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Episode 5 – Pushing forward with determination despite the challenges

This week has been a mix of progress, challenges, and some frustrating delays, but the Gazelles team pushed forward with determination. Here’s the lowdown on the highlights, technical details, and our unwavering spirit as we keep the countdown in mind.


Engine and Gearbox: In Place at Last

The most nerve-wracking milestone of the week was positioning the engine and gearbox into the chassis. This process was as delicate as it was exciting—lifting and aligning these heavy components over the shiny chassis tested our precision and patience.

Technical Insight:

  • The R380 gearbox was temporarily mounted with its heat shield in place, a crucial addition to protect the rubber-filled mount from overheating.
  • Fitting the gearbox mounts required carefully cleaned threads and correctly gauged bolts, sourced from our trusted partners, ensuring a secure and accurate fit.

With the engine suspended in place, the next task involves attaching the transfer box—a heavy and critical component that requires precision to match the Defender’s running gear.


Fuel Tank Assembly: Frustration Meets Progress

Installing the fuel pump assembly into the tank was another technical hurdle. Aligning the seal and securing it with the locking ring required a special tool and a fair bit of persistence. After some trial, error, and a helpful YouTube tutorial, the pump was finally installed—an achievement made sweeter by overcoming the challenges.


Transfer Box Modifications: Defender Compatibility

The transfer box, originally from a Discovery, needed adjustments to fit the Defender setup. A specific housing with a sensor port was swapped in, and parts like the worm drive gear and speedo drive were carefully checked and replaced as needed. These modifications ensure the transfer box integrates seamlessly with the Defender’s drivetrain.

Technical Challenge:

  • Swapping the housing required removing unique fasteners, such as a combination stud-and-bolt, and replacing old seals and washers to ensure proper functionality.

Clutch Slave Cylinder Setback

While inspecting the clutch slave cylinder, a broken plastic bracket was discovered. This meant separating the engine and gearbox to replace the part—a task that added to the workload but also provided an opportunity to inspect the clutch system for any other potential issues.


Wiring Spaghetti: Sorting the Looms

A major delivery this week was the wiring loom, sourced from Bradford 4×4. This included the chassis loom, bulkhead loom, and even a fuse board—an exciting package that now needs to be carefully untangled, checked, and routed. Ensuring the wiring is accurate and robust is vital for the vehicle’s functionality and reliability.


Brake Pipes and Axle Delays

While waiting for parts delayed in customs, the team focused on preparing brake pipes. A new set of pipes and fittings was delivered, ready to be routed along the chassis. Unfortunately, the absence of key components for the front axle assembly means the build couldn’t progress to mounting the front wheels and tub.


Supporting the Dakar Spirit: Charity Projects

Amidst the technical work, the team took a moment to highlight the humanitarian efforts tied to this project, supporting a school project in the Atlas Mountains (Morocco) and raising funds for Wonder Foundation, a British charity empowering women and girls worldwide. With a target of £5,000 by the Dakar event, the focus on giving back remains central to this adventure.


Looking Ahead

While the week ended with some frustration due to delays, the positives outweigh the setbacks:

  • The engine and gearbox are now in place.
  • The wiring loom has arrived.
  • Preparations for the transfer box and brake system are underway.

With 83 days remaining until Purdey returns to the UK for roll cage installation, every step counts. The team remains optimistic that next week will bring the long-awaited parts and a flurry of activity.

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