Newsletter February 2012

Quality, Value and Performance

Proud Sponsor of 2012 Safari ChampionShip

For more information, please visit our website www.terrafirma4x4.com

At Terrafirma, we understand that your Land Rover is not just a vehicle, but a representation of character. It’s a vehicle with pride. A vehicle which stands over others. A vehicle that acknowledges its destination and anticipates the path it will endure to get there. You turn the key. That’s your job. Everything else is a partnership.

With over 300 products, Terrafirma is one of the largest ranges of Land Rover accessories and enhancements to be offered under a single brand in the world. From our extensive range of Shock Absorber and Suspension lift options through to our winching, lighting, wheels and body protection systems, Terrafirma is the perfect choice to help your Land Rover face the challenges that lie ahead of it, and with a worldwide network of distributors, Terrafirma products have never been so accessible.

www.terrafirma4x4.com Telephone: + 44 (0) 1235 821122 | Fax: +44 (0) 1235 854444 | E-mail: sales@terrafirma4x4.com | like us facebook.com/terrafirma4x4

New Products

2012 NEW PRODUCTS

Terrafirma is growing from strength to strength with a

vast array of new products being developed.

6 new bumpers for Defenders have been introduced this year already including non-winch bumpers and the new Pro Taper winch bumper for both AC and non AC models. A fantastic roof console that adds valuable storage space to all non-sunroof Defender hard tops, station wagons and double cabs as well as 4 new wheel options for Discovery 2 and P38 Range Rover.

Terrafirma is constantly working on new products and accessories for recreational off road, commercial and military applications. Products that will enable your Land Rover to carry more, travel further in greater comfort with lots more fun and safer than ever before.

This is just the start of things to come with lots of new Terrafirma products being added to the range in 2012.

For more information and to see the entire range go to www.terrafirma4x4.com or contact your local Terrafirma distributor.

In stock and available to purchase from our worldwide distributors

DAKAR WhEElS

TF108 Terrafirma Dakar alloy wheel in matt blackTF109 Terrafirma Dakar alloy wheel in silver

TF106 Terrafirma bead lock wheel in matt blackTF107 Terrafirma bead lock wheel in anthracite

Terrafirma bead lock ready 7x16 alloy wheels, introduced with 5x120 stud pattern for the Discovery 2 and P38 alongside the popular Defender options. Produced with a 35mm offset and 1300kg load rating these wheels are amongst the strongest available. These wheels can be fitted as they are or with the addition of the TF103 bead lock kit for serious off road performance.

Terrafirma Dakar 7x16 alloy wheels, again following the success of the Defender version the Dakar wheel is now available in 5x120 stud pattern with a 45mm offset for Discovery 2 and P38. With a massive 1450kg load rating these must be the strongest wheel for this vehicle on the market.

AllOY WhEElSFOR DiSCO 2 & P38

FOR DiSCO 2 & P38

TF005 Terrafirma tubular non winch bumper for all Defenders without ACTF005AC Terrafirma tubular non winch bumper for all Defenders with AC

These bumpers share the same styling and design features as the popular tubular winch bumpers for non-winch applications, complete with jacking and recovery points.

TF006 Terrafirma Pro Taper winch bumper for all Defenders without ACTF006AC Terrafirma Pro Taper winch bumper for all Defenders with AC

The Pro Taper bumpers are constructed from 5mm steel, black powder coated and are suitable for Superwinch Talon and most makes of winch up to 12,000lbs. These bumpers provide improved approach angle, strength, unique styling and include jacking and recovery points.

TF055 Terrafirma Heavy Duty tapered bumper for all Defenders, made from black powder coated 5mm steel, tapered and styled for increased strength and approach angle.

TF055WRP The same Heavy Duty bumper as the TF055 but with the addition of recovery eyes and a super strong 20mm pin centre recovery or towing point.

www.terrafirma4x4.com Telephone: + 44 (0) 1235 821122 | Fax: +44 (0) 1235 854444 | E-mail: sales@terrafirma4x4.com | like us facebook.com/terrafirma4x4

AllOY WhEElSFOR DiSCO 2 & P38

hEAvY DUTY BUMPERS

TFDRC Terrafirma Defender Roof Console. Provides additional storage space and convenience for all Defender station wagons, hard tops and double cabs (without sunroofs). • Reversible trap door storage tray• Single DIN radio aperture• Additional gauge/switch panel• Utilises original interior light• Additional interior light• Full step-by-step instructions

ROOF CONSOlE

Real THING?BetterThan

The

Terrafirma: Your Story

Real THING?

BY Graham CoSTEr 4X4 GErmanY

When my customer Jan visited me at the start of winter 2009 and said he was looking for a special Land rover, his spec was simple; it must stand out from the crowd and be extremely capable off-road.

Having just started up my workshop as an independent LR workshop I was looking for a flag ship project that I could use as a show car to show my talents and Land Rovers capabilities.

Scouring the small ads, not just in Germany but Europe wide I fell upon a G4 90 in the Netherlands with 91000 Km on the clock. It had suffered a huge crash, rolling sideways down an embankment 3 times. After some investigation it proved to be a real G4 90 LHD, one of 10 built in 2003 by Land Rover, this was getting interesting. Jan and I had long conversations over the vehicle before we parted with hard earned cash. What is if the chassis is bent? Does the motor start? And perhaps the biggest question, what would the project G4 cost?

After studying the photos of the wreck, pictured on a forklift, in the snow through the internet the deal was done, €5000 and 1 week latter the vehicle was dragged into my workshop.

It would be easier to say what was NOT broken on it than to say what was broken/bent/missing. There was no roof, side panels or battery. Every window was broken. The chassis was nearly 3cm out of line. The rear right radius arm was bent 90 degrees. The bulkhead on the left side was nearly 4cm forward than the right side. Gearbox mountings split, there was no antifreeze in the engine.

The customer’s daughter commented that the steering wheel wasn’t round; I said that at least the passenger door was straight… “Huston we have a problem” sprang to mind. Jan and I discussed suspension systems, roll cages, diff. lockers and other “serious” modifications like a hydraulic winch, a plan was thought out and we started. One Saturday my team and Jans family stripped the G4, putting all the good parts into labelled boxes (there weren’t many). The scrap was thrown outside onto the grass.

I had already done a few chassis swaps using new galvanised chassis from Richard Chassis before, they are GOOD and fit first time so we ordered one. A new bulkhead was sourced, cleaned in an acid bath and dip galvanised. People have often said it can’t be done; this motivates me into proving it can be done. The bulkhead has got “waves” in it but is straight and true. It is good to feel that it will NEVER rust. The axles were out, stripped, cleaned and brush painted using black Berox 3:1, this doesn’t harden like Hamerrite and has the added advantage of rust protection and looks good. All steel hardware (Bulkhead fittings, spring carriers etc) were sent to be sand blasted and galvanised.

We had started the engine before removal so we knew we had a runner. I had done some back ground work in the Guarantee archives at Land Rover and discovered it had an exchange

motor fitted some 9000 Km ago! The first piece of good news! With the engine out it was checked over and a new one piece flywheel and HD clutch was fitted, reducing the chance of the dreaded Td5 rattle. The old 2-piece flywheel was scrapped. The Transfer box received a 1.222 Discovery ratio conversion from Ashcroft Transmissions which lowers the revs for normal road work but retains the offroad ratio, a new output flange to the front prop shaft for the new Double-Karden prop shaft. The main box was left as it was; we had to risk it been faulty because a test drive through the gears wasn’t possible before it came out. We did what we could, new output/input seals, top seal and linkage bushes.

The chassis arrived and within a week we had G4 rolling again. A new +2”, Heavy Duty Terrafirma suspension kit from Allmakes correctly matched to hold the forthcoming weight of accessories was fitted to keep the beast level on the road. We went the whole way, castor correction arms front and rear, HD Big Bore shocks (almost as big as the internal dimension of the front spring) and extended stainless steel braided brake hoses. The radius and panhard arms were fitted with Orange Polybushes with new bolts and nuts. All G4 challenge vehicles are Tangiers Orange (paint code LRC 241) so the polybushes match perfectly.

The bulkhead was back from galvanising, so it was sent to the paint shop with a second hand roof, side panels, bonnet, wings and rear tub. These parts I had sourced from the UK, all delivered in one job lot. The outer wing received the newest after market plastic wing panels, as this beast was to see real off-road action we hoped a plastic wing would absorb the odd knock, you can’t tell the difference from the real aluminium part. We had assembled the whole vehicle before painting for the fitment of the Safety Devices full FFA spec roll cage, the fitment involves wing/tub cutting. The paint job was to be perfect, so we couldn’t risk damage when drilling and cutting for the cage.

When the freshly sprayed bulkhead and tub were fitted we set about the fitting of the Milemarker 5.6 Ton hydraulic winch (as fitted to USA armed forces vehicles). This power house, driven from a dedicated 22cc pump directly from the Transfer box, sits in a Terrafirma competition winch bumper. The fitment was straight forward, even with the aircon condenser and hoses in the way . The hydraulic tank fits snugly between the seat battery box and tub, access to fill is through the tub floor behind the driver’s seat. Pump actuation is through a dog clutch lever next to the hand brake lever, combined with a 2:1 pull we are looking at a recovery potential off over 10 tons on the last drum layer. If that’s not enough then call a Chinook helicopter!

We didn’t want to fill the battery box with a hydraulic tank as we needed the space for Red and Yellow top Optima batteries; the Luna split charge system and potentially a few tools. A 12v 600 Amp NATO charging socket fitted in the passenger foot well supplies through a 5m cable a jump start for another vehicle without having to remove the driver’s seat base. An ARB compressor was grafted into the right seat box with the air lines for the front and rear ARB lockers run on the right hand chassis rail, tucked well out of harms way. A separate air line feed to inflate the BF Goodrich MT 255/85 R16 tyres should the need arise, sits in the passenger foot well. The tyres mounted on 7Jx16 Wolf Modular wheels also have an air pressure warning system fitted, it detects falling pressure/rising temperature in all 4 wheels to alert the driver. The existing swing away reserve wheel carrier transfers the spares weight away from the new on piece steel door directly onto the rear chassis rail. A raised air intake fitted directly to the front right hand roll bar riser also hides the extended breathers for the axles and gearboxes, with special attention devoted to sealing the seat box the beast should potentially survive short swimming trips! Every single seal to the doors, roof, tub, windows, roof etc were replaced. Where possible new Stainless steel screws and bolts were fitted, all pre coated with copper slip.

The engine bay received extra sound deadening, as did the door innards and roof panel. A tuning package consisting of a

Silicon hose set (G4 orange) and 40% bigger intercooler were shoe horned into the space between the engine radiator and new aircon condenser. This combined with the removal of the EGR valve, middle exhaust box and fitment of a Green Cotton free flow air filter gives the beast a mighty growl. There is no motor ECU tuning as we were not looking for better acceleration, letting the engine breath better through the mentioned adaptations means a longer life span. You can change a Donkey into a Thoroughbred, temporally, but eventually it will go into early retirement with a heart attach.

Finishing touches included a light bar with 4x Hella FM75’s and the front number plate plinth, a Mud UK console on top of the dashboard houses the ARB locker switches and light switches. The original front seats where straightened and the rear tub fitted out with 2 G4 fabric front facing Exmoor Trim seats with 3 point shoulder safety belts. Access to which is helped from the integrated steps on the NAS tow bar.

The car flew through its TÜV in November, almost 6 months after we started. We only worked on the car between other regular work in the workshop; this reduced the labour costs, making the project more financially viable. Attention to detail costs time. Getting the front wings and radiator grill + bonnet 100% level cost me a whole Saturday! Good planning BEFORE fitting saves time. For example fitting

brake lines, fuel lines and air lines for the lockers on a “naked” chassis rail takes only 30 minutes, however when the body is on it would probably be nearer 3 hours (and not so neat).

Driving is a dream even with the hard-core suspension and tyre combination. There is no harshness but a taught comfortable ride. The castor correction arms and return to centre steering damper makes the steering light and positive. There is power in “big grin” quantities from a happily breathing Td5 engine. There are no squeaks or rattles associated with a nearly 10 year old Defender. When off road the tamed beast comes alive, the suspension eats bumps and ruts, when the going gets tuff first the transfer box diff can be locked, if that doesn’t give enough traction the rear goes in. As a last resort the front can be locked, but that isn’t often needed.

The vehicle is insured for way over 60000, 00 Euros’, which is a fair representation of a complete refurbishment to these high standards. Why so much? Well if one morning its missing from the drive try finding a real 2003 G4 90 with a galvanised chassis/bulkhead with all the aforementioned goodies to replace it…..no you can’t. This G4 is no longer an original Land Rover as off the production line at Solihull, but better than the real!

Quality, Value and Performance

parT no. fiTTinG info

826025B 2 IN 1 DEFENDER TD5

FTC4630B DEFENDER 98-06 , DISCO 2 98-04

GCKTD5B 3 IN 1 DEFENDER TD5 98-06 , DISCO 2 98-04

LR012199B DEFENDER 2007 ON

UQB000120B DEFENDER 98-06 , DISCO 2 98-04

URB500060B FREELANDER 1 (PETROL AND ROVER DIESEL)

URB500070B 2 IN 1 FREELANDER 1 (2.0 TD4 ENGINE)

UUB000070B SLAVE CYL-CLUTCH FREELANDER 1 (2.0 TD4 ENGINE)

Does your Land Rover’s clutch stand the test of time?With over 100 years of engineering excellence, Borg & Beck OE quality clutch components are manufactured under strict material control and have undergone rigorous product testing procedures. So when it comes to replacing your Land Rover’s clutch, Borg & Beck is a good quality and affordable choice.

This range for Land Rover Defender, Discovery and Freelander vehicles are in stock and available to purchase here at Allmakes 4x4. Order yours NOW!

Each pr2 part has less than a 0.5% failure rate in its sales history - and it’s proven!

SDB000614G

front brake disc for Disco 3 and range rover Sport 05-09 by Delphi

Getting in Touch General Enquires: tel: +(44) 1235 821122 | fax: +(44) 1235 821133 | email: allmakes@allmakes.co.ukUK Sales: tel: +(44) 1235 862020 | fax: +(44) 1235 854444 | email: uk@allmakes.co.ukEuropean Sales: tel: +(44) 1235 821122 | fax: +(44) 1235 821406 | email: speedexport@allmakes.co.ukInternational Sales: tel: +(44) 1235 821122 | fax: +(44) 1235 821406 | email: complexexport@allmakes.co.uk

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Quality, Value and Performance

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