Welcome back to the Gazelles Off-Road “Project Purdey” series! Can you believe we’re already five weeks into this ambitious build? Week five was a storm of progress, problem-solving, and a few more unexpected challenges. Here’s a detailed look at how things unfolded.
Broken Glass and Wiring Woes
The week started with some smaller tasks while waiting for crucial deliveries delayed by a bank holiday in France. First up was removing the broken windscreen from the frame—a messy and frustrating job but a necessary one to ensure Purdey has a clear view ahead.
Next, we tackled the rear chassis wiring loom. Originally designed to run through the chassis, we debated whether this was still practical with all the modern connectors. Instead, the team decided to route it externally along the chassis using rivnuts and P-clips for secure attachment. This approach will simplify maintenance and prevent potential damage.
A new tool made its debut this week: a brake pipe flaring tool. After figuring out its many combinations, the teamsuccessfully flared the ends of the brake pipes, which were then bent and routed along the chassis. Using Priscilla as a reference vehicle, we mapped out the path to ensure everything fit precisely.
The long-awaited deliveries finally arrived from eurospare containing the vital Defender components needed to advance the build:
- A steering box
- Swivel bearings and shims for the front axle.
- A replacement fuel filter housing for improved reliability.
These parts enabled us to fully assemble the front axle and install the steering box, making Pie a rolling chassis for the first time—a major milestone!
With the eurospare swivel bearings in hand, we began assembling the front axle. This process required meticulous adjustment of shims to achieve the correct turning resistance, a task that was as satisfying as it was precise.
Next, we added the brake discs and calipers, ensuring optimal braking performance for off-road challenges. The front hubs were greased and fitted, completing the assembly.
The fuel system saw significant progress:
- A missing fuel pipe was sourced and installed, allowing the entire system to be secured with clips.
- The new fuel filter housing replaced a damaged second-hand one, offering greater reliability and peace of mind.
EGR Valve Removal and Timing Belt Replacement
The engine also received some attention, starting with the removal of the EGR valve. This step prevents dirty exhaust gases from recirculating into the engine, enhancing performance and reducing maintenance needs.
While the fan was off, we seized the opportunity to replace the timing belt. This task was far easier with the engine exposed and ensures Purdey heart beats reliably for many miles to come.
At the end of week five, Purdey chassis is starting to look like a car. The front axle and wheels are in place, making the vehicle mobile—a significant achievement. However, some components, like the gearbox, are temporarily removed for adjustments and to simplify the transfer box installation.
While it’s encouraging to see progress, a conversation with our mentor Jonathan revealed that we’re only 20–25% through the overall build. With just 80 days until the roll cage installation, the countdown clock is ticking.
Despite the challenges, we remain optimistic and excited for what’s next. The focus now shifts to preparing the bodywork and getting it ready for installation—a big step in Purdey transformation.
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