Appears to be almost exactly where Eric cut my old Monty. He's a tall guy and it gave him room to stretch out in. I think you are going to have some fun with this project!

why is that man never online, I have questions for him. haha. mainyl about if he just used the door skins or cut the whole door.

I am trying to save weight but not add a huge amount of work.

I got some more info on my Canopy setup, the material is 3mm thick ally plate. and it will weigh in at 150kg mounted :geek: :geek: :geek: YES!!!

That is great news as I will save huge amount of weight, I figure it will be about another 20kg heavier than that with 2 tool boxes mounted underneath for batteries, but that will leave my engine bay open and less prone to body cracks from the heavy weight on corrugations.

On a previous trip I had the rig weighed,
2610kg all up
with:
80L water
190L fuel
80L fridge with beer
all food
all camping gear
2x spare tyres

I figure I will be able to loose 300kg now if my math is correct. so loaded for a trip I will weigh in at 2300kg and with a gvm of 2500kg I will finally be running light which should net me some better fuel economy, less wear on parts and even better mobility on sand which is already awesome to say the least.

The grinder is out....

Well, the chop has begun... I am committed, no backing out now. LOL

Pretty straight forward to chop, pulled all the wiring out. and dropped my second fuel tank to make the cut.

We started at about 1pm and had the back of the body sitting on the ground by 5. It would of been quicker, but there is a video that goes with this and filming takes a while to setup ad get the shots right.

A good day. mixed it with beer and a bbq too, a lot of fun was had. Many thanks to those who showed up to help

With all the doors pulled off:




Starting to mark it out:


I used plumb lines to line the cuts up. a bit tricky on slightly curved surfaces. but I had my 1m ruler to help make sure it was all straight and square.. this was a measure 8 times deal. haha



Time to cut:
photos coming soon

After the cut!!!







Nice straight cuts:


The sills and roof support:




The frame with the body off, it was very clean. impressed for a 90 model. haha.

[img]http://i85.photobucket.com/alb...2%20rebuild/frame3_zpsae0d8253.jpg[/img]

[img]http://i85.photobucket.com/alb...02%20rebuild/frame_zps5db64d12.jpg[/img]

[img]http://i85.photobucket.com/alb...2%20rebuild/frame2_zps8ff1f247.jpg[/img]

The first cut is always nerve wrecking. Good job! Where is the gas tank from?

it was a fun day though. haha

The fuel tank replacement is a 132L 4wd systems tank 900.00
The fuel tank sitting under the door is a 52L Aux from long ranger automotive, it was 1500 with all the stuff to setup the transfer system

If my math is correct that's 48.6 gallons of fuel capacity! How many miles does that take you?

<img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" />

looking good, i took mine for a drive right after the chop looking out the back while drive seemed unreal. looking forward to see how yours looks with the new rear on.

All highway I hould be able to eek out 1700kms

on sand I can do 1000

with a mix of on and off road I was able to get 1063km out of 132L tank. 400km highway, 500km dirt tracks, 163kms low range 4wd

*edit*
All distances stated are fully loaded, 2610kg without me in it. so 2690kg all up. empty it does a bit better.

have you thought about making a little trailer or camper out of the section you cut out?