[Spinnerr]

@Anil

That is one killer makeover.

I noticed that you are missing the small chrome hub caps on the alloy wheels. Have you ordered merc replica ones?

I could find lot of options on ebay. But then, since you have Middle East contacts, I am guessing it should be eazy to source from the used car market there, than look at these costly ones.

Alternatively, there are these brand neutral one here.

[Anil Vincent]

Originally Posted by dieselhead

An awesome work done. Anil can you please let me know the total cost of custom job as I would be interested.

Thanks for all the suggestions and feedbacks, I have been receiving a lot on queries of the cost involved, to be honest this being the fist one did, there were a lot of trial and errors and took 5 months to complete hence the kind of labor hours and materials cost as of now is not at all a realistic figure. Before i start the work of second vehicle (Red One) i will have an accurate cost worked out which will be very much more affordable to most of the Gurkha / G Wagon fans and will share the same for sure.

Originally Posted by apachelongbow

In the side profile the bonnet is flat. If you see the original G, the bonnet slopes slightly from windscreen out. The rear bumper must be in line with the rear wheel fender

The bonnet extruded shape was attempted but didn't continued since we felt that could bring some odd proportionate looks. The real G's fenders have a sloping design from the windshield towards to the nose where as Gurkha has a flat straight shape of fenders this itself is giving an upright stance from the front and side, in addition to this if bonnet also extruded that was actually looking odd and more noticeable that G's overall proportions. It was better to leave it as original of Gurkha. The front and rear bumpers need some re alignment, will be done soon.

Originally Posted by Kiterunner

Eagerly looking forward to the engine and interior upgrades.

Interior upgrades are now on going including a full NVH damping, expected to complete by end of this week.
Exploring various options to get some extra BHP and performance with out deviating from OE specs, hopes http://dieseltronic.racedynamics.com/ will be of some help, I don't know if this works on DI engines and not found FORCE included in their compatible list of vehicles, experts please advice.

Originally Posted by Spinnerr

I noticed that you are missing the small chrome hub caps on the alloy wheels. Have you ordered merc replica ones?

The original hub caps came along with the wheel is not matching the required appearance and looks, searching for something better and flat surfaced. Thanks for the reference.

[dhanushs]

Originally Posted by Anil Vincent

Exploring various options to get some extra BHP and performance with out deviating from OE specs, hopes http://dieseltronic.racedynamics.com/ will be of some help, I don't know if this works on DI engines and not found FORCE included in their compatible list of vehicles, experts please advice.

Please dont go for a tuning chip. It is a bypass, and is a messy way of increasing power. The correct way of doing it is a remap.

If you want to go full on - what you need is:

1. Get a custom free flow exhaust.
2. High performance Air Filter, and custom exhaust plumbing removing restrictions.
3. Need to check injectors, and change if needed.
4. Bigger Turbo, or wastegate adjustment.
5. A REMAP to Fuel all the above, or rather, all the above to complement a proper remap.
6. Change the final drive ratios, as per requirement.
7. Finally change the brakes and suspension to tackle the increased dynamics requirement.

[DDiSLover]

Originally Posted by Sankar

Keep the ...

Also go for ORVM with indicators as in the picture above.

Amazing conversion job buddy!

On the point of headlights, don't the headlights look eerily similar to those on the new Royal Enfield Thunderbird?

[Frankenstein]

Very well made , and looks elegant. What are your plans for the interior and powertrain?

Why not go full mercedes with the om 606 and add a turbo. or a nissan petrol 6 cylinder.

[apachelongbow]

Originally Posted by dhanushs

Please dont go for a tuning chip. It is a bypass, and is a messy way of increasing power. The correct way of doing it is a remap.

If you want to go full on - what you need is:

1. Get a custom free flow exhaust.
2. High performance Air Filter, and custom exhaust plumbing removing restrictions.
3. Need to check injectors, and change if needed.
4. Bigger Turbo, or wastegate adjustment.
5. A REMAP to Fuel all the above, or rather, all the above to complement a proper remap.
6. Change the final drive ratios, as per requirement.
7. Finally change the brakes and suspension to tackle the increased dynamics requirement.

I agree. This is the proper way to get more power out of a diesel. If possible, ask Force if they can sell you a Force one engine plus gearbox. It mostly will be a direct fit and out of the box you get 140bhp and 320nm of torque and a modern 5 speed gearbox. This will solve your power problems forever.
If the above is not possible buy a used Tata 2.2 dicor or a Mahindra 2.2 engine with gearbox (should be cheap) and with a bit of workaround it can fit into the Gurkha

[Anil Vincent]

Originally Posted by dhanushs

If you want to go full on - what you need is:

1. Get a custom free flow exhaust.
2. High performance Air Filter, and custom exhaust plumbing removing restrictions.
3. Need to check injectors, and change if needed.
4. Bigger Turbo, or wastegate adjustment.
5. A REMAP to Fuel all the above, or rather, all the above to complement a proper remap.
6. Change the final drive ratios, as per requirement.
7. Finally change the brakes and suspension to tackle the increased dynamics requirement.

Thanks for the detailed advice and it looks not much of deviation from OE specs and no question on reliability issues, I will get in touch with your for more detailed advice on the same.

Originally Posted by DDiSLover

On the point of headlights, don't the headlights look eerily similar to those on the new Royal Enfield Thunderbird?

Yes you are right Enfield Thunderbird headlight is a very close replica of G's headlights

Originally Posted by Frankenstein

Why not go full mercedes with the om 606 and add a turbo. or a nissan petrol 6 cylinder.

Interior works are now on going, expected to take a few more days to complete will share the photos as soon as completed.
I don't intend to go in for a non OE setup, these are brilliant options but I am concerned about the reliability issues.

Originally Posted by apachelongbow

Ask Force if they can sell you a Force one engine plus gearbox. It mostly will be a direct fit and out of the box you get 140bhp and 320nm of torque and a modern 5 speed gearbox.

Force One engine and GB is worth considering, will check on the same, hope the pricing also will be in affordable range.

[alphadog]

Great Job and an amazing conversion of the Force to a Merc!.
It does look the part and only a motorhead will be able to make out the difference. I like your choice of colour too - quite butch and mean, at the same time classy.
Looks like Marvel motors is going to have a lot of fresh business coming their way.
Enjoy your ride.
Cheerio!.

[vshar126]

Amazing workmanship
In this era of bolt-on/direct fit parts
skilled fabrigators are a rare find who get your point and are ready to go exta mile and take the risk and put in the effort
i would say put the G badge at the back as well, try and make it sound a bit similar cause that's what G is all about
Suggestion would be go for diamond stitched leather seats maybe orangish brown colour
Cheers to you making the dream come true and going in for it

[Miyer]

Amazing job Anil and team. I have a newfound respect for mods and the ashan's of Kerala in their (moody) workmanship. Amazing patience and eye for details. This is a transformation of par excellence...!!!

Miyer

[Anil Vincent]

Interior transformation is left with Mr. Binus of Binu's boutique, one of the best car interior specialist in Kerala. Binu's is the most skilled and one of the best craftsman i ever met and know, not only in KL but any where else. The cars seats redone by Binus are far better in quality and craftsmanship that the original ones from factory.

For interior I wanted something simple and elegant matching with the overall looks, Binu's was not happy with the simple design and suggested to go for Diamond stitch pattern however i felt it is more royale appealing.


As of now the car interiors are completely stripped down, seats are taking shape at one place inside Binu's crafting centre and at the other side NVH damping jobs going on. Binus has not even spare an inch space of car interior with out insulation, complete floor starting from inner firewall, door inner, quarter panel inner etc.

These are 7mm thick damping sheets, and is expected 3 to 5 decibel reduction in interior noise.






Manoj bhai in action with NVH damping sheets.

[manveet]

Excellent work being done - love these no-compromise builds. Am very curious on what you end up doing in the engine dept. Last thing we want to see is an all-show-no-go-G-Wagen clone.

[Frankenstein]

I did this damping on the w124 and amby. I used 2 layers of the damp mat and mld plus carpet. Its a total waste of money . Did you record the db level before the insulation? i HAVE DONE IT, THERE WAS NO DIFFERENCE. Also these insulation adds a lot of weight to the already heavy and underpowered gurkha.

Damping i felt is good for music system to arrest resound.

[Anil Vincent]

Originally Posted by manveet

Am very curious on what you end up doing in the engine dept. Last thing we want to see is an all-show-no-go-G-Wagen clone.

I wish if the Xerox copy of the currency notes has the same value as it original , look and feel of anything can be replicated but not its performance !

The only intention in this mod is to enjoy that look and feel of G within the reach of my pocket, of course some engine mods are planned without deviating much from the OE setups and putting reliability into question. Some basic remapping are expected to increase the power by 20 to 25% which is more than enough for a normal SUV performance on and off roads

Originally Posted by Frankenstein

I did this damping on the w124 and amby. I used 2 layers of the damp mat and mld plus carpet. Its a total waste of money . Did you record the db level before the insulation? i HAVE DONE IT, THERE WAS NO DIFFERENCE. Also these insulation adds a lot of weight to the already heavy and underpowered gurkha.

Damping i felt is good for music system to arrest resound.

I had used the same material on Mitsubishi Pajero 3.8L which the dealer here orders without the sound damping kit, whenever I switch driving between Prado and Pajero the feel was horrible. Pajero comes factory fitted with a 13 speakers Rockford audio system but no sound damping. It's front seats passengers will get annoyed with engine noise above 120 speeds and rear seats passengers ears will be tortured with growling noise of tyres, which is why I tried these sheets on Pajero and the result was impressive it become quitter than the Prado and the drive felt like knife on butter. Audio quality was unbelievable and all my friends and colleagues who owing Pajero got the same installed.

I purchased 10 SqM roll for Gurkha and the weight was only 2.2 KG, which was carried with me as check in baggage and it is not at all a considerable add-on weight om Gurkha body. Since interior jobs are not completed we have not yet driven Gurkha, will provide a correct feedback on how effective it is on Gurkha after driving it.

[dhanushs]

Originally Posted by Anil Vincent

..

Manoj bhai in action with NVH damping sheets.

One very important thing you should take care before damping the floor is, waterproof and rust proof the sheet metal. Or else there will be build up of water vapour between the metal and damping sheet and it will rust. And of course the water being trapped.