Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
@ LW
Many thanks for all the info on Solar Panels LW.
Though don't think you've been to Scotland have you ? ..... it's certainly no Outback
Due to lack of sun, I'm not overly concerned re solar panel performance.
I have the space, so I'll fit it; if I get a benefit, that's great; if not, not a problem.
@RogB
No it's not a Coleman, but sounds very similar [being a single skin] , but at 4' high there's no way you could stand up in it.
I use it as a utility tent for one night stop-overs.
Mine is the narrower 120cm One person tent.
Click image to enlarge
For stop-overs of 2 nights of more I've got this larger utility tent.
Click image to enlarge
Anyway, got the Airline rails fitted today.
Click image to enlarge
Decided to fit them higher than I've seen others do.
However I had to drill through single, double and triple metal to achieve this [all separated by just a few mm].
I wanted them higher so they fit in with the aesthetics of the D4 .... e.g. in line with the door tops.
Click image to enlarge
Before I finished for the afternoon, I drilled and offered up an alu strip that'll hold the side boxes.
Click image to enlarge
.... and it's another day tomorrow !...... always on the road less travelled 🚧
31st Mar 2023 6:48 pm
Lightwater
Member Since: 21 Oct 2018
Location: Sydney NB
Posts: 97
Only got as far north as Leamington Spa three times in th 70s, 80s & 2010 to see an aunt. Otherwise Tasmania 5 times, same sort of thing!
Aurora Australis from Mt Anne, Tasmania 1992.Visitor - Freelander owner
1st Apr 2023 7:04 am
Jacks11
Member Since: 17 May 2022
Location: Worcestershire
Posts: 83
Great post and watching with interest. How did you wire in the usb connectors?
3rd Apr 2023 9:08 pm
DJEwen
Member Since: 19 Apr 2017
Location: Cairn o’ Mount
Posts: 51
ronp wrote:
Anyway, I got the Airline rails fitted today!
Waaaa! No going back now. Great work on the aesthetics, good idea mounting higher. 2005 Discovery 3 HSE Zambezi Silver 56,000mls
3rd Apr 2023 9:44 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
Def no turning back now!!
Always thought the Disco was a boxy car, especially at the rear ..... no it's not!
The rear side window/roof line tapers down slightly, the rear side windows are curved.
Found that out when bending the alu flat bar for the side box supporting straps.
With just the aid of a vice, lump hammer and my thigh, I put a bend at the bottom, than put in a curve, then a bend where the glass kicks in.
I just need a 120deg bend at the tops to turn in to the roof rack, where it'll be fixed.
Click image to enlarge
Also started on the battery platform.
The battery is very heavy and the positioning is as akward as you can get.
Anyway, added a couple of back to back brackets and made up some support rods with top plates that can be screwed to a wooden base.
Click image to enlarge
Made a template then cut out an mdf base.
Click image to enlarge
Offered the battery up to it, but very tight near the terminal posts.
Click image to enlarge
So lowered the brackets and rods, added some off-cuts and offered up the battery to check.
Much better clearance, however I need to watch the vertical metal of the wheel arch.
So will have to re-cut the base platform to fit.
Click image to enlarge
..... and it's another day tomorrow !...... always on the road less travelled 🚧
4th Apr 2023 5:18 pm
tanters
Member Since: 24 Oct 2007
Location: Oireland
Posts: 4287
Nice job Ron
How’re you going to lash it down?
Also, do you know what all those foam covered connectors are for? You might be missing out on some extra bits to add A happy childhood ... is the worst possible preparation for life.
4th Apr 2023 9:52 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
Have a battery tray with lock downs (see first pic of battery on the tray).
Had to mash the ends down of the tray to take the length.
That’ll bolt down to the plinth and I’ll also add a bit of rubber matting as an extra preventative to slipping.
There’ll also be deadening carpet added to the inner wing & wheel arch.
Reckon the extra wiring is for rear air con, but there’s absolutely no way anything else is going in there after all the other stuff I need to install. ...... always on the road less travelled 🚧
5th Apr 2023 8:23 am
Lightwater
Member Since: 21 Oct 2018
Location: Sydney NB
Posts: 97
I am not familiar with the layout, but I hope the threaded rod is not been used as a support.Visitor - Freelander owner
5th Apr 2023 11:32 am
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
They will be part of the support, but will be sleeved by hollow metal tube.
And I’ll be bolserting it up in other ways.
This was just a trial fit to see how the battery positions itself.
But why do you say that the rods should not be used as support?
...... always on the road less travelled 🚧
5th Apr 2023 12:17 pm
Lightwater
Member Since: 21 Oct 2018
Location: Sydney NB
Posts: 97
Ok. So if the threaded rods are used, they will be in tension in the tube, good!
I know this is a totally different arrangement, but there maybe some ideas to utilise somehow.
(2 of 4 x 26AH gel batteries under seat)
No room in the Freelander for anything. All made from aluminium, it is solid as a rock. All bolted & generally tapped M6, together with, Nyloc nuts. I would have put the 2 other batteries under the other seat but I had already installed 2 of 3 ARB compressors, which was torture with all the cardboard templates I made, but it worked perfectly.
If bending aluminium bar by hand, 3mm thick is as much as one can do, about 50mm maximum width, put it in a bench vise & heat the folding area with a heat gun for a minute or 2. Push over with a block of wood at soon as possible being extremely careful not to burn yourself.
Heating will reduce stress cracking in a tight fold, but be organised to fold the aluminium instantly. The folding process won't be any easier but the stress cracking will be reduced.
Have a bucket of water at hand just in case you touch the aluminium to dunk body part in.Visitor - Freelander owner
5th Apr 2023 2:25 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
Thanks for that.
Absolutely great you’ve got a flat floor on your Freelander battery installation.
My predicament in the D4 is effectively like trying to fit a battery into a stepped filler funnel …. you want to try that!
The rods are threaded, double locked, into the bodywork, replacing 3 existing M6 bolts….. so that’s a start point for me in trying to find some sort of level.
It’s still work in the progress until I find the best & most stable solution ….. for a stepped filler funnel.
The aluminium straps I’m using are 50 x 5mm (not 3mm) and I’ve bent all the angles & bows, cold by hand.
I’m aware that bending to an obtuse angle of approx 120 that I’d need to use heat.
However as I believe the aluminium can only be heated once, more than that and it would be too brittle.
So I would need to heat, bend, then offer up to the D4 to check before it naturally cools.
And if I didn’t get the angle right ….. well that’s it, no further tries.
I’ve therefore decided on an alternative method of securing the top straps to the roof rails....... always on the road less travelled 🚧
5th Apr 2023 7:34 pm
DJEwen
Member Since: 19 Apr 2017
Location: Cairn o’ Mount
Posts: 51
You’re moving along at great pace.
Was creating a plinth/cubby out of timber to fit the side and support the battery not an option?
I do hope you’re going to walk us through your electrical set-up as you install it. What do you intend to run from the additional battery, fridge and lighting? Would I be correct in thinking the D4 already has a secondary battery, what does it supply?
I’m strangely not receiving emails for new posts on this thread anymore.2005 Discovery 3 HSE Zambezi Silver 56,000mls
5th Apr 2023 9:51 pm
Lightwater
Member Since: 21 Oct 2018
Location: Sydney NB
Posts: 97
ronp wrote:
However as I believe the aluminium can only be heated once, more than that and it would be too brittle.
Flat extruded bar will be 6060 alloy. After heating, but you probably never get it hot enough with a heat gun, that's my experience, & heat dissipation to lose its temper. But 6060 alloy natural age hardens over a few weeks.
But regardless of that, only bend it once. If you haven't got the bend exactly to the correct angle, a bit more of a bend will be ok. You are not straightening it & rebending it. That is a no-no.
You could get a thin piece of metal to bend a template for the correct angle, then set that up next to the actual piece of metal you will be using.
(I was in the aluminium industry for a couple of decades)Visitor - Freelander owner
5th Apr 2023 11:33 pm
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15264
Having a re-think around battery support platform.
Now looking to remove this large odd shaped bung, then plate over, then use that small flat area to build up a platform.
So leaving this for now whilst I mull things over.
Click image to enlarge
Meantime, I drilled out the Alu straps then offered up a side box to the D4.
Still waiting on some hardware via the post to complete the top fixings.
Meantime, made up some nylon block spacers to attach to the roof rails to give me the height between the roof rack rails.
Click image to enlarge
Also, a few days ago I offered up the window vents …
Click image to enlarge
….. then trimmed out the thermal window panels (& repositioned a couple of suckers) to keep the vents clear.
Click image to enlarge
….. and it’s another day tomorrow !...... always on the road less travelled 🚧
6th Apr 2023 6:33 pm
Lightwater
Member Since: 21 Oct 2018
Location: Sydney NB
Posts: 97
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