Blowedupmotor.. you sound like the man for the job of doing this! It sounds like you know your stuff... I am still trying to learn about all the mechanical aspects of off road trucks.
That sandrail Thing is awesome.
That sand rail Thing brings up something else I have been trying to find in my research... have you ever heard of a complex roll cage that has been built with no bends and no welds? Think of something just bolted or fitted together using universal type joint fittings. I know that that would reduce the strength a lot... but I am thinking you could make a good "body frame" for something like the Kubelwagon flat body.
I would like to take the body of the kubelwagon and the Land Rover Defender body and combine them.. I think the Defender body panels are riveted....
Gonna try again! I spent about an hour writing a long reply, hit submit and it turns out I had been logged out in the time I was typing so POOF! my post disappears, never to be found again! This probably won't be as well thought out since I'm kinda ticked off about the other one going bye-bye but, hopefully it will be of some use to you!
First off, thanks for the kind words! I wish I was smart enough (and persuasive enough) to get something like this rolling!!!
Rollcage with no bends or welds= impossible! There are going to have to be some bends and weld to make it work. Yes, you can make a completely unboltable rollcage but, you are going to run into big $$$ in tubing adapters and properly graded bolts.
A frame for a Kubelvagen would be a pretty basic undertaking (two bent rails with crossmembers between them) BUT, adapting that body to go onto the frame is going to entail a LOT of fab work. Also, all the body mounts are going to get complex. Additionally, by taking out the unit body style floorboards to put the body on a frame, you lose all body rigidity and you'll have to build a LOT of reinforcement to such an extent that you'd be better off just building a rollcage and attaching the body to it.
For the Defender chassis Kubelvagen/Thing body- it'll be a TON of fab work to make the two of them work together and you are going to have to either adapt the floorboard of the Defender into the Kubelvagen body or make a completely custom floorboard. (either way a TON of work) There are other issues too- not the least of which is modifying the Defender chassis or stretching the Kubelvagen/Thing body so that the wheelbase lines up with the fender openings.
Also, many people will not like this combo- a British military vehicle and a German military vehicle mixed together is going to ruffle lot of feathers! I think it could be a really cool project IF you used a Discovery or Range Rover donor (literally tens of thousands cheaper than a Defender since they are more common here) and a Kubelvagen/Thing with rotted floorboards. Taking a good Defender and a good Kubelvagen/Thing and combing them would be a waste of money and nice vehicles, IMHO.
A better alternative (I think) is a Series Land Rover body onto a Discovery/Range Rover frame. You combine vintage good looks and simplicity with a cushy coilsprung solid axle suspension and an all aluminum EFI V8! (still a LOT of fab work though but, a better end result, IMHO)
Another cool vehicle you may want to look at is the Bowler Tomcat! It is similar to the idea of doing a Thing body on a Defender chassis in that it is a lower profile body (lower height and thus lower center of gravity) on a Defender chassis. Most that you will see have a swoopy Dakar rally type rear bodywork (if you want to see the really rally looking ones, Google: Bowler Wildcat) and a modified Defender frontend but, I prefer ones like this that use modified Series/Defender body work the whole way 'round and run a soft top (coincidentally, this one is actually based on a Range Rover chassis, just as I mentioned above):
Oh, and that restored military spec Kubelvagen looks QUITE nice!!! It would be SICK to see what ICON would come up with for a Thing! I'm guess ing it would contain a Porsche motor, ultra long travel shafts, four wheel independent suspension and a LOT of other craziness in a dang near stock looking package!