This is the diary of the extreme overland camper ‘DOGGER’
First came the CAD model, complete 100% including the standard P38 range rover was modelled in CAD and a custom visio template designed for the new wiring loom.
Everything was pre designed to the 1/10 millimetre, the build was in inches but hey ho that’s life 🙂
First get a range rover, the P38 cost 1200£ from ebay, L322 is Chris my Brother/Fabricator/and chief Sikaflex applier ( SWMBO doesn’t even let me paint the house)
we ran it around for a day then started work
We ripped out the old 2.5 diesel and the entire wiring loom and all the ECU’s
then moved the ABS ecu and the transfer box ecu up high behind the dash and placed the new BMW M57 ecu high also. The ECU has the immobiliser removed and a torque /High MPG map installed, we also carry a spare so we are never left for dead…maybe
There are nearly 1000 wires in the complete new loom
I reverse engineered the comms to the HVAC and dash display and made a bespoke BECM to make them work. including cruise control that’s built into the engine ECU.
The engine mounts from the old engine are a close fit , the right hand side has to be dropped on the chassis side for the turbo to fit nice.
Trouble removing injectors from the M57 engine , required a big puller which just snapped the injector in half :-(, the eventual engine I used was bought with no injectors so I knew they would come out, copper grease ensure they will again.
Everything fitted and ready for the new engine.
This is a custom plate between the gearbox and engine as used on our Dakar cars to ensure a tight seal for wading.
air box removed with a grinder and slitting disc.
I thought it best to test the WEBASTO diesel heater and the engine water system before finalising the design. Thermal imaging camera helps with the setup
new M57 3 ltr diesel fitted, now to sort the air filter out and the snorkel.
breather pipes for axles and diffs and gearbox, green for ARB lockers, white for fuel burning heater, they are colour coded, black are transmission breathers, green are the air lockers and clear is for the webasto cab heater
breathers routed into snorkel, this cap goes on the air filter and seals tight
back inside and the switch module is deleted and the interior switches converted to standard simple mode of operation, only two needed now, carbon effect covers the old holes
The Air suspension switch has been reprogrammed to work the Air compressor and ARB diff air lockers.
Finally started to gather all the wires into the new fuse box location
Custom fuse box finished, behind it is the ABS ecu and the engine ECU
The finished engine bay, P38 with M57 engine and everything else redesigned to fit correctly in the bay.
The custom front bumper is CAD designed , it fits the standard Range Rover and protects the washer bottle and A/C components neatly
it carries the Hi lift jack and down the front is the Tirfor winch rope
Hot dip galvanized, we did this on Merlin our old 4×4 truck camper and after 17 years there was zero rust, its worth the effort
first fit and it looks good.