent it bouncing upwards, at the front I cut the centre section short so that the two thickened edges just fit under the sides of the recently fitted dog guard:


Click image to enlarge

The underside of the leading ends were then chamfered to help with sliding it into position:


Click image to enlarge

In the top face of the board above the thickened edges, I routered two slots to inset two lengths of cargo rail that I bought from MudUK. These rails are 9.5mm thick and I set them approx. 6.5mm into the ply. The protruding 3mm was chosen to match the thickness of rubber matting that I wanted to use on the top to give a completely flush surface.

The ply was then primed and painted on all surfaces before final assembly of the various hardware.

Whilst 18mm ply is pretty strong, I wanted to reinforce the front and rear edges and so I bought two lengths of 25 x 40 x 4mm unequal steel angle and fixed them to the underside of each. 25mm was chosen as, again, it would project up above the upper surface of the deck by 3mm, forming a lip to contain the rubber mat. They are fixed with a variety of No.8 stainless self-tapping screws, which have all been countersunk into the steel to provide a flush finish. That bit took ages to complete!


Click image to enlarge

The matting is 3mm thick wide rib rubber. I bought a 3m length, which allowed enough to cover the main floor, the centre section of the deck and two strips to cover both the edges of the deck and the tops of the wheel boxes. The matting is secured to the deck with carpet tape, which is sticky enough to keep it in place but not so much that it can’t be removed if necessary.

Whilst the front was secured by its’ shape and the finished deck is quite heavy, I still wanted to secure the rear to prevent it bouncing upwards. To that end, I used two adjustable over-centre catches to attach to the standard tie-down rings. As I couldn’t find any catches with hooks at both ends, I ended up fabricating some out of 10mm wide strip steel and bolting them to the catches:


Click image to enlarge



Click image to enlarge

I’m really pleased with the finished result. It’s strong enough for me to climb on without deflecting and I now have a completely flush floor with flexible inset lashing points. Underneath, there is enough space to accommodate the usual mix of tools, trolley jack and various work-related equipment that’s easy to reach without being buried by other things.


Click image to enlarge
 Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia


Last edited by LandRoverAnorak on 25th Jun 2020 6:04pm. Edited 1 time in total
Post #839523 24th Jun 2020 9:41pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

England 2004 Defender 110 Td5 CSW Bonatti Grey
Excellent tidy job Thumbs Up looks great Ray
My build thread
http://www.defender2.net/forum/topic17615.html
Post #839532 24th Jun 2020 10:05pm
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Co1



Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3605

United Kingdom 2013 Defender 90 Puma 2.2 HT Loire Blue
Yep, very tidy indeed.
Post #839548 25th Jun 2020 5:06am
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3141

Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
Very well planned and accomplished. Nice. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #839552 25th Jun 2020 6:21am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Thank you, chaps Very Happy Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia
Post #839559 25th Jun 2020 7:12am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16809

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Top class work, that is very neatly done. Thumbs Up
Post #839564 25th Jun 2020 7:51am
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Rosco



Member Since: 03 Dec 2010
Location: Burntwood
Posts: 1797

United Kingdom 2015 Defender 110 Puma 2.2 XS CSW Montalcino Red
Thats a cracking bit of workmanship. Puts my piece of ply board dropped over the wheel arches to shame Embarassed perhaps I'll have to borrow some of your ideas and give mine a refesh Bow down 2007 - Stornoway Grey 90 XS SW - Gone
2002 - Black Discovery II - Gone
2014 - Montalcino Red 110 XS SW
Post #839566 25th Jun 2020 7:53am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Heh, heh, by all means borrow away Laughing Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia
Post #839578 25th Jun 2020 8:36am
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ak615



Member Since: 22 Aug 2018
Location: essex
Posts: 174

very nice job, well done!
Post #839701 25th Jun 2020 4:35pm
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Green Machine



Member Since: 19 Nov 2010
Location: North Yorkshire
Posts: 1226

United Kingdom 2005 Defender 90 Td5 CSW Tonga Green
As always, very neat indeed! Great job Darren - a 'simple' and very effective solution, very nicely executed. 2005 Td5 | 90 Station Wagon | Tonga Green
Post #839710 25th Jun 2020 5:15pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11240

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey
Thank you, both Smile Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia
Post #839721 25th Jun 2020 6:07pm
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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green
That looks an excellent solution & very well executed.

Nice to see it shared with enough details for anyone else to copy. 👏
Post #840069 27th Jun 2020 4:51pm
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