Ex-Mod Outrigger

[PlumgoodRVR]

I have a '73 Series 3 109 ex-mod in bad need of replacement outriggers that support the front of the rear springs. The regular 109 outriggers aren't big enough. Has anyone replaced these before and perhaps have a fabricator who already has the measurements and can make them? Thanks in advance for any thoughts/suggestions.

[SafeAirOne]

I've replaced both of those outriggers on my 109, though it's not an ExMod.

Do you have Google Sketchup installed on your computer? If so, I can e-mail you the outrigger construction plans I drew up, otherwise I can just post them here as pics.

[PlumgoodRVR]

I'd be interested in seeing them. I don't have Google Sketchup so posted here as pictures would be great. Thanks!

[SafeAirOne]

These are the generic dimensions, but as long as your building it, you might as well customize it to your exact chassis dimensions, which will be detailed in subsequent pics. Material is 14 gauge mild steel, just like the original (civilian) chassis. Maybe overkill for an outrigger, but it is sturdy!!. Note that 14 gauge is more than most small bending brakes can handle:

http://farm9.staticflickr.com/8453/7930772192_0d7a22185b_z.jpg




Exploded view of the components. Note that my bender is only 24" wide, so I had to make the top piece separate from the bottom piece. If your bender can handle the full length of the piece, than you can eliminate the tab and make the top piece part of the bottom piece:
http://farm9.staticflickr.com/8306/7930836622_39242fff85_z.jpg




Top Piece:
http://farm9.staticflickr.com/8041/7930772020_5d690386fc_z.jpg




Side Pieces. Note that the 1/16" dimension on the left side is the bend allowance; That 1" tab will be bent 90 degrees in one direction or the other depending on if it will be a front side piece or a rear side piece:
http://farm9.staticflickr.com/8179/7930771882_66f701d847_z.jpg




Bottom Piece. Again, the 1/16" dimensions are bend allowances along the bend lines:
http://farm9.staticflickr.com/8175/7930771678_ddae477a0c_z.jpg

[SafeAirOne]

It ends up looking a bit like this when you're done:

http://farm5.static.flickr.com/4062/5168090298_fa8f41edfd_z.jpg

Suggestion: Make some sort of distance piece so you can properly locate the fwd spring mount when you reinstall the outrigger on the chassis. I drilled a piece of bar stock to span the distance between the forward and rearward spring mount holes BEFORE I cut the old outrigger off. That way when I installed the new outriggers, I just needed to feed the bolt through the outrigger spring mount and the the hole in the barstock and it was perfectly located.

Good luck with your project!

[PlumgoodRVR]

Wow! This is absolutely perfect! Thanks!

[SafeAirOne]

Incidentally, it looks like our hosts sell replacement versions of these outriggers:

http://www.roversnorth.com/p-16717-outrigger-109-front-mount-for-rear-spring-lh-rh.aspx

http://www.roversnorth.com/p-6534-outrigger-front-of-spring-lh.aspx


BTW, why do you say that the regular replacements aren't big enough? Is it that your MoD chassis is taller at that location?

If so, I have enough 14 ga for at least one, more likely 2 custom outriggers. If the RN ones don't work for you, I can make some up to your dimensions for a reasonable cost if you can't source any pre-made ones.

[PlumgoodRVR]

Yes, I did see the ones that our host sells and spoke to them a year or so ago. They told me they wouldn't fit as they thought mine are larger - but after looking at your dimensions they're exactly the same. So, I've circled back to double check. If not, I'll be back in touch. Thanks!

[yorker]

I suspect the difference they were talking about is in the military/1 ton chassis that has the raised suspension to add clearance for the tires and or fit the 9.00 16s. Not all military land rovers came with that chassis- some had the regular civilian 109 chassis.

[SafeAirOne]

I suspect the difference they were talking about is in the military/1 ton chassis that has the raised suspension to add clearance for the tires and or fit the 9.00 16s. Not all military land rovers came with that chassis- some had the regular civilian 109 chassis.

Hmm...You don't have any sample pics do you? I wonder where the difference lies? Maybe in the length of the spring mount tabs where the through-bolt goes? The 'normal' tabs are pretty short with the top of the spring wrap pretty close to the bottom of the outrigger.

[PlumgoodRVR]

No decent pictures but the spring mount tabs hang about 4" below the outrigger.

[SafeAirOne]

Got it; Post #9 in this thread (http://www.landyzone.co.uk/lz/f6/ex-army-109-new-spring-fit-problem-140447.html)explains it, including pics. Pretty easy fix using a replacement 'normal' outrigger and your old spring tabs.

[Les Parker]

On the "1 Tonne " and MOD Chassis there were 2 locations for the front of the rear spring mount, for (as has been mentioned above) the fitment of 900 X 16 Wheels/tyres.

Unless you are going this route, the "civvy" version will work just fine.

2p

[yorker]

The Aussie army IIA 109's AND 88s had that raised suspension too. In fact I think it may have originated with the Australian contracts. I've often thought it would be cool to take an 88 and apply those mods.