 | Home > Maintenance & Modifications > Installation of side locker (pic heavy) |
 
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| Bushpig Member Since: 07 Nov 2013 Location: Risca, Wales Posts: 236   
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The locker was bought on a clearance sale and did not come with any instructions and was rather a poor effort form me on taking pictures of each step/process.
I initially made a cardboard replica of the locker and then marked and measured many many many times. Not having access to a Dremel nor Jigsaw, I first drilled the corners ensuring that I did not over cut with the angle grinder…  Click image to enlarge Click image to enlarge Click image to enlarge Unbolted the 3rd row seatbelt reinforcing bracket and cut the angle off the tub. Used all the 3rd row seat mounting and tie-down eye bolts for the locker mounting. Test fitted and cut was spot on. Extremely nerve racking taking the grinder to my pride & joy. Of the 9 mounting holes, only had 1 that was misaligned and needed re drilling. Painted all new exposed metal with stone chip… Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Onto painting the door and locker… All painted first with Dominion grey etch primer. Did the door in a satin white and then some satin clear coat. The locker with 4 coats of Gravel Guard, texture came out perfect and should last years before needing a touch up. Ran out of paint for the interior, I’ll probably brush paint it later or just leave as is… Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge The final fitting went smoothly. Cut the seat belt reinforcement and used it as a spacer between the tub and top of locker, the rear crossmember side was modified to ensure the tub would take the weight. Probably over engineered and it will probably take the weight of a sumo wrestler. Put a bead of sika between the lip and body. I had previously installed power to the rear of the tub with hella and cig lighter sockets (switched on the dash) for fridge, etc and took a feed from there for the locker. Made a simple box with Anderson plug for compressor, another cig socket, slots for spare fuses and 2 led strip lights (with switch) to aid seeing at night. Updated the fuse in the battery box from 40 to 80 Amp which should handle the load if both the fridge and compressor are running at the same time. As an after thought, I put in a door switch (wired to the safari door switch) and now when vehicle is locked and alarmed, if the locker is opened the alarm activates. Extra layer of security is a bonus and tested many times with no confusion with the 10as. Just wish I’d thought of it earlier and would of incorporated the switch into the electric box, making for a more seamless look. The supplied door seal was and inch or so too short and was not able to source the same size seal, so filled the gap with leftovers I had in the ‘spares box’. Did a waterproof test and passed with 100% (much better than the Landy did from the factory). All mounting points were sealed with Wurth weatherproof circular tape and bolts coated with an anti-corrosion paste (locker is stainless steel). Did a slight over cut on the wheel arch, will live with it for now but keeping an eye out for a cheap one at the local 2nd hand parts suppliers. Added cheap car rubber matting to help reduce the ‘clang’ from stones being thrown off the wheel… Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge All the gear loaded in, probably need to update the tyre plugs and adhesive (the kit is 4 odd years old and never been needed, yet). Used the bag from the new compressor for the jumper cables, turnbuckles, gloves, etc. The air hose is stored in 110mm PVC sewage pipe, painted black. Painted the rivets to match surrounding colours. Light on the door is brighter than expected (pics without flash). With it completed I don’t think I need to paint the rest of the inside. Now to move on to painting the rear crossmember, NAS step is currently being sandblasted, galvanised and re-powder coated… Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge[/b] Human beings, who are almost unique in having the ability to learn from the experience of others, are also remarkable for their apparent disinclination to do so. Douglas Adams 2012 2.2 Puma |
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30th Nov 2018 6:09am |
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| Fatbaron Member Since: 12 Mar 2016 Location: Devon Posts: 297 
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Great job there! You could use that LED as a reversing light it's that bright!
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30th Nov 2018 7:49am |
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| LandRoverAnorak Member Since: 17 Jul 2011 Location: Surrey Posts: 11240 
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Very nice. I particularly like your air hose storage solution. 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 |
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30th Nov 2018 10:11am |
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| donmacn Member Since: 07 Nov 2017 Location: Nth Scotland Posts: 1829 |
Thanks for taking the time to take and post pics during that job. I think 'pic heavy' is a great approach, as it makes life easier for others who might want to to the same job.
Very tidy work. Donald 1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong (The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html ) 2000 Range Rover P38 4.0L V8 in the past.. RR classic - fitted with 200Tdi 1984 RR classic - V8 with ZF auto box 1993 Discovery 300Tdi not to mention the minis and the Type 2 VW camper... |
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30th Nov 2018 11:34am |
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| JOW240725 Member Since: 04 May 2015 Location: Suffolk Posts: 7873 
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Great idea fitting it all in there and very tidy!
 James
MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html MY1990 110 200TDi SW beautifully faded Portofino Red - https://www.defender2.net/forum/post743641.html#743641 MY1984 90 V8 Slate Grey - https://www.defender2.net/forum/post744557.html#744557 Instagram @suffolk_rovers |
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30th Nov 2018 11:44am |
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| bigfatsi Member Since: 07 Sep 2018 Location: Teesside Posts: 48 
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Very nice!
S |
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30th Nov 2018 12:02pm |
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| Rosco Member Since: 03 Dec 2010 Location: Burntwood Posts: 1799 
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Loving that
But not so sure I'd be brave enough to cut that big a whole in mine 2007 - Stornoway Grey 90 XS SW - Gone 2002 - Black Discovery II - Gone 2014 - Montalcino Red 110 XS SW |
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30th Nov 2018 1:54pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10476 
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^^^ i know what you mean Rosco, i did it twice
 i was well nervous when i did mine, measured at least 5 times before i made the cut, all went well after that 
Nice work there and a great thought for all the items in there place
You can never have a " Pic heavy " thread  1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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30th Nov 2018 10:38pm |
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| kmac Member Since: 07 Oct 2009 Location: Middlesex Posts: 1294 
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Awesome install. As others have said, wouldn't have the "cojones" to cut the panel.
Still trying to psyche myself to cut the bonnet to install some AeroCatches What compressor is that - my eyesight is not good enough to read the label |
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1st Dec 2018 11:22am |
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| geezer Member Since: 27 Feb 2011 Location: Brissy Posts: 20  
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Nice work, it has me thinking for an aux battery location.
I go camping a lot. |
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2nd Dec 2018 12:00am |
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| legin Member Since: 22 Jul 2017 Location: Chelmsford Essex Posts: 1004 
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Great post love the pictures
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2nd Dec 2018 12:26am |
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| Bushpig Member Since: 07 Nov 2013 Location: Risca, Wales Posts: 236
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Thanks for all the compliments
& Yes, it is nerve-racking doing the cutting... But by just taking your time, making sure measurements are correct, the grinding goes smoothly. Kmac, it is a Trailboss 72l compressor. Local outdoor supplier had it on special for ZAR999. Was going to use my old one, but it was longer and would have had to install it length ways, which would have not left enough space for the rest of the gear. The new one works much faster with more oomph. The old one is 13 odd years old and was starting to show its age. I did modify the new one by swapping out the head with the old, as the old hose is 2m longer and has the gauge by the valve connection and the connectors were a different size. I'm still going to rotate the head so the air hose connection is easier (the filter will be to the rear. But need to file the piston to allow space for the reed screw. Did try just rotating the head but it sounded like a bag of spanners (at least trying this has marked the piston), will get to this after the crossmember and nas step. Human beings, who are almost unique in having the ability to learn from the experience of others, are also remarkable for their apparent disinclination to do so. Douglas Adams 2012 2.2 Puma |
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2nd Dec 2018 6:43am |
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| Steve_overland Member Since: 14 Oct 2018 Location: Gaydon Posts: 279 
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Looks very tidy, where did you get the box from and do they have any more?? @steve_overland on Insta.
110 expedition vehicle with pop roof |
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2nd Dec 2018 10:24am |
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| kmac Member Since: 07 Oct 2009 Location: Middlesex Posts: 1294
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Thanks - seems like its only available in SA Looks good though. |
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2nd Dec 2018 11:10am |
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