O'erlanderwagen build

[mk216v]

Many many thanks for Tony Cruthers at Motorsports(he's the MAN if you want Hutchinson's, ARB, RotoPax, etc etc etc...die-hard G-Wagen, Halfinger, SDP, Mog, Pinz, VW/Audi/Porsche etc nut! 503.244.9010) generosity to let me peek over and take pics of the Hutchinson install process(key word there!). I was glad to see the Hutchinson craftmanship(made in USA!).
Thanks also to my crew for helping me get these on the truck at the end of work today.

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[RBA]

The Koni Raid HT's(90's)? Sorry to hear.
I know a G55K owner who wheels a lot with them and he's been very happy, so have a few others. One G500 owner had 1 or 2 that were **** off the bat. I believe they have a lifetime warranty though and thankfully they're not as much a PITA to install as the longer springs, so I suppose if one leaks or blows, it can be replaced fairly easily.

I was disappointed that Bilstein didn't have anything beefier off the shelf. ORC has some built Bilstein's, but I couldn't find anyone else running them so decided to try the Koni's.
ORC's Fox coilovers are way overkill for me. I like OEM engineering.

Crap, my bad. I had the SPXs, sorry. Koni's customer service sucked for me. Hopefully you never have to deal with them. After I busted the first one, I contacted koni about the warranty. They said I needed to fill out a form first and fax it before I could mail in the shock for them to test and determine whether there was a problem and then they would send me a replacement. Once faxed I needed a number in order to send the shock. Well, I never got past that first step. The form asked question about the truck the license plate number the vin, etc, etc. not sure why they even needed that level of detail. They also needed the receipt. So now after faxing it, no one ever contacting me with this number. I called and faxed a second time and then just gave up.

[mk216v]

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Tony will be making custom caps to fit this 84.6mm centerbore(Hutch's shown on Harald's wheel site are the old forged units with 81mm centerbore...Hutch isn't making forged save for special military low-volume applications, so these are cast wheels). Notice the British military no-lose-em valve stem caps, thanks Tony!
The wheel halves studs on the other style Hutch(#0492) are long enough to accept the satin black caps that come from Hutchinson with the wheels.
My studs aren't long enough for the caps to thread right on, so I'll need to spend time milling down 64 black plastic caps. Woohoo!
I will be looking into H&R studs tomorrow which will help make it easier to mount the wheel/tire onto the hub in the middle of nowhere, as they're so damn heavy at 104lbs/ea!

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Now this is more like what I had in mind!

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PO didn't leave me with the key for the spare tire cover so we still need to grind that off and install the 5th Hutch/BFG-AT...bit worried about the extra 30lbs hanging off the cargo door...may be time for the DesertService rear bumper vs W461 split.

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[mk216v]

Crap, my bad. I had the SPXs, sorry. Koni's customer service sucked for me. Hopefully you never have to deal with them. After I busted the first one, I contacted koni about the warranty. They said I needed to fill out a form first and fax it before I could mail in the shock for them to test and determine whether there was a problem and then they would send me a replacement. Once faxed I needed a number in order to send the shock. Well, I never got past that first step. The form asked question about the truck the license plate number the vin, etc, etc. not sure why they even needed that level of detail. They also needed the receipt. So now after faxing it, no one ever contacting me with this number. I called and faxed a second time and then just gave up.

Ok phew, thanks for the confirmation.
I've dealt with Koni warranty plenty...difficult to get them to answer the phone, but leave enough messages and send enough emails, and stuff will eventually happen. They just need more than one guy(Paul) in warranty.

Unfortunately this is the way the industry is--you either send your broken damper in for it to go through the warranty process(while your truck sits), or you buy a new one, send the broken one in for warranty, it goes through the process, then they reimburse you for the one you bought when warranty is complete.
As long as you have your proof of purchase, I'm more than happy to help you get your one warrantied. Send me a PM and I'll get 'er done.

[Owyhee H]

Really looking good. Lots of time deciding on some really nice kit. She will be a comfy ride 4 sure.

[mk216v]

Really looking good. Lots of time deciding on some really nice kit. She will be a comfy ride 4 sure.

Thanks Harlan! Yes, lots of thinking time put into the planning. It's comfy but man are these wheels/tires heavy.

[traveller09]

Very, very cool! I love it.

[otiswesty]

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Now this is more like what I had in mind!

PO didn't leave me with the key for the spare tire cover so we still need to grind that off and install the 5th Hutch/BFG-AT...bit worried about the extra 30lbs hanging off the cargo door...may be time for the DesertService rear bumper vs W461 split.

In didn't have the spare key for my 2002 either, the dealer took it off for no charge
Just sayin'
Nice work brutha
E

[mk216v]

Thanks all!

I've ordered a new latch from Don and Ed in parts, so that whoever I sell this spare tire cover to will have a working one.

[MEUSOC]

Sexy Beast!