This is a 49 build, 50 model year headlight behind the grill 80 inch. It was originally sold in switzerland (hence the killer vintage CH badge on the back.) Its a fairly solid truck that we purchased as a shop truck for running errands getting parts etc. Depite being relatively well preserverd, it had suffered some famer fixes and needed some updates as well as a little "pangolin" touch. We decided that a diesel swap was in order. What better to repower a tiny truck than with a small reliable diesel? A Mercedes 240 was in order. A factory remain was sourced and the project was born. We added some trick equipment and custom work along the way to make a sweet little runabout. Its been awhile since we did this project, but, I have had a lot of requests for a buildup page, here goes:

Here is the truck as it arrived. Lots of character!

Bowed but unbroken.

 

Cool CH badge and early rear tow jaw. Also note the ag draw plate.

Here you can see the fluids are being drained in preparation for gutting the drivetrain.

Fenders off for the first time in decades!

Original 1.6L was still running, but didnt have the shazzam needed for a daily runabout.

Front end pulled.

firewall and transmission have to come off as well.

The motor needs to be prepped for installation in the truck. Due to the forward drop oil pan, both the upper and lower pan needed to be modified. Here you can see the aluminum pan have been narrowed, a new sectioned TIGed in and then machined flat with the new holes for the lower pan added. Even got the same bolt spacing as the original pan!

Here you can see the adaptor. Clutch assembly and the flywheel which has been machined for clearance. The 240Ds have two different flywheelhousing patterns, that differ slightly. This is an early one. The mean green starter was used for clearance at the bellhousing. Note the lower modified oil pan in the background.

The 1.6L and 2.0L motors use a different bellhousing than the later motors. The adaptor we had was for a later pattern. This means we had to use the SIIA bellhousing on the series one transmission. However the series one has a mechanical clutch as opposed to a hydraulic one. Early SII bellhousings happen to have the provision for the mechanical clutch (how handy) but we still had to adapt the mechanical throwout mechanism to the bellhousing. We machined a new bushing for the throwout and used a SII thowout housing with SI internals worked perfect and used only one custom part!

This is the complete drivetrain ready for the install.

Test fitting in the chassis and designing the mounts

 

Making sure there is plenty of clearance all aound with the new engine position.

Tig welding the new mounts on the chassis

Here is the RH mount. Completely made from scratch to accomidate the rover diesel mounts and support the mercedes engine. The seam is purposly left welded 3/4 of its length. This is actually stronger than a full length weld. Check the original construction of your chassis some time.

  

Here is the other side, with clearance for the original brake line routing. Fully TIG welded.

The entire front of the chassis was cleaned and painted with Bronze Green Enamel, just as it would have looked from the factory.

The tranny tunnel has to be remade do to the shape of the bellhousing area. The sheet metal work will incorperate new sections and original pieces for a stock appearance.

Now for some goodies. We build an original style bumper from 3/16 incorporating the original crank start boss. We also tracked down an areoparts capstan for that vintage flavor.

This is an awsome famer fix. Look at all that angle iron to support the steering box. Series ones had weak steering boxes and this one had been replaced with a series three unit. Probably sometime in the 70s. The plastic steering wheel along with this mess had to go.

Heres the motor with the firewall back on, the steering cleaned up and a good SIIA box installed (with the wirespoke wheel)

Complete engine compartment with modified radiator for use with the original merceded hoses. Future servicing should be a breeze!

Cant have the capstan as a bumper ornament, so we made this custom drive mechanism for use with the mercedes engine.

With the rest of the truck getting so much attention the interior needed a little help. The dash and instruments were redone, heavy duty floormats fitted and new seats.

The seats were built from scratch to mimic the original pattern and style. The ash frames were remade, the foams were all replaced as was the original cotton batting in the backrests. Original vintage style shovel back seats. You can also see the tranny tunnel which was made to cover the new drivetrain and an overdrive was installed for sustained cruising. It can now do 75 mph!

New 6.50x16 bias plys completed the vintage look. The finished truck oozes vintage style with the functional capstan winch, Bias plys, shovel back seats and original patina. While the modern (relatively) diesel makes it a reliable efficient runabout. The period plates are icing on the cake. A killer modified rover that looks like a vintage 50s workhorse!