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1995-2002 Range Rover P38A
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Discussion Starter #1
Decided to rebuild my P38 to an "Expedition" vehicle. Looking at what was available on the market, very few items fitted my vision of what I wanted to do, so decided to design and build everything from scratch. Not trying to build a Defender or a Disco wannabe... I wanted to build a Range Rover Expedition vehicle how they should have looked from the factory according to my views. Will keep on updating this thread as the build goes on.

My low milage Range Rover SE 4.0 ´95, still untouched
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New tyres in the trunk
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Maxxis Bighorn 265/75R16 being mounted
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The raws for front and rear bumper
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16.500 lbs winch being fitted
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Skid plate being fitted
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Managed to get my hands on one of the last remaining Lucky8s snorkels around!
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1995-2002 Range Rover P38A
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84 Posts
Wow I'm excited, please keep the updates rolling
 

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1995-2002 Range Rover P38A
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43 Posts
Discussion Starter #3
Roof rack pretty much finished, following the contour of the roof line!
Designed the roof rack so it is as low as possible in the front and about 4" height of the guard rail in the back.
Possibly I will also incorporate a hinged ladder that can be folded down when needed, and stored in the roof rack when driving.
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Installed a deflector mesh in the head of the snorkel
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1995-2002 Range Rover P38A
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43 Posts
Discussion Starter #4
Front winch bumper with winch shield taking shape
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The original Range Rover bush bar is being modified to fit the new oversized winch bumper.
Please note the recessed winch fairlead mount.
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LEGACY VENDOR
1995-2002 Range Rover P38A
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2,064 Posts
Very nice work! Where did you find the LED Light on the front of your rack?

Thank you

Scotty
 

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1995-2002 Range Rover P38A
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43 Posts
Discussion Starter #7
Getting closer to the finish line... Powder coat planned for next week
Then just all the other stuff awaits like snorkel and higher springs etc.

Roof rack shaped to the curve of the roof
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Front view with everything in place
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Some details of the front bumper
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Rear bumper mounted
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1995-2002 Range Rover P38A
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Discussion Starter #8
The winch electronics hidden inside the bumper
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The winch behind the shield
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1995-2002 Range Rover P38A
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Discussion Starter #10
The bumper is bolted to 10mm (1/3") mounting brackets that has been welded to the frame.
 

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1995-2002 Range Rover P38A
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Discussion Starter #11
All parts off to powder coating...

Now the 2nd phase of the project starts with snorkel installation, 120mAh battery, water proofing of the computer, ventilation hoses from bell housing and timing cover, 50" LED light bar, 2" additional suspension lift and the final component is the Terrafirma Rock Sliders that are scheduled for arrival and installation in mid December!
 
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why not make decent galvanised and powdered sliders yourself, should not be much issue seen what you made allready...

why vent on bellhouse and timingcover? bellhouse is not watertight on the engine anyway. and timingcover is not open anyway it is connected to the sump and vented with the entire engine through the sumpventilation.

How are you gonna waterproof the computers.... they are not most conveniently placed regarding water...... and inside the doors you have your outstations... inside the door water rises much sooner than inside the car, the doorrubbers are pretty watertight (experience ;-) )
 

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1995-2002 Range Rover P38A
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Discussion Starter #13
why not make decent galvanised and powdered sliders yourself, should not be much issue seen what you made allready...
Galvanized sucks to weld!


why vent on bellhouse and timingcover? bellhouse is not watertight on the engine anyway. and timingcover is not open anyway it is connected to the sump and vented with the entire engine through the sumpventilation.
OK.. have to check up on that! But from what I read on the P38's the bellhousing and timing cover should be "plugged" before wading! Will check that up further, so thanks for the note!


How are you gonna waterproof the computers.... they are not most conveniently placed regarding water...... and inside the doors you have your outstations... inside the door water rises much sooner than inside the car, the doorrubbers are pretty watertight (experience )
It's just the computer in the engine bay I'm concerned about! I'll post more on it when I finished it! ;)
 
R

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ah... that's the one I'm least concerened about... it's in a box, the bottom has two small drain holes and the top is right under the bonnet.... as long as you keep your dash above the water it should be fine ;-)as the ecu is placed bottom down in the box

with galvanised i meant after the welding before the coating, not starting with galvanised material

timingcover wadingplugs is with engines that have timing belts like the TDI's, the bellhouse on an auto has a few spots where it does not seal to the engine for the manual i'm not sure... been too long that i've seen one to remember (thank god):tongue:
 

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1995-2002 Range Rover P38A
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Discussion Starter #15
Parts coming back from powder coating is being mounted
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Looks good! :thumb: The detachable winch shield will come in handy when cleaning. But I would put the relays for the winch inside the engine compartment (next tot the fusebox for instance), where there less exposed to water and dirt than inside the bumper.
Filip
 

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1995-2002 Range Rover P38A
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Discussion Starter #17
Thanks for the tip, the relay box is IP68 classified so think it will be ok. Installing a 120 mAh battery, so won't be much space left below the fuse box. :)
 

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IP68 should be more than OK! I assume this is not the standard relay box? Most winches just have a non-sealing plastic cover over the relays.
 

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1995-2002 Range Rover P38A
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Discussion Starter #19
Just some minor uppdates.

Replaced the liner with checkerplate
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New insulation under the hood
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1995-2002 Range Rover P38A
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Discussion Starter #20
All the powder coated parts mounted. Next week the installation of the snorkel and suspension lift starts.

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