Mahindra Classic

DIY - Rear(l) view mirror for Mahindra Classic

2010-03-07T04:19:00.001-08:00

Do it yourself, just the installation part but the buzz is that after a term of one and half years waiting finally the Explorer is wearing close to its original spec side view mirrors with original Mahindra Classic like fittings from it's American Sibling Kaiser CJ5 Jeep.
Yes, finally I have got a set of original CJ5 Jeep's original side view mirror set which fits like icing on cake. I have a small problem though as one of left hand side unit shipped (brought) to me had a wrong hole on the arm causing a minor issue in alignment.
I can drill a 90 degree hole against the current set of holes in the arm to correct the problem. It will be done next week as now i'm on my way to Coimbatore. Just fixed the mirror in the Jeep and had a test drive to see if it works, man it gives me new view sight in the jeep which I was missing all along.

Warn/Saturn Overdrive with Mahindra Classic

2009-12-10T22:37:00.000-08:00

After I posted the last blog about my possession of Overdrive that is going to be installed on my Mahindra Classic. Couple of techies asked me about the gearing ratios and the figures that is going to prove the increase in speed, fuel economy and reduction in noise and engine RPM.

Here here is the worksheet out put of mathematical figuresThe actual speed change figures for ball back engine RPM figures will be made available after completion of the calculation. Just for your information, here is the formula to calculate the speed

Overdrive for Mahindra Classic

2009-12-10T04:08:00.000-08:00

Almost 2 years of my waiting time has come to end finally. Yes, here you go.

In simple terms an overdrive is the final/cruising gear. It reduces the power output by lowering the gear ratio. The overdrive mechanism increases fuel efficiency, and saves strain on the transmission and the drive train.

Warn has developed a overdrive for Jeeps, It is a very old design that has been around for decades. The same has been bought over by Saturn Company then ATV Mfg. started rebuilding it or producing the same for the niche market.

The Warn overdrive is a simple 2 speed gearbox that mates to the Jeep's transfer case and provides a 25% drop in engine rpm when engaged. Instead of creating the final gear as overdrive, the Warn overdrive model introduced new gear ratio between each gears. Hence a transmission in which the highest gear ratio is less than a one-to-one ratio. This means the drive shaft turns faster than the engine crankshaft. The overdrive feature saves fuel and, because the engine runs slower, engine wear and noise are reduced.

What I have got is the same Warn Design reproduced by ATV Mfg. for Mahindra Jeep transmission/transfer case specification. What makes the Mahindra Jeep different from its American cousins is that of Tooth and Spline counts in the transfer case, hence the regular or used Warn Overdrives will not fit directly into Mahindra Jeeps. Herm Till ford reproduced the gear with 29tooth and 15 spline count to suite the Mahindra Jeeps. The same is what I have got and going to be placed into my Jeep.

Instead of the normal 5speed gearbox with overdrive that provides an additional gear to rotate faster than the engine(crankshaft) RPM, The warn overdrive actually sits on the PTO port of Dana/Spicer T-19 transfer case and takes the input from transfer case main gear shaft and converts into different gearing ration and sends it back to the actual transmission. Because of this particular model, the warn model overdrive can introduce as much as double the number of existing transmission gears.

Currently my Jeep equipped with KMT-90 4 forward and 1 Reverse transmission, hence I'm running the Jeep with 10 gearing ratios including the 4 wheel drive Low mode. By installing the Warn Overdrive I will get 20nos of gearing ratio that will enable to choose huge range of gearing ratio according to my need.

The moment I enable the Overdrive all the gear ratio will be on the higher side, hence going to give me a smoother noiseless ride. Whenever I need to do Offroad the overdrive will be temporarily disabled by pulling the Overdrive lever back to the driver side position. Practically the overdrive will be left in engaged mode all the time as most of the time the jeep is driven on the road.

Now I will let the pictures talk about what are the items came with the Herm Tillford supplied overdrive baggage.

Come back to this space to see more on the installation side, then comes the actual driving experience part.

Goodies to accompany the offroader arrived

2009-12-02T04:37:00.001-08:00

Couple of goodies collected in the recent past for the offroader

That includes

1. Electronic tyre pressure tester
2. Vehicle work light with magnetic base for holding on the body
3. Halogen torch light
4. Hi-lift jack handle holder
5. Light weight screw driver assy
6. An emergency cutting blade kit

MahindraClassic gets a new Music System

2009-09-01T12:09:00.000-07:00

Hurray it's again time for little bit of entertainment after the many tiring works that got completed recently. I have also gone out with the Explorer for an OTR too. I will post the detailed report by tomorrow but before that here is the new Music system that got installed in the Explorer.
This system is made in China and not so costlier one, who dares to install a costly system on a open jeep. First of all the rain or moisture may spoil a electronic components or the unnecessary worries about loosing it to a thief. Anyway the Chinese make is not that bad, though the sound quality is not upto the branded ones but the package is good overall for a diesel jeep with canvas top where wind makes more sound than the music system.
The great advantage of this music system is that it can play MP3/WMA music files from SD card and USB Memory stick and what not it also got a FM and AM Tunner.

Flat tyre

2009-08-13T05:10:00.000-07:00

Today it was again day with Mahindra Classic shoe work, the rear left side tube in the tyre was flat. Not worried as I noticed the flatted tyre in the office parking lot and changed spare wheel.
When reached tyre store found that the mouth of the tube inside the tyre is gone and needs replacement, BF Goodrich tube gone in.
How about rotating the shoes? Yeah, that is what I was thinking and same has been done today.
I had issues with my steering directions last time during the offroad so my mechanic corrected the issue with tie road in the steering system. He suggested me to do the wheel alignment, hurray flatted tyres took the credit today the wheel alignment also corrected with computer assisted machines.

Tree Trunk(Bark) Protector

2009-08-12T10:26:00.000-07:00

Be nature friendly, that is what we always say when we talk about offroading. At time we have to run over bushes on the forest offroad but we always very cautious in protecting nature wherever we can. We normally carry litter bags to carry the litter back from our offroad trips, we don't cut tree or harm animals.

But during recoveries we do run into issues as we need to rob around trees to get hold for our winching operations. Some times we found the tree trunk bark got damaged, a simple search on the internet and winch company websites shown something called Tree Trunk Protector. If something I can achieve by spending money to save environment is always on the welcome list.
The latest recovery gear equipment is that of Tree Trunk protector, This one is 3tonne direct pull capacity and if used with basket model (routing the strap around the tree's trunk is called basket model pull) I can achieve 6tonne capacity which is more than sufficient for a Jeep weighting 1.4tonne plus 100 to 200 kilo grams on board.

I have also got a recovery gear bag custom made for the recovery stuffs along with the Tree Trunk Protector. Hmmm life is more easy now to carry all of them at once. No need to worry about forgetting something out of the complete gear whenever going for offroad.
This bag is made of tarpaulin kind of canvas material and very strong to hold all the heavy stuffs.

Mahindra Classic - Trac-Lok 30 spline LSD trial

2009-08-12T09:31:00.000-07:00

I'm now started considering options to put LSD (Trac-Lok Limited Slip Differential) into the Explorer's rear drive axle setup.

There are issues associated with this change
1. There is no ready made LSD kit available for DANA 44 / 19 spline axle

2. The currently available MM550 LSD (Trac-Lok) is matching to DANA 44 differential but spider side axle spline count is 30 against 19 in Classic

3. The axle track of MM550 is not same with CL340 DP - Classic, as heard from experts(CJ/CL 340 = 48 inches, MM540 = 51 inches and NGCS MM540 = 53 inches). but I have not measured the size of MM550 and Classic axles yet.

With the above constraints, I have few options to implement LSD setup on my Classic
1. Take the complete differential setup for front and rear from MM550 and use it in Classic
2. Take only the LSD from MM550 and custom fabricate axle to fit Classic axle length setup, this exercise may lead me to convert the semi floating axle to full floating type (Though bit tricky but I know a expert who has done it for his Jeep earlier)
3. Buy a on the shelf Dana 44 / 19 spline Auburn Limited Slip(http://www.drivetrainwarehouse.com/PDT259648.aspx) from overseas and get it installed in the existing housing and axle setup.

With the above constraints and options I've also got a MM550 LSD in my hands (just in case if I opt to take option no. 2)
Watch out this space for more information on how my LSD project is achieved.

Meeting with Jeep GOD Mr.UBS

2009-08-11T08:20:00.000-07:00

Right from the day I found my Mahindra Classic, the only person who is fully supporting me for any query on the Jeep front is none other than the National JEEP Daddy Mr. Uday Bhan Singh (Mr.UBS). One must interact with him to really believe how good and down to earth person Mr.UBS. I never think twice to take inputs on Jeeps from Mr.UBS and he is a living Jeep dictionary or service manual.Today was a great day as I got a chance to meet him 2nd time in the last 3 years. As a jeeper meeting him itself a great thing, but my day was made with multiple surprises. Guess what ? Mr. UBS brought a lot of Jeep stuffs for my Classic and CJ3B. I went to the Chennai central station to receive him and rushed to the platform where the coramandal express was slowly came to halt, As instructed by him earlier I was standing on the entrance of the three tier A/C compartment B3. At first I didn't recognise him, but he spot me on the second and waved me. I was so happy to see Mr.UBS today.
I have been always dreaming of fitting a PTO stuff on my classic and finally today I got a simple PTO utility that rotates with a gear lever. Thinking of such a celebrity like person carrying heavy weight PTO and stuffs for me on the train, I'm astonished.
I've also got original drop down tail gate and swing open stepney door for my CJ3B along with a set of headlight and parking light guards and side view mirror rod.
I must say this, expect the swing open spare wheel door rest of the stuffs are brand new original products. I'm the jeep items directly from JEEP god today.

Mahindra Classic - 76 BHP 2.5Liter

2009-08-09T09:19:00.000-07:00

Hurray, The Explorer got the heart transplanted successfully.

It was quite drive compare to my old XDP, smooth and very powerful.
Now following has got into my Explorer

1. Peugeot XD3P 2456CC 76BHP motor and usable bell housing
2. Bolero/MM550 type paper element airfilter with element damage indicator
3. 65amps alternator with vaccum pump (replaced the independant vaccum pump due to unavailablity of belt also the engine sump of XDP has replaced the XD3P engine oil sump as there is not inlet pipe for vaccum pump oil circulation)
4. four core radiator
5. Clutch and Accelerator cables were replaced
6. Radiator hoses have been replaced
7. Engine water jacket has been replaced with the M&M latest plastic part
8. complete oil service including engine, gearbox, differntials and break oil top up done
9. Clutch release bearing and fork changed

The following items will go into the Explorer in a short span

Mahindra Classic - Rare items on the lookout

2009-08-03T12:08:00.000-07:00

I have been restoring my Jeep from scrap level to whatever is happening today, but I could never get two things on my jeep.

1. Side view mirror fittings (I have the mirror and clamp, but the L type rod)
2. Emergency or hand break cable

While I was speaking to Jeep guru Mr. UBS, he asked me to send sample pictures of what I need here above is the same for all my readers to know.

Mahindra Classic - Air filter with paper element

2009-08-03T12:03:00.000-07:00

After the brief pause due to weekend holiday at the garage, now the jeep engine fixing is back on the rails. We bought a brand new Air-Filter setup of Mahindra Bolero vehicle that has paper filter element in it. Sure thing that it is going to reduce much of noise and give clean air to the engine to breath.
The new radiator is finally installed on the grill and the grill assy is now fitted on the jeep too.
Also the engine is mounted and clutch issue is fully solved, explorer sleeping just before making it maiden trip after the grand power transplantation project.
By tomorrow we will fix the air filter and an issue that has stopped our schedule today. The problem is that my earlier power plant got vacuum pump behind the alternator and oil circulation tube initiated from the engine sump and traverse through the vacuum pump to reach the oil filter assy where the oil pressure switch was connected.

Now with the current engine, there is no outlet on the sump and the vacuum pump also has no connectivity from oil filter. You know what I need to use a different oil pressure gauge which will take the reading with oil tube that runs from engine block to the dash board. This is seems to be a age old method, since there is no options for oil pressure electrical switch on this engine, I'm left with option.

Noiseless and Heatless

2009-07-31T10:38:00.000-07:00

As the clutch fixing issue dragged the whole day today, I took another sub-project with in the engine bay upgrade that is sound and heat proofing of the cabin area.

Once again we removed the engine down from the engine bay, as to work on the bell housing to fix the clutch issue. I received an information from a senior automobile enthusiastic Mr. Dhabhar Behram that the MM775 hardtop 8 seater (mahindra commander like jeep) had XD3P with cross shaft clutch setup. That gave me an idea how to solve my clutch.
I simply grind open the XD3P bell housing to make an arrangement for cluth fork to work on the right hand side. The previously installed XD3P bell housing has been removed and kept aside. Hopefully by tomorrow we will have the Jeep running with the new upgrade.
I know all you people who are reading my blogs must aware of the Mouse in our computer and the pad that helps the mouse to move smoothly. I'm using the same cushion used under your mouse pad for noise and heat reduction of the Explorer passenger cabin.
I'm still working on air-filter placement and the right air filter setup for the Explorer.

Mahindra Classic wears XD3P motor now

2009-07-30T10:35:00.000-07:00

The Mahindra Classic has got the Peugeot XD3P engine mounted and started now. But it is not completed yet as we are facing few teething issues with the clutch wire routing as the cross shaft clutch assy used in the previous engine is not usable with the current engine.
Hence looking for options to complete the installation, at the max I may fabricate a clamp to route the cable like original one.
As expected the engine mount was very simple as both the previous engine and the current ones are using similar engine bed (mounting platform).
We started to engine today and I fell in lust with the sound, It showed me a future of much reduced noise driving experience.
I have also took a picture of my current odo reading(48994) so, this will serve me a purpose of total number of kilometers that I'm going to drive the Jeep with XD3P engine.

Explorer is in the Operation theater

2009-07-29T10:55:00.000-07:00

My explorer is in the operation theater now, today only lots of preparation work has been done and the engine transplantation has been kicked off. The mechanic has carefully removed the winch, front grill and other components from the engine bay.
New engine is really cool looking after primer painting. All leaked oils, diesel have been cleaned properly and painted.
We found the clutch disc surface had water markings with minor rust and with the help of surface cleaning done by the lathe people now the ply wheel clutch surface is back to good condition.
I put my little effort to get the Peugeot XDP 4.9 2112CC 62BHP engine coming out of the engine bay, this is the last time the original engine sits on my Jeep. In fact my current engine had done its last run in this morning to the Mechanic's garage.

It was sad to see the engine getting down from the under bonnet compartment, but all for good. Tomorrow the Classic is going to wear a upgraded engine and all new power band is assured. (The current engine is good at compression and it pulled me all over the places I visited, it never let me down) Adieu Peugeot XDP.
The Peugeot XD3P installation required minor parts replacement such as water jacket replacement, clutch release bearing replacement, accelerator cable replacement and major issue are being worked on the battery and air filter fitment area.
The mechanic and myself are working to find a better solution, I hope we will come up with an idea before tomorrow afternoon so the actual transplantation will be completed before tomorrow evening. In any case I'm pretty much on the schedule.
Along with the engine transplantation I've also decided to change the radiator not that my current radiator got any issue or something, but I wished to have a four core radiator. As I have already plans set for Air-conditioning the Classic cabin, I'm working out all the possible requirements.

I have sourced SK radiator company's four core radiator today (Brand new) and same will be installed tomorrow. The current radiator from explorer will be installed in the Navigator (Petrol CJ3B)
Alongside all these upgrades the Explorer got it's origina front bumper corner protector shields.

Mahindra Classic - Heart Transplantation countdown starts

2009-07-26T18:31:00.000-07:00

I’m officially starting the ticker to set heart transplantation schedule for my Mahindra Classic. The power of storm is not going to be installed but adequate increase will be made possible to the Jeep now. With in the next one week time the Jeep going wear a fine tuned heart.

The current stock engine in the Jeep is Peugeot XDP 4.9 is a 2112CC (2.1 liter) 62BHP diesel motor. This engine is a wet liner and gear driven cam. The major problem that I’ve been facing with this engine is that of overheating, many have faced the same issue and I can feel my foot board always hotter. With the hot temperature outside and adding to the climate the cabin also heated up with the Peugeot engine most of the time I sit in the Jeep with sweat wetting my dress.

Air-conditioning with the current engine is not going to be possible as the engine may burn to death. I was looking at various options such as adding extra condenser fan, additional pressurized coolant or four core radiators. But the question will it be sufficient to run Air-Conditioning? Will it be ok to run Air-Conditioning with extra output Alternator?

Having installed the electrical winch, I’m also thinking of additional powered alternator, the current alternator is 65amps 12v capacity but I need something with 100+ amps. But the vacuum pump that is assisting the break booster sits behind the alternator restricting my options and increasing the money to be spent.

After taking all these issues in to the consideration, and the overhaul cost that may happen due to the age of my current Peugeot engine I opt to choose Peugeot XD3P 2498CC (2.5 liter) 72BHP dry liner engine that runs chain driven cam due to the super smooth driving compare to the older one.
This one is much quieter than Peugeot XDP 4.9. The major advantage of choosing this particular model is that this engine mounting beds is same as the current one hence I don’t need to worry about any alterations in the engine bay. So far so good, however I expect few change to displace the air filter and battery and also clutch setup may require some attention.

Watch out this place I’m going to achieve many new add-on to the jeep after my Jeep’s engine transplantation. Those are:

Opel Astra alternator – 100+ amps power output. (My XD3P engine got the vacuum pump attached above the engine as a separate assembly and no need to worry about the alternator upgrade, now options are wider to me)
Air-Conditioning become easy as the XD3P engine is designed for such facilities in the vehicles it was originally installed. I have even got the clamps to mount Air-conditioner’s compressor.
10bhp additional power, which can take few extra pounds on my Jeep. Hurray bigger rims and permanent placement of my recovery kit with in the Jeep.
A nice music system to pass my lonely time with the Jeep on the highway cruise. (You may ask me why is it not possible with the current setup, dude the current engine screams lot louder than you think so I can’t even hear what the co passenger speaks)
Noice and Diesel emission is going to be heavily controlled as the XD3P is Bharat Stage II standard vehicle.

Mahindra Classic gets an addnl. recovery gear

2009-07-18T10:31:00.000-07:00

Thanks a ton to Shibu, fellow Jeeper from Dubai who came down to Chennai last night to pay a visit to his Mahindra MM550 restoration work. He came from Dubai not just to see his Jeep work but to also to surprise me to an extent every Jeeper envy my ally with Shibu. I hope you know what I'm talking about, yes Shibu bought a bag full of goodies for my Jeep's recovery gear.
Except the Hi-Lift all cast 48" jack, none of the other goodies were in my wishlist, however after seeing them on hand I was like dream come true mode.

The items that he brought for me are

1. Tool organiser bag

2. Foldable handy Shovel
3. Rear view Mirror (Huge type with mobile rining alert, this is a must to have in any jeep as the noise of diesel engine over shouts my mobile ringtone as I always felt impossible to notice the mobile ring.)
4. Air pressure check meter
5. hi-Lift jack carrier plate which is broader than the Hi-Lift jcak's base to provide better base for the foundation. This is one plastic item but strong enought to carry 3 tonne load
6. Hurry! my dream come true here, I got a Hi-Lift jack 48' size

7. X-Trax Traction system for sand, snow and mud - another WOW factor
In addition to that, I would like to list my age old tow wire which is my first and foremost recovery tool added to the explorer. I'm listing it here as I have not blogged it before in this blog
The above tow cable is the forefather for all the other recovery tools I have collected.

Mahindra Classic & Mahindra CJ3B - Siblings

2009-07-12T06:50:00.000-07:00

I must not post this blog in the dedicated Mahindra Classic blog, but thinking on a point that the CJ3B is elder brother of Mahindra Classic I decided to post about my recently possessed Mahindra (Kaiser) CJ3B petrol Jeep.
It's a good news to share among the offroading community and jeep enthusiastic who visit my blog here. Actually my savings to a MM550 me to purchase a 1969 model Mahindra (Kaiser - that's what the book claims) CJ3B petrol powered right hand driven JEEP.
Now officially I'm owning my 3rd JEEP (Mahindra Classic, MM540 and CJ3B), many of you definitely know about my Explorer and the MM540 is actually working like horse in Neyveli now. The recent addition CJ3B is going to be with me and I'm going to prepare this Jeep in the looks of military line.
Oh yeah, this is also going to be with me for some offroad trips such as slush and sand.

I'm still confident on using my Explorer for boulders and rocky terrain. The first and foremost thing I do when I purchase a vehicle is to name them. So the new boy at my collection will be called as "Navigator" (Many of you must of already known, Professionally I'm a webmaster and Explorer and Navigator are well known in Internet arena and also they well suites the Jeep)
I'm not going to write regularly about my CJ3B restoration story in this blog, but to cut the long story short here is the update on my CJ3B restoration work.
Jobs that are completed:

Complete break overhauling done
Clutch plates have been replaced
New battery has been put on place
Getting the oil filter replaced with original style Fiat old type oil filter
Engine water jacket aluminum manifold has been replaced (Technically called Elbow)
The gearbox has been overhauled, replaced 2nd gear and synchronizer rings with bearings
Load gearbox levers have been put on place
Brand new front propeller shaft has been installed (MSL make)
Still the front axles are missing and trying to get hold of brand new MSL 22/34.5 axle with 10/19spline

Accessories for external looks have been collected and the list of collected items were:

1. Gun carrier
2. Front Grill black out lights
3. Pick axe
4. Body side handles
5. Jerry can
6. Jerry can stand, goes on the rear tail gate and the stepney will be moved to left side of the jeep
7. Small amo box to be fixed on the right side above rear wheel as first aid box
8. Large sized amo box to be fitted in the rear side of both the front seats as tool box
9. Head light protection grill
10. two shackle rings for the front bumper
11. Old type rear tail lights
12. Insect protection mesh for the front grill
13. Rubber pads for the clutch and break pedals

Parts that are getting sourced

1. Tail gate with Jeep written on it
2. Dash board small indicator lights and aluminum plates
3. Side view mirrors that goes on the body front side with a rod
4. A spiral pipe manual air horn
5. Emergency break assy with drum, carrier plate, break handle and cable etc.
6. Original military type Scissor top fittings
7. Right hand mudguard blackout light
8. 7.00x16 NDMS tyres (5 nos)
9. Rear Bumper protectors

Pending tasks

1. Tinkering
2. Painting
3. Canvas top
4. Electrical adjustments
5. Carburetor overhaul with new packing kit

Some more tit-bits that are interesting to a few:

1.This jeep will be done up in Chennai
2. The rear full door and completely covered rear part will be removed
3. The windshield and Lbow on the engine are badly damaged and same will be replaced as I got that word from our Jeep father Mr.UBS
4. Lots of tinkering will be carried on the Jeep but painting will be delayed for 6 months till next January
5. Mechanically the front axles, 4wd operation levers, front propeller shaft are missing and same are getting replaced.
6. I'm think of pull down type rear door, let me see how it is going to be worked.

Mahindra Classic - Recovery gear

2009-07-05T07:55:00.000-07:00

Since the self recovery tool (Ramsey REP8000 winch)has been placed on the front bumper of the Explorer, now it is time for me to look for all the necessary items that will support my winching a smooth operation. I have been going through the information provided from various Winch manufactures, especially the www.warn.com decided to add few items to the already available recovery tools bag.
Now the D Shackle (few different tonne collection), additional shackle hook, leather hand glove to protect my hands from damages during winching operations and "Do Not Operate" tag (small plastic plate that caters to stop anyone operating the winch accidentally when I'm doing some thing on the other side of the winch.

I also managed to fabricate a spacer to replace the Mahindra Classic original front chassis tow hook, it was removed to accommodate the winch platform earlier. As the platform increase couple of millimeter thickness and the mounting plate's bolt also came in front of the tow hook, we had issues in tow hook fitment. Now the spacer has solved the problem by providing extra height.
PVC Mat to be used as Work Mat for under Jeep body works and Trailer cover to protect the goods placed on the trailer has also been added to the recovery bag.
My previous collection for the recovery & Emergency bag consist of:

A metal rob half inch dia and 3tonne straight pull capacity
Hand shackle and axe
250psi electrical tyre inflate compressor
Compass
Nikon Binocular
Reflective jacket
Tyre handling Glows
Head flash light
Hydraulic & spiral type Jacks
A complete tool kit
5 liter plastic fuel can
Snatch block
Gunny bag to throw on the winch cable as energy observer

The only pending recovery stuffs in my Jeep are:

1. Hi-lift jack
2. Tree trunk protector

Jawadhu Great RECCE with Mahindra Classic

2009-07-01T08:20:00.000-07:00

My long wish to call all the jeepers for an OTR in JAWADHU came near to reality last weekend. I heard Ashwin of Krishnagiri interested in organising an OTR in a riverbed and asked him to change the venue to Jawadhu so I can organise the rest of the program. Though my previous attempts in Jawadhu showed a good trail, but they converted into tarmac in fasttrack by government leaving me with no option but to find new offroad streams. Hence the last weekend trip was RECCE III for me, however lots of good Jeepers from Bangalore turned to support me.

Myself and Anjan (The founder of Jeep Thrills, India) jumped onto my Jeep last friday evening and cruise toward my home town. As per our plan we wanted to stay overnight at Tiruvannamalai and proceed towards Chengam to start the offroading in the early morning.

Dr.Jones joined us at Tiruvannamalai in the next morning, so My Explorer and Dr. Prowler (both our vehicles had experienced Jawadhu on the first RECCE) started to move towards Chengam. I was expecting around 2-3 Jeeps from Bangalore along with Ashwin's Gypsy from Krishnagiri. We were surprised as many as eight capable offroaders turned out to Chengam.
I was bit happy but really worried about organizing their comfort zone. However I had strong belief in Jawadhu hill top as we get everything out there.
We all had our quick breakfast and one of the bangalore Jeepers Armada got the rear suspension cut, we were forced to send him to my hometown as that is the nearest place he can get the suspension fixed. The rest of the nine vehicles started moving towards the start point of the hill climbing task.

It was secnic yet undiscovered, beautiful but not tourist attraction a couple of words to describe about the Jawadhu Hills crawling path. This path was made during the british colonial time and abandoned for public use.
We slowly pushed the offroaders on bad roads / offroads and no roads condition, the altitude was slowly rising and shades of green under the tyres and upside the hood was shown. It was great as the toughest souls which drove the favorite offroaders gone fyling on the trail. It was around 36 kms of no road condition where the Vehicles travled.

We reached our favorite water stream crossing, but to our shock no water was flowing on the water body. But we found a bit of water stagnated and you know what, the brand new Gurkha which traveled along with us took the challenge to float on the water. I must admit the Gurkha is really capable and I set my mind for Gurkha if at all I'm buying a new car in the near future. It had cool and solid metal body, latest engine, power steering, A/C, power window and independent front suspension along with Differential lock and Four Wheel Drive option. So what else we need, the owner of the Vehicle really cool and he took a brave decesion to get on to the water. The rest of the story could be seen from the below pictures.

We reached the hill top at around after noon and after the lunch we moved toward the observatory, Since Bangalore Jeepers came with a Time restriction they were pushed their jeeps towards bangalore on the same night.

Myself, Dr.Jones and Ashwin (Mahindra Classic, CJ3B and Gypsy) were set our goals for the 2^nd day RECCE on this phase III. Since Ashwin is first time offroader Anjan and Dr.Jones decided to teach him a offroad technique.

Whats then, they bypassed the hairpin bends on the hill roads with the four wheel enabled vehicles and Ashwin followed them. Oh yeah he got stuck once, but we were equipped with Winches in our Jeeps so recovery was instant.

During the winching operation I noticed Dr.Jones Jeep's fuel meter showing down, I informed him but we really didn't took it serious. We were roaming on the forest roads to find our next trail and Anjan spotted a obstacle which looked almost impossible for me and he asked me to do, I really refused to do and asked him to take my jeep to try.
I thought he will not be able ot go even 2 feet on that obstacle. He was so skilled, took the jeep through that very narrow incline with great rocks created toughest obstacles. Unfortuntely my jeep lost the trackion on the top where he about to reach the road. Again we had to winch out, however the stunt was so good.

Dr.Jones didn't take his jeep on to it as we feared the nil fuel condition may stall the jeep while going up on the obstacle. But later in that same day, when we reached the fuel pump we found that his fuel tank was half full and the real issue was in the fuel guage.
We had marked few good streams while driving toward the downhills and decided do the RECCE on another day as we always thought Prowler was running out of Fuel.

Broken part - Ramsey Winch

2009-07-01T07:47:00.000-07:00

Oh to my badluck with in a weeks time the winch cable protector fitment holder has broken. This had happen due to a friend of mine put the hook on the chrome plated rod and tighten the winch in.

There was a crack created on the holder and I removed it fully to fix it with the glue. Anyway this piece got nothing to do with the winching operations so I'm bit relaxed.

Anyway I has been successfully fixed with anabond and M-Seal combination. Since I have fixed it, no issues. However the lesson learned is that never give away recovery stuffs to untrained people for any reason.

Mahindra Classic - Ramsey Winch

2009-06-14T07:23:00.001-07:00

A offroader without self recovery kit is dangerous as I really know what kind of help required when performing the offroad act. So I had a long wish to have a winch fitted in my jeep. But availability of good winch in India is a big issue. Forget about good one, we don't have have a bad one. The only option for us to import a winch from abroad, but it came with a big toll on import duty and shipping cost.

But I'm lucky my friend in bangalore got a lot containing few winches directly from Ramsey Winch company. I suppose they are the No.1 in the world and the only winch company that produces winches in USA only. As my friends got it directly from one of the distributor in USA, we got it in a good deal. Hmmm not to mention I have a sliece on that lot. Hence my visit to bangalore.

It was early saturyday morning around 4:00am I cranked the jeep for the recovery eqiupment purchase trip. After 6 and half hour long trip, I reached bangalore and got the winch which was safely kept in a gunny bag.
However the winch platform plate was not availed as a part of our deal, so we didn't had an option but to fabircate. The issue is that the total time to fabricate the plate may take more that 2 days but I wanted to entire thing to be completed on the same day. So my Jeeper friend Suresh came out with an option to take his mounting plate and fix the winch on my Jeep, so he can get his plate done in the due course as he lives in Bangalore itself. I must thank him a lot for the genrous help extended. He also helped the mechanics in removeing and fitting the platform on my jeep.
Here is the wire remote controller for the winch, this remote got two sides. The red one is to pull the cable in to the winch and the black side is to release the cable from the winch.
The winch also came with instuction booklet and couple of stickers and goodies.
After a day long opterations the crew in the bangalore Jeep garage got the winch mounted on my jeep.
The had couple of challenges mounting the platform and winch on my jeep as the Mahindra Classic came with fron tow hook and chrome bull bar which were not standard for the winch mouting plate.
So they did couple of alerations to the winch platform without disturbing the originality of my Jeep. Hurray after completing couple of stages the Ramsey REP 8000 was successfully fitted on my Mahindra Classic jeep.
Finally today morning I started my trip back to Chennai with newly fitted winch.
Now my jeep wears a great recovery tool that is also suggested by Mahindra the manufacturers of Mahindra Classic. Along with the winch I also got a Snatch block for the double power winching operation.
After fitting in Bangalore and today while entering to chennai the nature poured rain water excessively on my jeep saying monsoon is just getting closure for fruitful offroading days.
Now I need to upgrade my electical generator and battery in my Jeep to make the winching a pleasant one.

Mahindra Classic - Acting multipurpose

2009-05-20T07:25:00.000-07:00

Acting multipurpose was no simple job, oh yeah the Classic often acts too much of purpose full vehicle. That too farmers like me use it to the core.
Let it be for the real and practical offroading at the farm or
carrying anythings for transport purpose, when the quantity increases there is trailer that always comes first hand for cross country transport.
Me and My Classic a bond that born for each other.

Mahindra CL340 DP - Classic - Service time

2009-05-10T09:57:00.001-07:00

I completed a year and above offroading / driving my Classic after I completed the Mahindra Classic restoration project. What to look at now, first thing is the odo meter opps it showed 40,000 odd kms and it was 24360kms when I possessed the Jeep. Hurry more than 17,000 kms(including 1000kms of no speedo cable drive) long association with my Jeep has completed with in a year time.

I'm looking forward to grow this relationship as much as I can do.
Between the last oil service and now the jeep has completed 6,000kms and time to change engine oil, oil filter, diesel filter and fan belt. So rushed to the garage and got a request from my mechanic to service the radiator. Why to take risk added the request execution.

My jeep service is completed. The result of this service was evident in yesterday's night offroad which we did over the kelambakkam area of Chennai. We had bunch of cool offroader did a really satisfying offroad event as the dark added more fun to our OTR. Though the terrain was rough like the cactus plants seen out there the jeep engine revs felt smoother now.

As it is hot summer season the radiator service really helped me to attain cool engine and I added 4 liters of concentrated coolant to the radiator.

Mahindra Classic - Organic Farmer's Jeep

2009-05-10T09:31:00.000-07:00

My new avatar is called Organic Former, Oh yeah! I'm a former now successfully done Rice, Sugar cane, Ground nut and now it is mango season. All were in the form of Organic forming.

To my assitance the Jeep really stood along as transporting medium. Last to last weekend I was carrying around 800kg of "Senthura" variety mango from the farm to Chennai's vegetable/fruit market.

I went to the farm and plucked the mangos by hand gathered them into the Jeep Trailer, it took me more than 6 hours with 2 peoples assistance to fill the trailer. By the time we finished the harvesting it was too dark to take pictures. Hence the pictures shows half filled trailer with organic mangos of my farm.

Though my farming was full with organic ideas implemented, the market seems to be looking forward to spoil the corps with various chemical processing. Especially the Calcium Carbide ripening .. which is too dangerous and toxic.

If anyone who reads this thread please understand not a single mango that are selling in Chennai's open market is organic and the ripening process is used with Calcium Carbide stones.

Calcium Carbide when mixed with water produces acetylene which is highly combustible substance and when mixed with oxygen can be used for welding and cutting metals.

Rather said that besides acetylene, ethylene which is also a plant hormone regulator is also produced and this characteristic helps in ripening of fruits. As the science says, Calcium Carbide is carsogenic in nature and it is not in purified form and contains traces of arsenic which too is toxic.

I can supply to those who can buy 50kg or more organic mangos, as the ripening process that I use is the good old home process using the dry paddy grass method.

Mahindra Classic – Jeep Thrills Anniversary

2009-03-29T06:57:00.000-07:00

The whole weekend was Jeepers weekend for Indians as the Jeep Thrills (a Premier Indian Jeeper's Club) celebrates its 4th anniversary. Same is the reason for me to be part of the Jeeping activity last weekend.

It was started with workshop on Jeep assembling and parts, Patrick was demonstrating the internals of Jeep to the members of our club and lunch on Saturday, myself and my two pals geared up in my Explorer towards the get together organized in the evening for the Jeepers. We all traveled around 90kms to reach a rustic village, where the whole team planned to stay over night.
For me the first attraction was offroading with Anjan the founder of Jeep Thrills, we have been known to each other for a quite a long time but never did offroading together.
Secondly my two pals (Sharon, I should say a total energetic girl who cheered all of us for the Jeeping exercise and Dominic, a gentleman from Germany as a guest to the event with me.)
I think this is one of the first Jeep Thrills events where a foreigner participated. I hope he enjoyed the offroad event today as he also floated on the Palar river bed with my Explorer.
Thirdly the offroading event conducted on Sunday was on the Palar bed (a dry river that runs across Tamilnadu a state in India); This rever bed is like any other place and just safety for your jeep so you don't damage any parts. Othewise Palar or any other river or desert offroading is not so great to talk about. Since I had my friend from German wanted to play safe today ;-)
Now the actual story about the 4th Anniversary OTR, after our dinner on Saturday we crashed into the bed and the next morning was thrilling morning for me as for the above mentioned reasons. There were ten offroad capable vehicles (mostly jeeps) participated as mentioned below here:

Mahindra Classic (1 no)
Maruti Gypsy (1 no)
Willys MB (1 no)
Mahindra CJ340 (1 no)
Toyota Landcruiser (1 no)
Mahindra MM550 XD (1 no)
Mahindra MM540 XD (1 no)
Mahindra CJ500D (1 no)
Mahindra MM540 DP (2 nos)

The City I stay in India is called Chennai and it has three climates: 1. Hot, 2. Hotter and 3. Hottest. This is the hottest season for Chennai, We really had toughest sand terrain as the river bed was dry, I guess sand offroading suppose to be the most stressful offroad terrain for the vehicle as the engine needs to be keep on pulling the vehicles.
I brought my tyre pressure to 20psi to float on the sand, this was suggested by Patrick. Those who have already familiar with this terrain didn’t wait for reducing their tyre pressure; almost all vehicles reduced the tyre pressue. Hot + tough with no air-conditioned drive made most of our bodied to get dehydrated. The event organizers did plan it well, we had good amount of water and butter milk on the jeeps so we were not down with dehydration issue.
We had powder like sand every where in the river bed which totally took our vehicle engines for a task.
The most difficult part was that we need to climb around 60 degree sand incline. I couldn’t cross this incline with my jeep I given up as my 4 attempts were failed already.
Here the challenges were: 1. Too steep, 2. this is sand incline, 3. the run on space for the jeeps to pickup the momentum is too less. Except the Gypsy, Land Cruiser and MM550 none of us could do it. The reason being the run on distance for Diesel engines was high but we had really little space on the bottom to pickup, but Gypsy being petrol vehicle it picked up really fast.
When we headed back, it was almost 1pm in the after noon and the offroad was really tough and everyone dipped their head into the cold water availed in the location where we stayed. Patrick's son Rufus (14yrs old) was also done a great offroad jeep driving today, Collective video graph of the Palar River bed Offroad event is uploaded to You Tube and same has been posted here:

The anniversary program was turned out good as I also met good number of jeepers and the veteran like Jeeper Patrick. All the participants (like a family) posed for a photo shot and ended the event with smile.

Treating the Trailer – Mahindra Classic

2009-03-22T23:19:00.000-07:00

The long story short, My Explorer companion got facelift by adding color to it.

After long thinking, I decided to preserve the trailer’s body state by doing bit of body work. Initially I was not really sure if I wanted to do it now as the recession hit my work industry a lot. (Ok, who cares?)

It was on Saturday I started my trip to my home town, on the way I need to pickup my distant relative for farming ideas. Hence the one way travel extended to 350kms to my home town and 50kms for the farm.

It was fairly a decent drive and the trailer did well with the Jeep. Hmmm I noticed the brand new looked trailer's NDMS tyres started showing its face. Looks like the tyres were unused for a long time and the rubber in the tyres are dry leading the edges of the tyres get broken during the long drive.

On the way to my home town I visited East Cost Road for a minimum stretch and picked up my relative. My trailer visited the “Ayyanar Samy” temple to take pictures; since the ECR is full of beach sand I had engage 4WD in the explorer. Later in the same day I reached my home town with no big troubles and the dawn set to dark. The next day (Sunday), Me, Explorer and the Trailer started our work at 4:00AM in the early morning going towards my farm to pickup around 500kilogram of farm outputs (Rice, Black eyed bean, Chilli and Jack fruit). That was the first civilian load the trailer every carried in its life. I thought it will be a big stresses to the jeep, but my wonder no feeling of any addition.
I reached back home at my native to drop all the goods and took the trailer for the body workshop. This is the same place I did my jeep restoration. Since it was Sunday all of the laborers were on week off. I managed to knock the senior painter and called him to do my work, before that I also did bit of arc welding on the body to hide few small holes as the tinker said it need more time to do pucca job. So welding and metal pasting, though the surface inside the trailer was not made evenly with the way arc welding has done. But it solved my problem.We had tough time as it was sunday and no paint shop was open for us to buy paints. Though I decided to use low cost paint to the trailer, My painter managed knock a closed paint shop and got the paint items he required. Painter started his work by metal pasting followed by application of putty and inner painting (black) and outer painting (red). While the painter colored the trailer with red, the electrical power cut had happen and we had to abandon the job for about 2 hours. The trailer came out good but it was too late the job was completed around 6:30pm and I had to give 4 hours for the paint to dry.Since I went alone, 200kms of return trip without anyone as a passenger in the jeep during night trip with first time heavy towing experience was thrilling. Only I had bit of worry in my mind but the jeep or trailer didn’t show any symptom of the whole story and they sailed on the dark tarred road in the mid-night. First thing today I did was to click few pictures of the trailer for your eyes. The Jeep and Trailer looked as if they made for each other at my home in Chennai. Though the entire weekend was busy for three of us (Me, Jeep and Trailer) the complete plan was successful and we made the restoration of Trailer with time and cost constraints but relatively better job.

Registration number plate, electricals and T board are few missing items on the trailer and it will be carried over to forth coming weekends.

My Trailer restoration

2009-03-19T11:29:00.000-07:00

The trailer is undergoing minor restoration, though there is not power plant for trailer the body needs some minimal attention. As the trailer was parked in the open yards in military space, I thought will do some sand blasting and minimal painting job.
But after sand blasting I found the trailer also needs some tinker job, hence sand blasted and primer applied but no painting. As the recession hit the world and the symptoms are started showing up with me, I have decided to do the painting and bit of word at later stage.

Here is the picture showing my Trailer after sand blasting and primer painting. Njoy!

Trips with Trailer - Mahindra Classic

2009-03-16T10:38:00.000-07:00

I have been thinking that I will add a winch, overdrive and Peugeot XD3P 2.5L Diesel power plant to the Jeep. But never thought that I will be needing a companion to the Jeep itself. Though my farm and urban travels are always filled with my rear passenger area of the jeep, I never had an idea of trailer.

In the recent past, I wanted to give it a try to mate a trailer with the jeep. Few of my train travel via. Chennai, Avadi military scrap yard made me think like that. You know what today I own a trailer.

A month back I paid an token advance to take my trailer(Mahindra branded) from one of the army scrap vendor here, however I requested him to assist me for the paper work so the trailer is road legal.

I saw my trailer loaded in a truck, collected few pictures for future reference. Then my rush to know about the trailer gave me mind full of information.

1. Mahindra Trailers are equipped with Break assy. with the hook bar and emergency breaks.
2. Mahindra Trailers got cross bar to manually pull the trailer, this could be folded down when towing
3. Mahindra Trailers are got smalls hooks inside and outer side of the body
4. Mahindra Trailers got tools box on the right side of the outer body wall
5. Mahindra Trailers got Quadrilateral shaped mudguards and box typed mudguards

1. Bantam Trailers got no break assy but equipped with emergency break
2. Bantam Trailers got round shaped mudguard
3. Bantam Trailers got wiring for rear taillamp which could be attached with the Jeep (advantage)
4. Bantam Trailers were easy operatable when taking reverse as there is no breaks attached in the tow bar, the Mahindra's normally hit the break and makes bit tough for reverse operations.

Finally today, it was my towing experience. It was scary and exciting as I'm learning something new.
The first trailer towing experience was bit too long, as I had to tow the trailer for aroudn 30kms in Chennai's peak hour traffic. Unfortunately I had to drive the jeep with trailer during office close time and got stuck in the traffic. The issue came when I wanted to reverse the trailer, woah.. no way I could do the trailer goes on it's own path. I need to learn the tactics of driving the trailer now. Since I was not sure how to reverse the jeep with trailer finally I had to remove it from the hook and manually reverse then got it back to the jeep again.

The trailer has been dropped at my sand blasting unit, tomorrow morning the guys in the sandblasting workshop will do the required work for the trailer.

I hope to pick it up after 2-3 days as my office time realy prevents me going so far during week days.

Mahindra Classic - Engine water pump service

2009-02-14T11:24:00.000-08:00

Last week I observed sudden hike in thermal gauge, Initial investigation showed that the radiator water level was bit low, though I used radiator coolant I used bit water to top up the fluid level.

The same day again same over heating issue and water in the radiator was far lesser than what it suppose to be. I was suspecting the radiator and found no leak in it. Rushed to the mechanic and he said there is a leak in water pump and it requires attention. I got a brand new TVS Autolec water pump who incidentally the OE suppliers for Mahindra Vehicles.

Today we corrected the water pump issue by replacing with the newly acquired one. It was in a shocking state when we saw the water pump and most of the water pump body was damaged with corrosion and barely any metal wall was left over.

Picture of engine block after removal of the old pump.

Just for your comparison purpose here is the old and new water pumps next to each other.

This picture shows the engine with newly installed water pump.

Along with today's service, I did change the rear half gate handle, bit of house keeping work for the music system setup and Air-filter intake air hose.

I got some hint from fellow visitor and my references to the mechanic that the distinct sound from my Jeep may be from the Diesel pump nozzle and he urged me to check up before conducting any Engine work.

This is the first day I saw all the four friendly Jeeps came together to the garage, except Mad-Bull Ram who's jeep is parked next to my jeep in the above picture we three had a little chat on jeeps.

The two jeeps in the above picture are Vinod's and Samy's precious vehicles.

Indentifying Mahindra Classic

2009-01-30T01:42:00.000-08:00

There are so many queries about Jeeps, many folks turn to me asking for information about the Mahindra Classic. In fact many people think the word classic jeep is meant for the older jeeps. But the term Mahindra Classic is itself a product name and here is the information how to recognize a Mahindra Classic for those who wanted to own the precious and the last produced short wheel base Jeep in the world.

As many as people tried to fake the Classic model with Willys CJ3B, M&M CJ3B, M&M CJ340 and M&M CL340 (not a classic) by adding the stuffs to look like a original Mahindra Classic jeep.

Original classics are CL340 DP - Classic 4WD (Not CJ340)
Chassis number of CL340 DP/4WD starts with CL340DPCLS4....
Produced between year 1996 and 2000 (The first batch of CL340 DP/4WD (M&M Classic) rolled out in Q3 1996 and the last batch of CL340 DP/4WD was in Q2 2000, could be used in conjunction with the RC book)
Suspended pedals for gas, break and clutch (Other jeeps will have floor mounted system)
Front wheel got Disc break (I bet no other jeeps got prior to this)
1996 to 1997 models came with spokes wheels (Wire wheels) and then Alloy 96-99 Models came with spoke wheels, the alloy wheels were an option from 97-98.
Chrome plated 2 piece Front bull bar(actually the bull bar and cover to the bumper are 2 pieces not like the replicas)
Filmsy dash board with colorful indicator lights
Little wider track than CJ340s
Single lever 4WD operations with KMT-90 gearbox (Old jeeps got shafts for 4WD options plus one for normal gears)
Rear seat setup came with forward facing seats like Willys MB or CJ2A
A nicely designed roll over bar with a little bend towards the sky on the center of the middle pipe.
Seat belts on the rollover bar
Idling speed switch on the dash board
Right to left wiper arms
Plastic Rear spacers are bit wider than the MM540 type spacers (one on the read mudguard)
Front rear spacers with a carving for small side indicator (the smallest side indicator than in any jeep)
Originally availed Red, Black, White and Dark Metallic Green colors
Mesh(or insect shield) on the grill without a hole for bonnet knob (available for MM540)
Front tow hook on the right side
Side view mirrors (OVRM) setup from front of windshield with 4 screw mount each side, inside of the 4 wholes in windshield protected with a rectangle metal plate for extra support. (Not seen in any other CJ3B variants)
Extra Plastics for the location between fascia and the bumper with Mahindra written on it and neat plastic cover for the windshield joints.
Company fitted bucket seats
Ignition key on the steering column with steering lock
Lamda free wheeling hubs as seen in the Maruti Gypsy
Center mounted spare wheel brackets on the tail gate (all other Mahindra models to have it on one side of the door)
Three screw sun wiser attachment on the windshield like MM540
Servo assisted break operations (booster break)
The Emergency break or the Parking break on center of body tub between passenger and driver seats.
The air filter inside the engine compartment was fitted on the left side (passenger side) firewall, as to give space for the servo booster of break assembly in the right side (driver side), hence the air filter intake tube in Classic runs over the engine from left to right.
A prominent logo on the sides of bonnet saying “CLASSIC" and 4x4 on both the sides of rear of body tub
The diesel tank got a fancy cap which had 5 distinct circle kind of design and it was made in France
The diesel tank got a fibre cover to hide from under the passenger seat in the interior
Additional plastic corner covers for front and rear bumbers were made available as extra options from manufacturers
The hood (soft top) had a distinct model compare to other Mahindra vehicles, the model was almost as same to the Tiger top brand of USA. It had 2 piece metal frames one is static and one is foldable with 'Y' shape. The top was also came with soft door wich is not rollable (seen in the previous mahindra models), the doors have also got zipper top portion to look like window which could be rolled down.
The headlight of Mahindra Classic also got a grill which is not common in other Jeeps, it was added to the Jeep's face with 3 bolt nuts.

Allow me to take some time to post pictures for each point wherever possible to identify the Classic.

Thiruporur - mud drive OTR

2009-01-27T18:18:00.000-08:00

It's been some time now to write about a offroad that the Explorer had, though a week back I was in the Jawadhu and did the complete offroad in reverse, I didn't write about it as the blog is already seen many posts on Jawadhu front.
Last weekend We had a small OTR(25 Jan 09), It was in the afternoon which started at about 3 p.m and ended by 8.30 p.m We guys met at sleepy looking hotel in the end of IT corridor a place called hotel Harish in Padur on Old Mahabalipuram Road in Chennai. After all of us assembled the convoy of Jeeps headed to Thiruporur the same location chosen for the offroad this weekend, it was a new terrain for me but not for the other Jeepers who were with me.We had couple of Jeeps, Gypsies and Mitsubishi L200 as part of the convoy. After a few kilometers of on road drive, we got into the offroad terrain which splits through a village. We drove through a forest which had lots of eucalyptus trees and bushes. The terrain became wet loose soil one and the 4WD was engaged from there on.

It was quite a tough drive and I was following my friend Vinod who stopped few times to click pictures. He had come with his friend's family hence many more pauses to click pictures ;-). Hmmm I could hear my Explorer wanted me to take him ahead of my friend's jeep and finally it happen to that way.
After passing through the water channel and loose mud we got to stop as the there was a canal which is bit deep and too narrow for crossing, so we split into three groups and started searching for other ways to cross the place. This is where the problem happen to me, I was trying to climb a soft and steep mud wall right from the water channel and failed to achieve, hence I wanted move to the other location but got stuck big time.

As said here I had to reverse instead took a challenge of crossing the rut perpendicular with a steep mud wall. god stuck royally. As you can see from the picture below the later maneuvers took the jeep to the edge of the mud wall. bushes made the headway impossible, and the branch of the tree which was on the mud wall damaged my soft top and lost the front parking lights already. I had to roll the windscreen down and remove the top to prevent any further damage. In the process finally with the help of a Gypsy without any additional damaged I came out but couldn't prevent damaging the tail lamps.
During the scene we used Manpower to rescue another gypsy which got stuck where no other vehicle could reverse and position itself. The trail was amazing and it really a feist for our four wheel drive enabled vehicles.
After couple of hours of offroad, we were intend to get out of the trail through a lake bund. By the time my turn came it was already bit late evening and the dawn is out of the sky. I switched on the head lamps and guys shouted at me to switch it off as to save some power. The Explorer is without doubt one of the best performing Short Wheel Base jeep. I faced least problem in clearing the bund though this activity required some tough maneuvering. The bund lead us to crossing the embankment through fields to the main road.
As a whole it was another great Jeeping Weekend, and the week started with restoring the damaged that was caused to my Jeep. By the time when I was writing this blog the jeep is all set ready with new lamp assembly and stitched soft top.

Mahindra Classic - Major Service

2008-12-28T21:56:00.000-08:00

After many successful OTRs and Rescue operations during the last flood that happen in Velachery, Chennai due to the rain the Jeep was crying for attention.

I really thank to my jeep for saving us during the last rainfall, our house was flooded with 5 and half foot water and the only vehicle to take us out from the flood is the Mahindra Classic. It did really heroic action during the critical time.

Right from water mixed oil in the differential to broke components under body, I decided to address all of them at one stretch. So my future offroad plans will not have any interruption at the last minute.

At first we stripped the Jeep to an extend to see what are all the stuffs required attention

After careful investigation, found

1. Differential oil and Gear oil needs to be changed
2. Steering components (most of the joints) needs major replacements
3. Break career plate, cylinders, oil, disc break pads & caliper, drum break shoes and converter TC valve all required to be changed.
4. The suspension also been worked out so I will have comfort drive again
5. In addition few engine related items such as shields and valve door washers are also required attention.Hence we decided to change them all including king pin bearings and few other components. I hope to see the music system will have a change too in the Jeep.
My mechanic's team is fully aware of the importance that I have in my jeep hence they do have careful lookout of individual components for any attention that is required. I'm guessing the jeep will be delivered in a day or two before I make my debut drive after service.

Ubbalamadugu forest exploration

2008-11-16T07:42:00.000-08:00

Friends, This time I'm starting the blog with a video clip. Press the play button to watch my TADA forest exploration fun.
It was another off the road weekend, this time some friends joined together to explore the TADA aka Ubbalamadugu (Remember my TADA stunt post) little deeper than the last visit which happened to be solo offroading.The trip turned out as good as a picnic as families joined for the off road event. One of the families brought us delicious food for the lunch.We had enough water crossing and steep incline and decline route on boulders this time; the vehicles ranged from Mahindra CJ340 to Toyota Land Cruiser.

In one of the streams, I had to really go parallel with the CJ340, oooh! I wish I had removed my soft top and gone open.

While we were resting after couple of obstacles, I found a giant sized butterfly sitting just next to me.

I wanted him to flip his colorful wings, but no help even after long waiting.

In another steep incline I got to go really slow, however the engine breaking idea of Diesel engine helped me a lot.

Most of the day's activities were around many water bodies in the forest ; hence lots of water crossing.

For me it was not so difficult, as I did my exploration to an extent in my last visit at the same spot.

While returning we were traveling through a green paddy fields.It was a great experience driving in the middle of paddy fields. One of the Gypsys was running out of coolant and the engine stopped at one stage . We had to do little cooling treatment before we could start the vehicle. The picture below was taken while we were fixing the engine temperature issue.

Given a chance, I wish to award the man of the day title to Vivek who co-ordinated with all of us and did a great Jeeping today with the CJ340 he drove.

Anyway it was gala time today as we all got our hands put on the rugged toys.

RECCE one at Jawadhu

2008-11-09T22:24:00.000-08:00

It’s been my dream to do OTR in a forest, but doing it in a forest is no easy task. First of all, no one is clear on which is the right path and what may be the obstacles.After my couple of visits to Jawadhu Hills, I called the folks in Jeep Thrills for a RECCE trip. Thought it took some time to materialize but we could succeed it by doing nearly a 50kms offroad trail.

Bad roads, No road, Off road, Slushy path, Water crossing, Boulder crawling – we did all these during the RECCE.
At around 6 AM, my jeep roared from Chennai after couple of my calls to fellow Jeepers Dr. Jones from Kanchipuram and Rajmohan from Trichy. Another talkative friend Satheesh also came in my jeep to keep me some company in the long 230kms highway drive ;-)

We had breakfast at Vandavasi and Lunch at Jamunamaruthur & in between we had highway and offroad exercises. After fueling the monster jeeps our trip started climbing up hills in Jawadhu. With 2 short breaks for smoke and discussing about our jeep building histories our third stop was directly on the offroad terrain. Jawadhu hills has around 270 mountain villages, people in these villages needs to walk for 4kms to 20kms to reach the main road.

We rolled up our stuffs in the jeep to visit one of the villages that is 9kms from the main road, but people said only by walk we could reach them. But we had our machine and started rolling the wheels down to the path, and with in seconds the path was covered with boulders going steep into the jungle route.
We made some preliminary plans and each one of us started crossing the boulders in dark jungle and hurray first success was written on the jungle.

Dr. Jones did some extra stunts by driving the prowler in reverse climb. I saw a spark of interest in the tribal people’s eyes who gathered to watch our offroad activities. I think this is the first time they have seen an automotive piece coming near to their abode.

The next obstacle we found in our way towards the village (Patraikadu) was couple of steep turns and slushy land.. ohhh Rajmohan crossed it first with his MM540, we witnessed his NDMS doing action perfectly.The entire route was too good; if there would have been rain prior to our trip I’m sure the OTR would have been more thrilling too. After some times we reached the village and U turned to face the challenges we experienced again, however during the slush action in the return trip I felt that my jeep started loosing power. He he he but no cause for worries… It was my mistake, as I was not driving it in the correct gear.
After a while we reached the guesthouse and got appreciation from the jeepers for the accomodation. It was clean and neat; we took the air-conditioned accommodation and had our lunch (Parathas and Chicken Curry). Jeepers seemed totally tired after the long drive and offroad and they took quick nap. Then in the evening we went to the waterfalls discussing about interesting jungle experiences we had ourselves. My friend Satheesh made the trip hilarious by his questions and face expressions in the jungle.

We did take a break near the waterfalls with moon light reflecting on the water, four people inside the thick jungle in a late evening with moon light enjoying the water falls sound.. We really had our fun

Our return to the room directly pushed us with couple of bottle beers and dinner, oh yeah long discussions then we hit the bed. (End of Day one)

The day two started a little delay as we had our break fast late. Then our stop for shopping wild honey pushed us 3 hours late. Dr. Jones also got some tow cable from the village shop for the jeep. Though we couldn’t get the jack fruit as this is not the season, we kept moving towards Athipet village from where our actual bad road travel towards Mettupattu village initiated. It was really struggling roads and in between we reached the mouth of Cheiyar River where we did our river crossing and fun filled jeep stunts. An ex-postmaster from Jamunamaruthur fell in lust with the jeep after watching Rajmohan’s machine playing in the river.
Oh… god I did my attempt to get into the river’s same path as others but the riverbed got digged little deeper after two jeeps crossed hence my attempt directed me to hit the river bed with my front bumper. Dr. Jones’s Prowler with his newly purchased tow cable came in first hand help. Effortlessly in a moment I was out from the struggle. Later I took another easy way to play in the water and came back to the road.Our trip from here towards Mettupattu was in the roads of beautiful scenic mountain villages and we really enjoyed the drive. In the whole trip, I didn’t get my eyes crying of stress as we witnessed various shades of green everywhere.
After crossing couple of villages we started seeing the roads going worse and worsen leading a great of jungle travel. On the way we found a tree… Opps more than 30 ft circumference standing along with path, Dr.Jones marked our presence in the tree by sculpting “JEEP THRILLS” with an axe.
That’s all our somewhat comfortable drive the rest of our day was filled with boulder and boulders crushing our energy very fast as we really lost the lunch time. After 6 hours in the 42kms stretch finally we reached the downside of the Jawadhu Hills which is called Paramananthal Village. The final 14kms stretch was in the jungle and deep slopes in our sideways showing a dark avenue of trees.
We drove towards Chengam town and picked up our Briyanis and Mutton towards my farm where we had our lunch with tender coconuts for our dehydrated tongue.
After lunch at 6:00 pm we started our travel towards home and we expressed farewell to each other and the RECCE 1 was written as success in our books.

Here is the Video of Jawadhu Hills RECCE

Bathing Mahindra Classic

2008-11-03T09:07:00.001-08:00

I haven't done water wash of the jeep after it was restored. About two weeks back I have done a slush offroad with folks from Chennai. Though the terrain was too good, I missed my opportunity to click pictures that stopped my writing blogs about my trip. Since it was a slush offroad, loads of mud caught into my jeep's under body and badly wanted to do a water wash, but subsequent rain made the whole Chennai city into a larger water pool, so didn't give bath to the Jeep.

Last week Thursday turned out to be a perfect day after the rain for water wash.
I could manage to spray some oil in the under body portion of my jeep, I hope that will prevent any rust formation as it prevents the metal from directly exposed to the moisture and salty air (I stay close to sea shore.)

What else, the water service also paved way for greasing the Jeeps parts, hmmm I really felt the changes in the last weekend trip.
Last weekend was a great JEEP weekend, as I drove the jeep for about 750kms out of which about 20kms were offroading at my farm.

Mahindra Classic - Service record

2008-10-18T10:29:00.000-07:00

After the TADA incident, I'm very much convinced to fix the clutch issue. The issue is that the clutch arm under the body got worn out and requires replacement.I also noticed some minor wobbling whenever I hit something on the road while speeding up the jeep. So my mechanic observed couple of things that requires attention. Today I did the purchase of spare parts to fix the problems. By next week the jeeps minor issues will be fixed.

TADA Stunt - Mahindra Classic

2008-09-28T23:26:00.000-07:00

Indian Jeepers pride Mahindra Classic and me had a great experience yesterday in TADA. I was with Chennai Photography Club (CPC) guys for photo trip in TADA.After crossing the forest check/toll post for entry fees, we were driving in 1 jeep and 2 cars(SX4 and WaganR). As a jeep enthusiastic, I had all my plans set for an solo offroad done at the forest range. While everyone was in cars, we four guys accompanied in the jeep already got to know the essence of open top jeep.

I noticed a civil work to create new water channel on the way towards parking lot in TADA. The canal was around 25-30ft deeper and they cut the water channel live V shape. One side of the V cut was filled with loose soil and other side was white colored rocks. That is what attracted me, I remember the lessons learned during my Kelambakkam trip with Jeep Thrills. So, no more further thinking and my jeep was all set descending into the deep channel, The people around thought it was accident and I had a big crowd around. Some people said(thought?) it was some shooting as all of my CPC team guys had cameras.
Jeep went well on the descending path which was loose soil, after which the water crossing then I have to climb up on the other side, you know what it was too steep.. Once I was really afraid if I can make it, also none from the group know offroading fundas(otherwise I don't have option). Somehow I made my mind and started climbing upwards. once during the climb in a place my tyres started spinning hence I put on reverse gear and went little back and came up again and again three times and the third time the jeep picked up and I was on the right movement. Ohhh my luck didn't stay with me for very long when my jeep about to reach to top the clutch was suddenly became dead and I was totally out of the clutch but managed to reach the top. I'm in the forest side without clutch and no one can help.. I couldn't figure out the issue on that location. hmmm so I made my mind to try the real hard offroading now steep descending and ascending without clutch. The whole team started seeing the scene with climax effect.. If I can't make it, the jeep will be left in the water channel till I can bring a mechanic from 20kms outside the location.
I put the jeep in 4WD low and 1st gear, and cranked the engine and started moving, Listen carefully I just engaged the gears before starting the engine and started moving down no issues and everything went well on the descend path. While crossing the water channel I noticed the loose soil side near the water channel was too high for the tyre to climb and I had no clutch, so no much time to invent alternate path. so I rushed the jeep accelerator, the wheel started spinning in the loose soil and water made my way to get traction, wow jeep is on the ascending path.. I felt the thrill now and started pushing the acceleration little high. Probably now that is made a negative effect as the wheels started spinning on the climb, The spinning wheels made me go down on the back side in sliding mode, I was about to hit the water with the jeep and before the last second again the wheels gained the traction and started going upwards Ohhhhhh ooooohhh jeep is now going smooth and reached the top.

After coming up.. using the same technique I drove the jeep towards the parking lot and you know what, I became half mechanic with one more mechanical engineer's assistance (who was part of our CPC). We both went under the jeep finding the issue and found the yoke rod that is fitted between gearbox and the chase rail lost the nut and it was hanging. That is the issue, as i tcouldn't provide required tension to the clutch assembly to work. So we tried ourselves to fix the issue and hurray .. We were on the success path after an hour long under body mechanical work.

There were lots of videos and photos of my TADA offroading taken by folks traveled with us, as I was driving all the time, picture and videos were made out my CPC friend's cameras, will update the pictures and videos as soon as getting the emails from my friends.

Have Fun!

Mahindra Classic - Tools collection

2008-07-26T23:17:00.000-07:00

Time is running like the light, the most awaited offroad challenges that I have been waiting for the past three years are nearing soon. I asked myself and the offroading related clubs that I'm associated and got some answers. Hence the whole exercise of building the essential, enhancement and recovery tools for offroad challenges. Do i need a binacular yes who knows if i visit a good green hilly side, won't I need a binacular? (Never mind I have the Nikon Binacular as part of my Jeep accessories)
The first and and for most thing is my mandatory tool kit as suggested in the user manual of the Mahindra Classic. (You all have noticed that I have already stated in my previous blog about the hydraulic jack, hence I have not included in here but it is part of my jeep)
Since it is a jeep anytime anything can happen ;-) hence I wish I shouldn't stand in the dark night or on a highway without few things. Classified them here, A head strap attached tourch, a blinking flash light, reflective jacket, work glows, a hazard flag and compass. (A GPS device and maps are also found and it will be show cased when I start using them in the jeep as currently I don't find any map suitable for all the land in India)The mini axe and shawl tool is the import from Singapore. It could be folded and put it on the waist belt with the cover provided. (see the green colored cover under the tool)I found it when I was visiting a trekking accessories supplier. I remembered in my last quarry offroad where I had to switch off the engine due to a hindrance created by a plant with lots of needle like stem. I had to protect myself from the needles while handling the open top jeep with windshield folded.Hence a mini axe and few cutting objects are necessary on offroad ground also a shawl to do something on the ground under the tyre.Now comes another thing which I thought I need when I was first floated on the beach sand. I heard my jeep mates saying I should deflate the tyre to get broader surface to float on the sand. I asked myself what happens when I come out of the sand ? will the deflated tyres help me reach my destination, who knows? running the deflated tyre on the hard surface may cause fatal to the tyres. So needed something handy to inflate whenever required. Thus, I asked my friend who was returning from US of A to bring me a good inflator that could work in the jeep's 12v adaptor.

I'm not so fit and confidence to use hand or foot pump to inflate the tyre, so the electrical compact compressor with 250psi capacity. It took around 15mins to fill my empty tyre to fully inflated one. The electrical wire is length enough to pull the box around the 5 wheels in the jeep(including stepney). The box is too good as the wire and hose are tied around the compressor box.

I still need to buy a hand tow strap with hooks attached (Currently I'm using a heavy steel cable but looking for something lightweight), A highlift Jack, A good strong tool box and A Winch to fill up the whole recovery kit. Hmmm they are big budget grabbers so will take some time to bring them under the jeep's hood.

Mahindra Classic - Service for better driving

2008-07-23T23:32:00.000-07:00

Its been some times since I started observing few issues from the Jeep for settling down. I have categorized them in 3 options and few parts got changed for this categories too.

1. Enhancement

Since the wiper blade was keep on slipping during the rain, I found the factory fitted type milling on the wiper assembly where the Wiper arm connects got issue. Got is replaced with the ones comes with HM Ambassador cars. They are screw tightened and gives better grip to the arm.

2. Repair work for Security

I had issue with the oil circulation pump which comes in the rear side of the alternator which caused oil leak in the air vacuum rubber tube and subsequently spoiled my new break booster. Also noticed oil leak in the break booster MC cylinder stem. Already my break pedals got stiffer due to this issue, so i have replaced the whole booster kit with a brand new one.

3. Riding comfort

As I have seen the steering play and minor shake while applying break found few issues in the steering as one of the nut was missing and got replaced. The shaky ride during break is due to some issue with the tie-rod ends. So the original RANE steering tie-rod ends were replaced too.

Mahindra Classic - Farm and Forest safari

2008-06-29T21:33:00.000-07:00

Last week turned out to be a safari week to me my jeep. The trip to my farm ignited an idea to my mind for visiting the “Jawadhu Hills”. The Mango farm which I have is in the western side of the hills and is a scenic place for the eyes. So just to spend my weekends I geared up in my Jeep to the farm.Since it was a cloudy day there were lighting and thunderstorm hitting the area, while I was looking at the scenic place, all of sudden a lightning attacked a green palm tree and the next second the tree was burn to death. Look at the video below

Ever since I landed in the farm, my mind was set on the hills and its thick forest in the background. Though my farm is right under the hills but the motorable path to the hill top is around 100+ kilometers from my farm, but the passion to explore the hills boosted me to drive all the way 100kms to the motorable road.
It was really nice view on the mountain roads with lots of hair pin bends and scenic green fields everywhere. The Jawadhu Hills are a famous mountain in the eastern guards and there are few tourist attractions here along with an Asia’s largest observatory, it is located in a village called Kavalur in Jawadhu Hills... The main village in the hills is called “Jamuna Maruthur”.Since it is a forest with lots of sandel wood there is couple of government offices such as Forest department office, Block Development office, etc found in this village.Last weekend also seems to be a kodai festival for the villages here; hence all the surrounding villagers came together in Jamuna Maruthur. The most attracted event was the 50CC bike race; I had a terrible time with the small bikes with altered exhausts to produce more sound so the villagers feel as if to drive a huge Bike.
The hill roads often get some small road branches that are taking path to the small mountain villages.
The tribal people staying in mountains are very friends and their life style is totally different than ours.
The Jawadhu hills got animals like “Leopard”, “Elephant”, “Fox”, “Python”, “Beer” and “Deer” etc. But none of them could be spotted on the road side as this forest is too thick and huge. Also the Jawadhu hills are famous for delicious Jack fruits, Bamboo honey and Tamarind. I enjoyed my whole trip with the jack fruit dipped in the wild honey…wah what a taste.My trip with in the hills to the Vainu Pappu Observatory became a failure as the observatory opens to public only on Saturdays.
The trip was so much of fun driving back in the down ways of forest surround hill roads.

Mahindra Classic : Offroad @ Quarry

2008-06-22T08:59:00.001-07:00

Today another great day with Mahindra Classic, a real offroad session organized by the local Jeeper's club called Jeep Thills. As the name says the club got lots of thrilling activities to feed the adventure hungry jeeps.
We have gone to a quarry where the blue metals were extracted from exploding huge hills. Basically these quarries use dynamites to explosion and break the stones that could be used in the crusher machine to produce blue metals used in the civil industry. We had real adventures offroad session today to climbing up hills and going down with a loose soil, it was a wow experience.

Since the whole things was in the hills we got lots of opportunity to testify the jeep's capabilities. Altast for all of us, it is a wow thing with the jeep.
The quarry was drilled so deep about 100-200 meters deep and we went uphills to watchout the whole quarry in our jeep. It was an awesom experience to trek with jeeps.. lol. See in the below picture and spot the jeep that I'm driving.
For those automobile enthusiastic personals who visit my page, I request you to visit my Yamaha RD350 restoration blog in this url: http://yamaha-rd-350.blogspot.com

Mahindra Classic - Offroad @ clay land

2008-06-15T02:38:00.000-07:00

I could hear my explorer crying yesterday night, I know the reason too. looked like explorer wanted to do some serious offroading trial. From hardcore offroader perspective it is my jeep's right to go for offroading. Since there is no immediate company to come with me for a trial, I had to try with the road work debris to test drive the jeep.
Then I took the jeep to Velachery marsh land. This is the place behind Pallikaranai marsh and near to the Velachery MRTS. Wow, it was amazing and I was totally thrilled with my explorer.
In a particular situation were were got caught into the clay but it was only for few mins hard try and explorer could find its way out. No one to push or pull but the four wheels!

Mahindra Classic - Highway cruising

2008-05-28T09:49:00.000-07:00

I was visiting my home town(Tiruvannamalai) last week and here are some pics., see the hill in the background which is the holy hill for Hindus and considered as Lord Siva.I took in the highway which goes through the rural India.
This trip back to my hometown also helped me filling the steering wheel with the jeep theme color.
This is how a jeeper feels in Mahindra Classic at highways, play and enjoy the video here.

Mahindra Classic - Offroad @ Beach

2008-05-17T08:17:00.000-07:00

Here is one of the offroad pictures taken during first sand floating session.

Chennai is too hot during summer, this is how jeeps get relaxed!!Proud owner with the machine

Lonely warrior
~~~Fortune Friends~~~
At the end of my OTR the Future Sailor, pointing me the path to go on road...... My son Adhava (one and half year old) who is always excited with jeeps and I quote him as saying "my compass".

Mahindra Classic - Driving comfort

2008-04-29T09:34:00.001-07:00

Last week jeep had few updates for comfort driving. Got the four shock absorbers replaced, while replacing the shock absorbers found the rear wheel had a oil leak. The root cause is being identified as damaged rear wheel hub and bearing, it was long process to get things right, as I had also replaced the rear wheel hub and other packing items such as oil seal and sims. After doing the break and shock absorbers, I also found the leaf spring bush was damaged due to prolonged use. Hence the whole (front and rear)shakle kit was replaced with the ones comes with nipple for grease application.

The leafs in the spring also got corrected for its positioning with each components in the leafspring assembly of both front and rear pairs. I had to replace one of the main leaf as it was already broke and hanging on the 2nd lever.

Folks in Jeep Thrills gave me this idea of nippled shakle kit.

The driving comfortablity was greatly improved to an extent after concluding the above listed work. Since I couldn't find a wire wheel for the spare wheel on the jeep, I took Maruti Gypsy rim as spare and cover it with Mahindra stepney cover to make it look better. ;-)

Wheels are Aligned - Mahindra CL 340 DP

2008-04-25T05:41:00.000-07:00

After a notable tyre depreciation mark, I have taken the jeep to the computer assisted 3D wheel alignment center. Though they could correct only the tow part of wheel alignment with strighting the steering wheel.

Got a chance to look at the underchase parts in my classic as the jeep was lifted with the power lift.

Ofcourse, the wheel alignment finally corrected the tight steering wheel issue and now I can easily turn around with my jeep. Apart free turn of steering my next issue to address goes with the break as one of my jeep's wheel get jammed as and when I press the break pedal tightly causing skid over the road. Need to visit the garage to fix the issue as it invovles great risk with the break.

Naming ceremony - Explorer

2008-04-25T05:35:00.000-07:00

The re-born boy Mr.Mahindra Classic has also undergone a naming ceremony, As I have officially named my Jeep as Explorer.

The name in reflectors sticked on the windshield and looks awesom.

Show Off - Mahindra Classic

2008-04-16T21:47:00.000-07:00

The day one experience in my office with Mahindra Classic is really amazing, as almost all the vivid automobile enthusiastic reached me asking for details of the Jeep. Even some of them wondered if I spent huge budget to bring it to this condition (Not their mistake as they compare the work with modern car's maintenance cost).

Driving to office in Classic is not so easy as modern cars but the impression I create on the road is amazing experience. I could see the crowd in local transport buses, two wheelers, Drivers of other cars apply break to see me. My parking lot in office was already surrounded by the smokers who pass by every time, the security guards stopped asking me the ID as they recognize me with my jeep ;-) he he he (Unique feature)
I have not really engaged the 4WD in my Jeep though few tests proved it in good working state, will make an attempt in the near future. The spare wheel, exhaust pipe and side view mirror are the last pending work that I need to concentrate as of now, hope to get it done very soon.

Tyres for Mahindra Classic

2008-04-14T19:53:00.000-07:00

The first run in chennai for my mahindra classic is to the tyre shop as I have to do that in high priority to save the wheels and suspensions of the jeep.215/75 R15 the tyre size of Mahindra Classic was been the last work to complete on the Classic, along side the windshield also changed yesterday. The below picture shows the old tyre with black colored wire wheels. I need to avoid the chrome plating work as the guys in garage advised me not to do, because the alignment of spokes may get spoiled if i do that. So simply colored it with black.
While I was looking out for options, I made my mind with Haida (Made in China) tyres which had a good button type for both off and on road. This tyre is also worked out economically compare to its Indian/US counter parts.Now the jeep looks appealing with the new tyre, here is the picture of fitted tyre. All the 4 wheels wear a new shoe now.

Aspecious Ocasion

2008-04-13T20:39:00.000-07:00

The Tamil new year's turned out to be the aspecious day for the delivery of the jeep from garage, though some more work needs to be done in chennai.

The jeep was taken for a Pooja in Tiruvannamalai temple and short run followed in the night.

Today I took the jeep from Tiruvannamalai to Chennai around 200kms distance, without windshield I really felt the wind though the soft top was on.

During the first run to chennai I had a short break and picture is for your persual.

Cosmetic operations

2008-04-13T20:23:00.000-07:00

Jeep has reached a state where the final cosmetic touch-up of 2K painting, Now the jeep really looks cool with hot chilli red color.

Last week was one of the busiest week(end) for the garage guy working day and night for the delivery of the jeep.

The liner also done a good job making a good seats for the jeep, they are sexy looking and as usual the crew has fitted it nicely. The liner also made a verygood floor mat and thermocol lining both inside the engine compartment and under the dash board to reduce cabin heat.

Sunday was also turned to be a good day as we have also fitted the soft top and its frame, to say the jeep has almost reached the state of final work. Though I need to change the tyres and fit new windshield glass etc.

Mechanical works - Mahindra Classic

2008-03-30T10:20:00.001-07:00

The base red (orange?) color has been painted on the jeep's outer body, only two more coats of red will be applied on the base color after mechanical and electrical work. To move the jeep from Body workshop to Mechanic's garage some of the basic mechanical work has been completed. as another milestone in the restoration work that is today the jeep has seen its re-entry into the mechanical workshop.
As a parallel work, last week I bought two color Italian leather fabric for the lining work. The liner is making a special seat cover for the jeep. Here in the below picture see the liner making the red and black themed seat for the Mahindra Classic.

In the paint crew's hand

2008-03-23T11:17:00.000-07:00

The image is exactly what I meant by rubbing work. The painter used water with emery paper to rub and get the surface as he needed.
The whole painter crew was fully involved in each and every corner of the Jeep with rubbing work.
Here is how the jeep looked after complete rubbing on the NC putty. Actually speaking I was seeing brown, ivory and grey shades here and there after the rubbing. Painter was stating this is how the uneven surface getting leveled for the next course of action.
After making the jeep to this state, the crew applied Deco-pu surfacer mixed with Deco-pu hardener and Thiner. This process had dealt with the air gun painting machine.
Here is how the final state of surfacer applied jeep's look in the below picture.

After completion of this process is what the actual coloring of the jeep. However there is a patch and fix work for the minute surface issues on this stage. That makes the jeep to get ready for the first coat of painting. The surfacer will harden the primer, metal paste and putty applied surface for the painting process.

Metal paste work - CL340 DP

2008-03-23T10:56:00.000-07:00

The picture here shows the past week's metal paste work. Actually the painter has rubbed all the metal paste neatly to get a good shaped rough surface.
If you remember my last post about the tailgate work by the tinker, I recall it here with this picture for your review.
This was the condition I saw the jeep when I've visited during the last weekend.
During the weekend, one day the climate was not suitable for the painting or related work, the town(Tiruvannamalai) where the work is going had rain fall and it was a cloudy day. So we were force to loose a day for the nature's demand.Later we applied NC putty and again the rubbing work to make the surface neat and shine. See it in the below picture.
After the whole body applied with NC putty the Jeep looked as it shown in the picture below

Electrical equipments - CL340 DP

2008-03-19T08:44:00.000-07:00

As I didn't visit the garage last week, I was so much involved in finding a tyre and disc deal for the Mahindra Classic jeep but still didn't come to a conclusion. There were good deals from China and Indonesian made all terrain capable tyres.

The whole week was so much occupied finding the remaining stuffs for the jeep and I managed to find the steering lock with ignition key set and few other electrical items.
In the above picture you can see the following items:

set of Roots Horn
9 in one melody relay for the horn
FM Antena
Parking break auto light switch
Cigar lighter
Ignition key with Steering lock
Diesel logo for the tank mouth (non electrical)

End of Body repair - Mahindra Classic

2008-03-19T08:28:00.000-07:00

The rear tail gate & windshield have been completely tinkered to get it's original state. I was searching for a spare tailgate and I couldn't source, initially in a dilemma to do the tinker work but after the professional touch on the tailgate I'm so confident that the tailgate is as like as the stock one.

In addition to the above two parts, the front grill and radiator holders are also completely done and they are up to their original state. As I could source the OE muffler (The equipment used to reduce the noise emitted from exhaust pipe), the JEEP is going to be a silent macho machine, isn't that interesting. The picture here shows my son holding the newly purchased muffler.

As I couldn't visit the garage last week there was a gap in the blog about status update. Though I couldn't post the pictures, the metal pasting work has been completed and the surface of the jeep looks neat. The new body bolts and the rubberized body bed also been installed properly.

It’s great day - Mahindra Classic

2008-03-06T08:26:00.000-08:00

Yet another milestone in my restoration process, the mechanical and rare parts were collected successfully. Look at the below picture which will show a partial list of latest spare parts.

I’ve managed to source the OE fuel tank, soft-top, soft doors & its aluminum frame, rear seat, break-booster, clutch cable, front bumper mahindra plate, motorized windshield washer kit and miscellaneous gasket rubbers.

It was my long pending list of must have stuffs for my classic jeep. A friend of mine suggested few good resources where I could source all of these items in Mumbai & Chennai (Wait for an index of all the resources in the forth coming blog, as I’m still procuring items for the jeep).

[Above picture shows the soft-top and fittings.] Almost cosmetic collections of cosmetic spares are over and now I’m in the verge of correcting the mechanical issues. The coming week will be painting week and jeep will go for massive paint process.

Painting and the mechanical work will progress simultaneously and the smaller items needed to be fixed before the final touch-up.

Windshield washer kit, it was not so tough to source this as the latest Mahindra Bolero also uses the same old model used in Mahindra Classic. Kudos to Mahindra for continuing such spares in modern utility vechicles.

Mahindra CL340 DP chase and underbody work

2008-03-02T08:13:00.000-08:00

At last the body tub has been removed out from the chase, there were couple of folks were engaged on the duty.

This activity pushed the jeep to next level as the major tinkering work has been completed. The only part left with the tinker is to straighten the uneven surface with file-hammer and applying metal paste on the tinkered areas.
While the tinker working on the body tub's bottom part, the painter also started cleaning the chase for anti-corrosive treatment. We found lots of accumulated mud on the engine and gear box area due to the greasy nature. Hence cleaned the whole chase and engine with petrol and soap water.
The below picture shows the Mahindra Classic's chase mounted with engine and gearbox. The rest of the activities on the jeep will be building the components from this stage.

Hydraulic Jack for Mahindra Classic

2008-02-25T08:11:00.000-08:00

Folks, This items has got no direct relation to my Mahindra Classic restoration project but It is a essential tool for person like me with a Jeep(apologies for being too lazy not being able to manage the manual jack), This item attracted me while browsing for a better tyres. I have taken this hydraulic bottle jack as to find a permanent place in my jeep, probably need to make some locking facility somewhere in the body tub for this jack with tinker's assistance.The Hydraulic Jack which can lift upto 5Ton weight, If you looked at my previous blog about the spares that I have collected you would have noticed another Jack which is fully manual. I may sell the other one for a good deal if someone is interested.

The above picture shows my 3 year old son with lifted height of the jack, the operations of the jack is so easier as my son can manage himself, though it is not a children toy.

Tinkering on the flow...

2008-02-24T07:58:00.000-08:00

Hmmm... The jeep is reached a major restoration part in the past week, almost much of the rusted body surfaces have been replaced with a new anti-corrosion(coated) steel sheets of 18 Imperial Gauge thickness (1.22 mm).
The work is on the runway speed and the whole body work team is motivated to achieve a optimum performance in the restoration project. You know what my kid Adithya is the supervisor for the project, he never gets away from the work area & fully addicted to the jeep's restoration.

As a result of last week's work, we could restore the platform to its original like condition. if you look at the below picture, the embossed lines in the rear platform are manually done by the chief Tinker.

We have plans to move the Body tub away from the chase in this week for treating under body surfaces with Tinker and Painting solutions.

Ready for Operation theater

2008-02-13T08:00:00.000-08:00

Here is how my Classic getting ready for operation theater.
The pictures here shows the jeep after removal of dash board, electricals and seats. The platform is the major part that will be replaced during the operation.I think this is the time when the wiper motor can see light in it's life. See where is it fixed, this is the original fitting of viper motor the relay that goes from viper motor connects the viper blades in the external body.

Mahindra Classic - Pharmacy

2008-02-13T07:47:00.000-08:00

As per my Mahindra claasic's dermatologist, my purchase of colorful pharmaceuticals (Paint items) got completed in Pondichery (Really got a good deal). The paint, surface treatment items, anti corrosive itmes, primer, hardner, clear and thiner are the couple of items procured. Except few the important items were from the company ICI and the paint branded 2K.
Above are the paints purchased from Pondichery.

Berger paint's anti corrosive enamel (black)paint and primer will be used for chassis and under body treatment. These 2 items are actually industrial paints, as suggested by a painting expert taking it for my Classic's skin work.
You can see from the above picture showcasing medical crew (Painter & Electrician) removing the electricals and applying oil primer to the bare metal body(is to avoid further rusting on the exteriors).

Mahindra CL 340 DP - Parts Catalogue

2008-02-09T03:51:00.000-08:00

Today I got another important stuff which helps me to find the right spares. Yes. It is the Mahindra's original Parts Catalogue. I'm lucky enough to get to see the original book from one of the spare distributor, you know what he accepted my request for photocopying the book. Life is little easy now, I found the exact list of spares in it.
Above picture shows the original parts catalogue and the photocopy.
This book helped me identifying the tow hook and bonnet rubbers from the distributor. He says he will inquire and let me know about other part numbers I was ordering to him. Apart from the two items, I managed to grab some auto roller seat belts from the second hand market. Is it not good to see the jeep with seat belts ? Basically I need it for sure as my kids love to travel in the awesome vehicle (JEEP), after all security first ;-)

Spares Cond...

2008-02-06T07:14:00.000-08:00

Here comes my next bunch of spares, lucky enough to get the 2nd batch of spares odered. However still I couldn't source the wire wheels (though the dealer says it is in the transit), softop and frames.

What you have seen in the above picture are:

Rear spacers (comes above the mudguard)
Tail lamp assembly
Front Indicator assembly
Side indicators (Compromise! as I couldn't get the ones of Classic, I have made my mind to use the MM540's side indicators. There will a minor tinkering work to fit this on the mudguard.)
Wiper-water spray nozzles.
Internal rear view mirror
Stearing Wheel (One that is used in Mahindra Bolero, Actually there is no difference expect the work mahindra used in classic and the mahindra's logo in Bolero stearing wheel.)
Set of bulbs
Parking light assembly
two way switch
Mud flaps for front and rear

Look at the below picture that shows the side indicators of MM540 and the water nozzle for wiper. Choosen this for making myself safe with the unavailability of Classic's side indicators.

The stearing wheel of bolero with Mahindra's new logo. (Classic's original stearing wheel is in the same size but instead of logo there was a Mahindra script.)

Classic Spares

2008-02-01T22:31:00.000-08:00

The difficult part of the project is getting all the right spares, I could manage to get some relevant spares for the jeep. However there are still problems in many areas. wherever there is no on the stock spares, I have decided to fabricate them.

Above picture shows the first part of spares I procured for the jeep. You can see the piano switch which is not the orginal Classic's piano switch. This one is bigger than the original as the latest jeeps got this type(Probably here I made a compromise.).

List of materials procured:

Front grill mesh
Headlight reflectors
Monograms
Piano Swithes
Side Mirrors
Tool kit
Wheel Jack
Coolent tank
Rubber boots
Bonnet Hooks
Speedo Cable

I have managed to order a set of 5 spokes wheels, I will take one for my spare and I will sell the other four as the distributor accepts order for 5 nos. only.

Mahindra CL340 DP 4WD - Body Work - Sand Blasting

2008-01-29T08:33:00.001-08:00

As the orignal color of my jeep as per the RC book is Red, I make up my mind to restore the original color. The project body work started here with Sand blasting.

Sand Blasting is been taken for removing black paint on the surface. My jeep stands for blasting action in a sand blasting company:

There two blasting required one is the hard blast to remove the paint, rust and damaged putty and the second blasting is soft blasting with nice sand material to clean up the surface. Here is the 1st blasting:

Opps, Lately I learned a lesson after loosing my windshield glass. Before blasting the jeep one should remove all the glass items.

After the surface cleaning activity, this is how my jeep looked:

After removing the broken glass and windshield folded position

Getting ready for the first drive - Mahindra Classic

2008-01-29T08:26:00.000-08:00

He he he ... Though my baby is un attended condition for 4 years, He is quite alive and started his exploration immediately after bath and haircut. Little bit of mechanical work to service the Jeep.

New battery, Oil service and Water service with some minor work made him up on the road.

My Mahindra Classic

2008-01-29T08:15:00.000-08:00

Spotted Mahindra Classic crying for a owner to give'm a new life

Got to go for a new life, He is in the hands of Siva(Proud owner of the orphan baby). I have named him at the first look as Explorer.

Rusty Wire Wheels, a most attractive wheels produced for a Jeep in bad shape:

Engine, Dashboard and Misc pictures:

The Mahindra Classic: Specifications

2008-01-29T08:07:00.000-08:00

CL340 DP 4WD - General Specifications:

Cooling System :
Water cooled, centrifugal pump type, thermostat controlled.

Clutch Type :
Single Dry plate, heavy duty, Outside dia .235mm.

Transmission :
Ratio Type :4 Speed, 2nd, 3rd, 4th Synchromesh

1st gear 3.986:1
2nd gear 2.368:1
3rd gear 1.473:1
4th gear 1.000:1
Reverse 5.315:1

Transfer Case :
Type 2 speed, single lever located on Floor. Ratio :High 1:1, Low 2.46:1.

Front Axle :
Full floating hypoid type.
Capacity : 907 kg. Axle Roatio 4.88:1.

Rear Axle Capacity :
Semi floating Capacity 1134kg.Axle Roatrio 4.88:1.

Steering :
Recirculating
Ball Type. Ratio 20:1 3 Spoke steering wheel.

Turing Circle radius :
5.3 m.

Brakes :
Service :- Tandem Master cylinder, Servo Actuated Disc in front, Internal Expanding shoe brake at rear
Parking :- Internal expanding operates on Rear Wheels, Floor mtd. lever between Driver &
Co-Driver seat.

Suspension :
Semi elliptical leaf,tension side of leaf shot - peened (under slung).

Wheels, Rims :
Tyres
Mag wheels
215 / 75 R 15 Radial.

Electricals System :
12 Volt Battery/70 Amp.Hr.Alternator 65 Amps. With vaccum pump.

Instruments :
Speedometer (kms./hr), Temperature and fuel gauge ,oil pressuren guage, Voltmeter, light indicators for battery charging, oil pressur, high beam and temperature,parking brake, hazzard & brake fluid level warning indicator, 4 WD high & low indicator .

Fuel Tank :
Capacity 40 litres with electrical fuel gauge.

Seating Capacity :
4 including driver.

Curb Weight :
1245 kg.

G.V.W. :
1600 kg.

Engine Specifications :

Engine : Diesel XDP 4.90 B

Type : In line, 4 Cylinder, 4 Stroke

Bore/Stroke : 90 mm * 83 mm

Capacity : 2112 cc

Maximum Horse Power : 62 @ 4500 RPM

Maximum Torque : 12.3 Kgm @ 2000 RPM

Fuel Injection System : Distributor Pump

Compression Ratio : 22.4 : 1

Weight of engine (Dry) : 184 Kg

Dream come true!

2008-01-29T07:56:00.000-08:00

Welcome Jeepers!

Here is my dream come true! Now I own a Mahindra Classic alias CL340 DP 4WD. One of the precious and ever wanted JEEP from Mahindra & Mahindra. This Jeep is made upon Willys CJ3B platform with some latest addons.

Though the Classic's production started during 1996, M&M got to stop the Classic line of production with in a shortwhile on 2000. Hence very few of these Gems are available on the road on the market. Hence getting this jeep is a real challenge for many. I was searching for this jeep for more than 4 years and found one in a wreck condition. This whole blog is our restoration of my Mahindra classic Jeep.