this months projects - land rover

[top drive]

Original paint on the axel and tie rod.

Gear box bellhousing full of mud,needs a new slave though, fork is unmodified so ill get a new one. The thrust bearing was utterly shagged

Front shocks - no wonder it sidnt feel like any damping , there wasnt.

Quality engine i tell ya :/

Looks better in a pile than it did as the sorry *** truck i started with.

 

[top drive]

Bulk heads back into one non rusty piece

Bad news today thought, i work in the yard alot so obviously since my hedge hasnt grown yet my stuff is visable, i try to keep the door down as much as i can but 5 doors down - about half a mile away had their garage broken into on friday night , everything gone , tools , welders, power tools.

So new security measures implemented- not putting them on here for obviosu reasons but it will lead to mass confusion should they gain access

 

[MBfreak]

Great job.
I had a 109" with the old 6banger while living in Liberia. Lots of fun. The electric fuel pump conked out all the time, learned to repair it in less than three minutes after a while.

For rust protection in closed beams, boxes etc. Use linseed oil. When it oxidizes it expands in volume and keep creeping out of spotwelds seams forever.

If really ambitious get hold of the top linseed oil product " Mike Sanders Rostschutzfett" from Germany. A bit of a struggle to spray since it needs to be heated but beats everything else.

Ola

 

[top drive]

still going - perilously close to starting to build something now. - was too windy to finish my bulkhead off yesterday so started on the front axle/brakes.

needs new pistons in the front brakes , new brake lines and a pair of radius arm mounts welding on , a quick dicht with some tetrosyl and refitting. Woo

Masking didnt really work so ill just have to sand the paint out wiht a flap wheel.hope its fairly close to gwyns trailing arms.

Its pitted but is that a huge issue, doesnt leak yet , probably get worse once i use it but i dont want to spent 160 on balls and housings right now if ill get a little while out of them so i can get my other axels sorted.

 

[top drive]

https://scontent-b.**.fbcdn.net/hphotos-xpa1/v/t1.0-9/10351660_628601583125_1589003190394887121_n.jpg?oh=0464d824bb0ed62bf62aecb76c2bbaa1&oe=54BE3B23

forgot - quickie of the new engine - note the high strength bunji holding it in... not ideal but i hadnt planned on buying it that day so had nothing better in the motor. - the joys of mini vans number 1 being unplanned engine purchases made easier. no running off for the trailer.

 

[ctb]

It's just coming right along, I'm enjoying this. Didn't those swivel balls have leather gaiters covering them originally?

 

[top drive]

Naw never had any but i could fit em they are cheap enough....dunno this things gonna mainly be used offroad/winter roadwork i dont know if i want the mud/water and salt trapped in there or access to clean it off and keep em greases etc etc..

Some came out like at.

Others had to see my friend mr meddings the drill.

Then i tapped the hole and fitted a bolt. They came loose eventually. For the most part it was the metal seal ring had corroded to the piston.

Masked off the feed and bleed ****** threads and painted the outside.....

Easiest way to mask off the bores? ....heavy grease in the bore enough or should i put the piston back in the bore ? Obviosuly this would work better if the top seal was stil in but i could clean that up with a stanley and some sand paper after , so long as the bore was clean.

Got all my polygushes fitted tonight as well , that just leaves the chassis ones to do when i fit the arms. Felt good assembling something for a change ....

Hopefully my paddocks order arrives tomorrow. Yrm won the courier race , they really have been top notch with the parts , you pay enough for delivery but you get your moneys worth, and when they sent me the wrong bit in one order they sorted it asap. And as long as i get gwyns delivery by the weekend.....i might be working towards a rolling chassis by sunday night if i can rope in some help this weekend- most likely be rolling next weekend though

 

[RogueFab]

Nice work. What a big project. Glad you made it home with that engine...looks sketchy.

 

[top drive]

more new stuff arrived last night - new turret/dislocationcones / HD turret rings/+5 shocks for the front/Extended blue brake lines/cranked rear trailing arms.

wednesday saw all the gaskets / seals / pistons/diff pan and radius arm brackets required to make my axle and brakes good.

Shouldnt need another delivery for a long time - which is a good thing as im skint now

suspension should be like that when im done - with the addition of a locker of some kind in the future would just finish it off ..... that said it will only get into dificulty long after a standard suspension landy was already stuck.....

 

[top drive]

New stainless pistons went in a dream very easy job even the metal outer rings went in not bad. I did practice with an old one i salvaged first after the warning on here

Rough afternoon making headway into front axle. Got it all welded on in the end though.

And my good deed for the day, cut and fitted my neighbours door handles for her.

Now i only have 1 1mm disk left

Ill also revise my rolling chassis dead line from tomorrow night to ...... haha.

 

[top drive]

welded up and painted for protection - will grind it back later before i spray them

mrs top drive managed to reverse into the axel on the stands yesterday though - survived the drop onto the deck without busting my welding

also got the brake halfs back together with square seals - loctited and torqued to 50nm now being stored ready to go back on the car when its brake time - keep em in the dry for now.

 

[top drive]

long way off needing it but got a killer deal on a winch bumper for the front - obviously not on my truck.

 

[top drive]

Another few hours today.... Somehow everytime i touch it there becomes less and less landy

Wire wheels all the rust off , was harder getting all the oily grime out from where the airbox used to sit....white spirit and brake cleaner and lots of elbow grease.

First coat of tetrosyl on

Have to start going up from here , i cant physically remove much more

Willget another coat of paint on it on friday afternoon. Another couple on saturday while i tend to the remaining axle work. Then maybe , just maybe i cwn throw parts at it on sunday..... I need the space back in The garage

 

[top drive]

drivers radius arm bracket fitted to axle on saturday , finished early as we went into town for dinner and a comedy show.

sunday - assembledthe front suspension - removed the frontsuspension - assembled the frontsuspension - removed the front suspension - assembled the frontsuspension..... this is my suspension - there are many like it but this one is mine........

Things were not going together smoothly - trying to work out where the issue was such is life with custom parts....

turned out the radius arm brackets were undersize - the bushes were oversize - oversize into undersize doesnt go.

then it was a case of take them both to size and work out the best order of assembly.

FYI it is ....

wheels off axle lying on the floor - fit radius arms then rest chassis on top. - fit radius arms to chassis mount....... lift the chassis with the crane fit turret rings and spring seats - fit springs. Fit retainers for springs Bolt down - fit shock bushes - then shock then turret. use handy clamps to clamp down the turret and compress the shock slightly - bolt it all up - do up shock mounts.

lots of cursing was done yesterday. 9am start - 9pm finish - it looked no different at 9pm as it did at mid day .... only the thing was assembled correctly and not just resting in place with me scratching my head at why it wasnt going together.

 

[top drive]

Gear box mounts, a frame mounts , a frame all fitted tonight, forgot to clean and paint the pan phard rod to chassis mount so cleaned that and gave it a lick of paint. Will get that on tomorrow , seem to be short of a panhard rod bolt too doh. Forgot to order stainless panhard bolts doh. Will put together with old ones for now and slip new ones in my next paddocks order.

Hopefully i can take wednesday off and get the rear axel out and the diff pan cut off and welded on ready to chuck it at the rear of the chassis

 

[top drive]

Yeah dawncer .... 4 wheels on my wagon , just need a couple o horses to gies a tow.

The only other photo i took today. Didnt have the luxury of time , today was my last week day off for about 5 weeks , shopping saturday , cycling sunday morning ....then probably away to turkmenistan for 25 day at somepoint next week or the week after

 

[top drive]

a couple of daylight photos that actually show something other than dark.

next step is to roll it out the way and apply 5S to my workspace now that i have a mobile chassis again.

dropping a bolt or a nut and picking up 5 old ones before you get the one you dropped is getting real old real fast.

one of my colleagues sent me this this morning ...... thinks hes funny i think ....

 

[nine4gmc]

LMAO at the pic your colleague sent. You have come far, much better than I had expected, can't wait to see the finished job and I now have no doubt it will get there soon!

 

[afirover]

looking very nice SIR

 

[BJ42LX]

That looks amazing, especially given where you started.

I'd clean up the space under the truck on principle - a fresh start in a clean build area.

 

[top drive]

Damn straight. Its been doing my head in.

Now she moves i can get under it

 

[top drive]

Stopped raining long enough for that to happen today.

Its now living under a car cover with weights on.

Back to finishing off the bulkhead now that i can move in my garage again - engine and box took up an unsurprising amount of room.

 

[AussieDan]

You've come a long way! Love the old landys, not sure I'd have the guts to tackle one quite that bad though

 

[top drive]

Ach id have felt guilty doing this to anything in much better nick , i do support landy conservation but this was heading for the breakers/scrappers , didnt have much going for it in a purists fashion. - **** engine , **** steel work , untidy body and shot suspension.

This is kind of a practice run for another project , i really want a 109 station wagon at a later date - they are a horror to rebuild.

 

[top drive]

long day yesterday where not alot happened.

swapped over a few ancilleries to make the plumbing easier - PAS pump , Alternator and the crankshaft pulley.

plumbed in the rest of the cooling , steering , the oil feeds to the turbos , made up fuel lines for the feed and return , fitted my prop shafts. - discovered i need to drop the gearbox crossmember to fit the downpipe cause im a muppet.

finally got my front bumper off - what a mess inside - need to fit new crush tubes in the front dumb irons for the bumper and the jate rings before the new bumper and steering guard can go on.

- finally ... its stratos blue at the moment

that colour with limestone wheels(disco steels) and roof. - and i have a pick up cab for it now too...

or marine blue - with the limestone wheels and roof....

we used to have a marine blue SIII back in the 90s - always had a soft spot for marine blue , it'll always be the classic landy colour to me.

 

[top drive]

progress hindered slightly although i have acquired a months supply of innes and gun for doing a brake disc and pad swap on my mates clio. his disks were actually rotten on the inner faces and he wondered why they were pulsing under foot. - 10 bolts a side on the eurobox - less than an hours work - spent longer having bacon rolls/coffee/******** afterwards.

i did get him to help me lift the tub onto the chassis though so i could work on it there.

the pink is roughly applied special metals primer to stop it corroding before i can get round to painting it - lotta prep work to go in before that happens.

seatbelt mount corrosion - - got the YRM pieces to sandwich that panel above and below with lots of primer and seam sealer between. - the lower piece is in situe in this photo just checking the fit and working out where the holes inthe upper piece need to go.

striker post eaten alive - again got the repair panels to fit.

 

[top drive]

Stripped the loom and steering column off the bulkhead and ground back the welding. Fitted top corners - 12inches of top rail- door posts , outrigger brackets and footwells

Then a skim of p38 and knifing putty to smooth it off

Ashtree it is not..... But better than twas it is.

 

[top drive]

Having a mare with the paint atm, keeping my garage warm enough but not combustable is hard.

Finally got a finish on the bulkhead im happy enoug with, it aint perfect but its blue at 30ft

So bulkhead back on , starting to take shape.

 

[dutchgray]

I always liked marine blue as well, its the classic Landy blue colour and just looks right on them.

 

[vegar]

Great progress �� I always want a Land Rover 90.

I have been in Aberdeen some times. Mostly done service on some of the supply ships in the harbor, but also been on some of the offshore platforms

 

[top drive]

paint preps taking for ever - last night pulled off the glass out the cab front and back and got it all sprayed up marine blue.

Tonight i will do another coat i think

tomorrow night , prep and coat the roof its self in limestone.

saturday - finish the front of the tub - then bolt it down - get the roof and cab and screen on so i have a weather resistant structure :d

ive only ever been to stravanger to go to the transocean barents floating hilton - place is decked out better than my house.

 

[top drive]

Test fitting the bodywork.

Stripped it all back off to paint it. Pulled the steel frame out the bonnet , cleaned it up and painted it before reassembly.

Rear tub floors pretty grim - pressurewashing blew holes in the alu where it contacts/rests against the steel. Due to time contraints and the fact that they wont be an MOT failure they will be repaired at a later date - Same thing with the rear most quarter panels - I have 5 months now to get it road worthy - and im currently sat in perth australia for the next month with work.

Reassembled properly now. all bolted up- all looks pretty good on the alignment front which given how much ive chopped and welded up this chassis and firewall has made me pretty happy , the proof will be in the door fitting i guess - which i will be ordering in a couple of weeks , brand new series conversion items from SP4x4 back in the uk. Still undecided about splashing out on rocky mountain ALU door tops but i guess at 49 quid for a glazed door top from SP i can order them for now and decide if i really need rocky mountains (folks say the RMs being stiffer create a better seal with the door frame and thus you stay drier - give my LR its due even in the pishing rain i NEVER got wet - i think its a rare beast that...

Need to do something with that chequer resh - chequer rash is for places you might stand ..... you cant stand on a vertical surface. How ever close inspection shows its holding that tailgate together. I might see if i can unrivet it and turn it over to the smooth side and rerivet- then spray it blue- or i may just spray it blue Till i can find another tailgate.

How she stands now in the scottish winter. hopefully not ******* the neighbours off too much since its progressed significantly in the last week from a heap on the floor to an actual car dear lord it is tall though , its only a 2 inch lift. I hope it settles a little as its still rolling on 205/16s and it will be 750x16s on the lime stone rims that are leaning against it once im done which will be another 1.5 inches height i believe !

PS the engine(a newer 200 tdi so needed to do some loom chopping) even turns over now - after i wasted friday looking for a black earth wire from the starter relay which goes into the wrapped loom as a black and according to my multimetre probing it comes out as a black with green trace. this is the "starter inhibit" wire according to my wiring diagram - not exactly an obvious one is it ! - it earths on the gear box not the bulkhead as my diagram says it should.

 

[vegar]

Looking good. Pepper LR color

 

[top drive]

Gave up on the old loom , by the time id bypassed all the broken non continuity wires i almost had a new loom in its own right - and it looked ****.

picked up a used 200tdi loom to match the engine ,only a couple small bits need changed in the cab for it to accept this and then its a factory install.

Got it starting on the key now as factory intended it too no bodges. Got all the front lights/indicators/side lights working as they should with all the different options working.

check my wooden windscreen.

plain old sealed beam units + wipac LED side and indicators.

Wipac rear LEDs - dont like the NAS fog and reversing light so got some square incandecent types for now - eventually ill stick LED floods on the roof for reversing i think. Badly timed photo as future mrs T-D cycles past ha.

How long will those zinc hinges stay silver ? i quite like the silver on blue contrast........

reckon theres probably another 8-10 full days work in it before i present it for Roadworthyness tests. (MOT)

 

[top drive]

painted my headlight surrounds

We have full electrics at both ends , a fully working heater and everything on the dash works except the fuel low warning light - i dont seem to have continuity from the sender wire to the light - thats easy sorted.

Got my steering repaired with a new drop arm , HD linkages , ball joints ,damper and PAS pipes as somewhere between removal and refit the old ones rotted out. - hence all the ATF all over the drive

bled up the brakes and the clutch , all working grand


fitted the windscreen how ever it has delaminated along the bottom and it split left to right from a small chip in the edge when fitting .... but thats ok means moar justification for a heated one

 

[top drive]

We have full electrics at both ends , a fully working heater and everything on the dash works except the fuel low warning light - i dont seem to have continuity from the sender wire to the light - thats easy sorted.

Got my steering repaired with a new drop arm , HD linkages , ball joints ,damper and PAS pipes as somewhere between removal and refit the old ones rotted out. - hence all the ATF all over the drive

bled up the brakes and the clutch , all working grand


fitted the windscreen how ever it has delaminated along the bottom and it split left to right from a small chip in the edge when fitting .... but thats ok means moar justification for a heated one

 

[top drive]

im a little dissapointed with the allignment of the doors - how ever they do shut 1million times better than they did when i started.

the quality of the repair panels i used seems to be quite poor with hole placement.

the panels in the right place to the mm. how ever the doors about 8mm too high at the front -but given the amount of chopping and cutting i did ill live with it for now

ill rectify that down the line how ever im getting married in 3 months and me and the best man are supposed to be arriving in this as its a vehicle of significance in our lives - many adventures had in it

. I still have to get an MOT/ Vehicle roadworthyness test done. Im working on the interior at the moment and i need to go under the bottom of the truck with the torque wrench on all the suspension and steering. Then secure the loom and fuel lines with P clips as ive just got them zip tied out the way of the props atm. #

as you can see by the patch under the front - i had a steering pipe burst on me and i split the original 80s screen in 2 places - but i swapped that out yesterday with a heated number and its a really the **** - given LR heating is shite it will be a godsend in winter !

Need to take it out for a road test an all make sure it doesnt shimmy its way down the road.

 

[gavmac]

thats looking good ,lots of hours been put in there ,great colour

 

[top drive]

cheers gav ,

whats your locale in the shire ? unusual to see another Aberdonian on here

This weekends progress was finished off the brakes and got a decent pedal.

tightened up all the suspension after a we shake down drive.

got the passengers door locking propper.

Got rid of that goddam chequer plate tailgate , stupid looking awful thing. Chequer plate is for standing on , there is no concievable way you could have stood on that chequer plate .... its either vertical or on an overhead surface. Its gone now for a more traditional if not beat up one that ive painted to match the rest of the car.

inside i made up a plinth to go between the seats to house some big speakers , not because im a boy racer but because at 65 on the A roads you need big speakers to hear the radio

no photos as it was a busy day and i didn't get in till gone 9 and still had to cook the dinner

 

[gavmac]

hi im out foveran way, great forum this, enjoying your build
bit of a tool collector me and biker there are a few more from aberdeen area on here