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#Post#: 58491--------------------------------------------------
Re: New project - 109 2A 1968
By: Boris Date: April 24, 2013, 1:21 pm
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That's a nice find :thumbs: will be good to see the other
pictures :smilewide:
Gary
#Post#: 58558--------------------------------------------------
Re: New project - 109 2A 1968
By: drumlisden Date: April 24, 2013, 6:36 pm
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[quote author=espacekiller link=topic=2246.msg58483#msg58483
date=1366825783]
Cracking find, you can get an original master cylinder rebuild
kit from dunsfold for it for sensible money if you haven't
already sorted it, just done mine .
[/quote]
Brakes are next on the to do list so I'll bear that in mind
cheers.
Unlike most on here I don't do highly skilled resto jobs 'cause
I'm not skilled. Mine is more of a beginner's guide to bodging
built on false confidence gained by welding a new half chassis
on my 88" a couple of years ago.
As seen in the vid above the chassis was very crusty and didn't
stand much scrutiny with a screwdriver. I set about it with the
flap disk and liberal lashings of phosphoric acid.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109acid_zps8ad97065.jpg[/img]
This made it go a nice black colour which I quickly covered in
aerosol undercoat.
The rear cross member was shagged so a bit of jiggery pokery
with some four by twos before I hacked it off.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109jig2_zps4ee06368.jpg[/img]
I started rebuilding the cross member but gave up when a
replacement became available for £30.
The old one
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109crossm_zpsfcc801f4.jpg[/img]
The patching begins.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109patch1_zps07378c37.jpg[/img]
Weak metal
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109patch2_zps1fc88d0d.jpg[/img]
I ended up replacing 3 sides of this rail. The other side needed
similar treatment.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109hole1_zps875a07af.jpg[/img]
The shock absorber mounts needed lots of attention and the top
of the rails had disappeared.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109shockmount_zpsa8afdc76.jpg[/img]
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109shockmount1_zps0637b672.jpg[/img]
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109shockmount2_zps7d75ebc0.jpg[/img]
The other side
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/109shockmount3_zps965d093d.jpg[/img]
Feel free to laugh at my welding :rolleye0012: I used the stick
for most of it before treating myself to a nice Esab mig in time
to finish it off.
I welded in about a dozen patches all told including rebuilding
the rear spring mounts. Cutting a hole and a patch to fit the
hole takes me ages. Thank god it's all done.
More recent pics to follow....
#Post#: 58568--------------------------------------------------
Re: New project - 109 2A 1968
By: Arjan Date: April 25, 2013, 2:05 am
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:thumbs:
I will not laugh at the welding you've done - I can only
spatter...
Well Done
#Post#: 58577--------------------------------------------------
Re: New project - 109 2A 1968
By: Drew Date: April 25, 2013, 2:59 am
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Inspirational, what with the work I'm about to embark upon 8)
#Post#: 58700--------------------------------------------------
Re: New project - 109 2A 1968
By: drumlisden Date: April 25, 2013, 5:27 pm
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Hopefully inspire you to do a faster and tidier job than me
Drew!
Here are some crappy pics of the painted chassis. The spray on
undercoat came off and one layer of red oxide and two of Aldi's
cheap but glossy metal paint were brushed on.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps080f3260.jpg[/img]
The replacement rear cross member I acquired was for an 88" and
had extensions and spring hangers which were obviously in the
wrong place. I butt welded it and put a patch over the top join
for reinforcement. The previous cross member had been welded on
with the tub in place and so hadn't been welded on the top of
the rail. Hopefully mine is a better job.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zpsdaf2f6bc.jpg[/img]
Not sure whether to slap underseal on the chassis too.
The rear Salisbury axle and back plates were very flaky and one
plate had corroded right through.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps1ecefe1a.jpg[/img]
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps87e5a47b.jpg[/img]
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zpsbc17c288.jpg[/img]
I got one off a 110's axle which seemed to be the same and gave
them the flap disk/acid/paint treatment.
[IMG]
HTML http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zpsc0ddd61d.jpg[/img]
Other bits cleaned up like spring plates etc so this weekend
I'll be trying to get chassis bushes out and putting the hubs,
axle and springs back together.
#Post#: 58710--------------------------------------------------
Re: New project - 109 2A 1968
By: Lurch Date: April 26, 2013, 1:56 am
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Looking good John 8)
#Post#: 59301--------------------------------------------------
Re: New project - 109 2A 1968
By: drumlisden Date: April 29, 2013, 6:38 pm
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Spent a few hours on the 109 this weekend and tonight.
Fortunately I'm not charging myself by the hour otherwise it
would £300 to change one spring hanger bush :haha:
The satisfaction of completing such a job is a function of the
difficulty overcome. Something like -
Satisfaction = (difficulty)^2
Particularly when you give up, pissed off and fed up then go
back to it an hour later with fresh impetus and get it done.
That's why I like spannering, completely different from my 9 to
5.
The springs need a clean up so I thought I would see if the main
bolts would loosen. With the spring vertical beside me, I tried
a socket on the nut and gave it some mongo (as parksy would say
and henceforth so will I) and, with a bang, the bolt sheared and
the bottom plate flew across the garage :eek: Luckily, my
bollocks weren't on its flight path. I know I should have had it
in the vice but my plan was just to loosen the nut. Lesson
learnt.
I now need a bolt for this spring. Does it need to be high
tensile? It has to have a small head to fit in foot on the axle
too :-?
#Post#: 63437--------------------------------------------------
Re: New project - 109 2A 1968
By: drumlisden Date: June 5, 2013, 2:02 pm
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Small update:
One of the springs has a broken leaf but, to make it mobile,
I've put the axle and springs back on. (Hopefully Blenky can
sort me out with those new springs his mate has a crate of)
I took the seat box off and cleaned up the chassis rails.
Fortunately no holes to weld up.
The transfer box is stuck in high and it looks like I'm going to
have to dismantle the thing :eek:
Rusty rods
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zps36a6be1a.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps36a6be1a.jpg[/img][/URL]
I knew the dumb irons were needing attention so bumper off.
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zps81feea29.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps81feea29.jpg[/img][/URL]
I went in search of good metal with the 1mm disc.
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zpsb9ee15f5.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zpsb9ee15f5.jpg[/img][/URL]
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zps03df506f.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps03df506f.jpg[/img][/URL]
The professionals would replace the whole dumb iron but I'm an
amateur.
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zps7619cf22.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps7619cf22.jpg[/img][/URL]
[URL=
HTML http://s777.photobucket.com/user/drumlisden/media/LR/image_zps1bf178c5.jpg.html][IMG]http://i777.photobucket.com/albums/yy60/drumlisden/LR/image_zps1bf178c5.jpg[/img][/URL]
One day my welding will be good enough that I want need to flap
disc it all off.
Next on the to do list -
The transfer box
Brake lines and cylinders
Refit the fuel tank tub
Fix hole in the bulkhead (might get Dave's papier mâché recipe)
#Post#: 63472--------------------------------------------------
Re: New project - 109 2A 1968
By: espacekiller Date: June 5, 2013, 6:05 pm
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That all looks very familiar to me, good work on the dumb irons,
make sure you get some waxoyl inside there and they should be
fine.
#Post#: 63526--------------------------------------------------
Re: New project - 109 2A 1968
By: drumlisden Date: June 6, 2013, 3:21 pm
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Cheer EK. I'll get down to Aldi for their candles!
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