A 4x4 Is Born

World-renowned engineering enthusiast Mark Evans dusts off his overalls to take on his first off-road project - the transformation of a 4-door, 1985 Range Rover into a unique 100" wheelbase Land Rover. It's a 21st Century tribute to 25 special vehicles that Land Rover built for the French and Swiss armies in the late seventies. First Mark cleans 30 years of crud off his donor vehicle and gives it a mechanical health check. In the workshop, Mark buys the body panels, and sets about modifying the chassis to support it all. There's a lot of metalwork to be done. He starts with some new outriggers and quickly gets into a spot of bother « read less

With so much metalwork to do, Mark calls in professional welder, Paul Harris to run a MIG-welding masterclass. There's also some TIG welding to be done to stitch up the seams on the new tub - it's a nightmare of a job ! « read less

It's Mark's favourite part of the project - rebuilding and upgrading the monster V8! Cleaned, stripped of its ancillaries and decapitated, Mark assesses its condition. Mark visits a gearbox specialist to rebuild an R380 gearbox and transfer box from scratch for his project vehicle. Meanwhile, the completed, blasted chassis is galvanised by the hot-dip process. It's a very dangerous procedure but the finished chassis looks magnificent. « read less

With the help of some "specialist" friends, Mark makes himself a unique roll cage out of the longest piece of tube he could fit in his van. He shows how to bend, assemble and fit it. Mark strips down and assesses the internals of his V8. Is it as really as good as he first thought? « read less

Mark paints his rocker covers and sets the variable valve timing kit on his newly assembled engine. Mark fits his core plugs, before venturing to his bench to show how to correctly remove a broken stud. Attention is then turned to rebuilding the oil pump. The clutch and gearbox is fitted to the engine and then unites the newly fitted clutch and gearbox to the engine. Mark then takes the strain as he fits the rebuilt engine/gearbox combo into the rolling chassis. « read less

Mark's very special Land Rover is really starting to take shape, and he turns his attention to the brakes. Then it's on to the fuel system and there's a problem with the fuel tank filler. Mark fits his new racing exhaust with its ceramic coated headers and Y-pipe. Finally, Mark fits the ancillaries to the V8 engine. Can he get the monster to roar ? « read less

Not wanting his unique vehicle to be stolen under his nose, Mark invests in a state-of-the-art alarm system that will call his mobile of his Land Rover is touched ! He also makes his own tailgate, fits a powerful winch, side protection bars and snorkel. Oh. And forgets his Wedding Anniversary! Mark learns how to operate his new winch on an Off-road driving course. « read less

It has been a journey of blood, sweat and tears that has taken Mark, Les and Phil (the team) 2500 hours to complete over 5 months. Mark put the finishing touches to his unique 100" Land Rover, before bringing it outside into the Spring sunshine. It's bright outside but it doesn't dim Mark's enthusiasm for fitting some extra lights ! Mark runs into a problem with his suspension while testing outside the workshop, but he gets its sorted in time for the big test. Off road, Mark has the time of his life at the helm of his latest creation « read less