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#Post#: 1725--------------------------------------------------
'68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:08 am
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Originally posted on Forumer Website: Wed Mar 02, 2011 9:19 pm
Seems I haven't included a thread about the 109 here, so as
seen as I am rebuilding it on a new chassis, I thought I would
start one.
This is how he looked a few years ago.
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/20032007130.jpg
The new chassis arrives:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Chassis0.jpg
Preparing for a paint, garage starting to look like a scene
from Dexter:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Chassis1.jpg
Topside done:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Chassis2.jpg
Onto the side for the underside:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Chassis3.jpg
Underside completed:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Chassis4.jpg
And then I decided to strip down the 2 1/4 Diesel that came with
him (Currently sporting a 2.5 NA at the mo).
Jobs currently pending for the engine are:
Engine block away for a rebore.
Crankshaft away for a re-grind.
Injectors and fuel pump away for a rebuild.
Cylinder head nearly sorted, awaiting oil seals which seem a
pain in the arse to get hold of, however phoned up a main
dealer on the off chance today and will be getting them for
tomorrow morning, seem to be cheaper or comparable with most of
the usual suspects too.
Anyway yesterday saw the front end getting stripped down:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Stripdown1.jpg
And that's about it for now, hopefully tomorrow will get the
rest of the body off.
#Post#: 1726--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:09 am
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Originally posted on Forumer Website: Posted: Fri Mar 04, 2011
9:50 pm
Today, has seen the rest of the body come off. And the engine
prepped for removal. Would have got more done, but the engine
block that was supposed to be ready and finished by Wednesday
wasn't finished until 345pm today.
Rest of body off:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Stripdown2.jpg
Engine back from machinists, now 40 thou oversize:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Engine1.jpg
Found this crack on the topside of the chassis after removing
HTML the tub [img]http://images/smiles/icon_eek.gif"
alt="Shocked[/img]
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Crack1.jpg
#Post#: 1727--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:10 am
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Originally posted on Forumer Website: Tue May 03, 2011 6:40 pm
Engine built, in, timed up (hopefully), ancillaries now bolted
onto the engine, I don't think there is anymore work to do on
the chassis at the time, maybe just get the bumper and grab
handles on to get them out the way.
Some pics:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/DSCF0999.jpg
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/DSCF0996.jpg
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/DSCF0994.jpg
Next stop bulkhead
#Post#: 1728--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:11 am
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Originally posted on Forumer Website: Posted: Sun May 29, 2011
5:16 pm
Not been up to much as of late, going to COW, getting ready for
COW and other stuff. Well anyway, I thought I would start
fettling the back tub, as once I've finished it, it can get
out of the garden and get rested on the body, taking up zero
space in the garage.
Well anyway, after finishing fitting the back tub supports,
new rubber was fitted (thanks Gadget)
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Tubrubber.jpg
Then some repairs, crude as they wont be seen:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Backbinrepair.jpg
Mount:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Tubrepair.jpg
Pop rivets drilled out and dome heads fitted in place:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Rivets.jpg
Then I started strippng the galv cappings before running out of
stripper:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Cappings1.jpg
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Cappings2.jpg
Finished now for the weekend, as the missus wants to go and see
the new Pirates movie.
#Post#: 1729--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:13 am
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Originally posted on Forumer Website: Sun Jun 19, 2011 6:05 pm
Well anyway, progress on the bulkhead has started:
Step 1: Take one bulkhead:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Bulkhead1.jpg
Step 2: Strip said bulkhead:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Bulkhead3.jpg
Step 3: Build a blast cabinet of some sort:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Sandblastercabinet.jpg
Step 4: Blast bulkhead:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Bulkhead4.jpg
Obviously not blasted it all, as those bits that were well and
truly knackered I left alone. Talking of which, gearbox
tunnel, panel above it (between tunnel & dash) and the
inner foot wells have been well and truly buggered. Anybody's
ideas what to do, as I don't think you can get these bits
aftermarket can you?
See if you can see it in the photo, to see what I'm talking
about;
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/Bulkhead5.jpg
I have no idea how it came to be, initial thoughts were gas
welding distortion, however it just looks a bit more knackered
than that!
#Post#: 1731--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:13 am
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Originally posted on Forumer Website: Posted: Wed Jun 29, 2011
8:03 pm
Anyway started welding on the bulkhead this afternoon after
running round getting bits for the welder and bulkhead, namely
pillars, feet and some sheet steel. This afternoon the
bulkhead looks like this:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/DSCF4854.jpg
Panel replaced with some sheet steel and the gearbox tunnel
picked up from LATP for a few quid
Tomorrow I'm starting the drivers side footwell and pillars. and
see where we go from there, see if I can do some better welding
tomorrow!
#Post#: 1732--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:14 am
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Originally posted on Forumer Website: Sat Jul 02, 2011 8:48 pm
Well anyway, I think I've just about completed the majority of
welding on the bulkhead. Fitted New pillars, feet and footwells
(ribbed for her pleasure)
You may have read somewhere else I was going to get it
galvanised, well I've decided not to, just in case I've fucked
something up with the welding etc etc, after all on Wednesday I
had the theory behind welding and very little practice. You can
definitely tell the difference in welding as the week went on.
Another picture of the bulkhead, looks very similar to the
others, might have a game of spot the difference:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/110702-Bulkhead.jpg
Used the old chassis to keep things in line-ish.
Need to get the grinder out tomorrow, and grind back some of
the weld.
#Post#: 1733--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 8, 2012, 6:15 am
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Originally posted on the Forumer Website: Mon Jul 25, 2011 3:55
pm
Well, anyway I got a call today to say some bits and pieces were
ready for collection. Made my excuses at work and skipped off
down the road to pick up these beauties:
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/IMG_0256.jpg
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/IMG_0257.jpg
Finish is not as good as I would have thought, however the
money that I have spent out on getting the bits and pieces
shotblasted, welded then galved far out weighs the cost of a
refurbed Ashtree front panels and bulkhead. All in all it has
probably cost me in the region of £300 to get them shotblasted,
welded then galved.
Will have a fetal some time when the Safari is working a bit
more better!
#Post#: 4203--------------------------------------------------
Re: '68 109 - The big red 'un
By: stuey Date: January 13, 2012, 5:01 pm
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After moving the forum, I realised that I hadn't updated this in
a while, not a lot has happened in the grand scheme of things
due to other things happening in our lives. Anyway, the galv
bits got painted before the cold weather set in, bulkhead then
got fitted. Fabricated some new seat box ends and fitted those
and that was about it until a few days ago.
In the past few days, has seen me starting to rebuild the
bulkhead back up, pedals fitted, most of the accelerator
linkage (except for governer, lost the bar).
Some blurry phone pic, but I'm hoping you get the idea:
[IMG]
HTML http://i131.photobucket.com/albums/p309/stumgoo/Elvis/Rebuild/photo2.jpg[/img]
Next few days, I'm going to be looking at trying to get the
brakes, clutch and fuel system plumbed in. Steering set up and
the fuel system plumbed in, then hopefully running! :)
Plan is, if I can get the motor running in the next few weeks,
It will then give me a self esteem boost and then sort out the
bodywork between now and the beginning of April ready for the
painting season 8)
#Post#: 4229--------------------------------------------------
Re: '68 109 - The big red 'un
By: Gadget Date: January 13, 2012, 8:37 pm
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If you need a hand just shout :)
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