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#Post#: 71003--------------------------------------------------
My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Tom Date: August 16, 2013, 5:02 pm
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Hello everyone,
I've finally got round to putting some pictures up of my engine
conversion from 2.5NA Diesel (very worn out and slow, but
reliable) to 300TDi (very fast in comparison, and much more
economical!!)
OK here's my landrover, the family heirloom, we've owned her
since new in 1961 :grandad, dad, and now myself. I’m only a
youngun at 25!
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1308_zps099bbc9b.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1308_zps099bbc9b.jpg[/img][/URL]
My original gearbox went pop, the mainshaft fractured just
behind the 3rd/4th synchro. My friend had a discovery 300TDi
gearbox with a long bellhousing that i could have for free, an
R380 suffix J. for free I couldn't turn it down!
Now i know what you're all thinking... That'll never fit in
there.... well guess what, you're right! well it does... but my
rear prop was 305mm long from flange to flange.. which had a bit
of a binding problem and i had to drive up hills very
carefully... hillstarts were a no-go! I didnt have a front prop
because it was approximately one mile in length. you live and
learn..... I only had 2WD through the bad snow last winter which
i was gutted about.
The old engine was breathing more and more through the oil
filler cap so it was time for it to go.
here's my new engine as I bought it... £255 off ebay, what a
bargain!
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1105_zps191dbd10.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1105_zps191dbd10.jpg[/img][/URL]
I thought i'd treat it to a new timing belt, so I got around to
fitting that. I made a flywheel locking tool out of an old
12.5mm steel drillbit. There is a nice amount of clearance
between the flywheel housing thread and the locking tool.
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1111_zps09485bf7.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/th_DSC_1111_zps09485bf7.jpg[/img][/URL]
In work we're lucky enough to have autodesk inventor (CAD:
computer aided design if you're not sure!), so I drew a basic
'chassis' and axles/propshafts etc to calculate at what position
to fit the engine and gearbox. Basically the front of the
flywheel pulley sits 35mm from the chassis crossmember.
This allows a standard series SWB prop to fit on the rear, and a
defender TD5 front prop to fit on the front. Please note though
that I had to chop 20mm off the sliding joint on the front
prop... this should be OK because the shortened slip joint is
still longer than the original one!
Here are a few pictures of the R380 being shortened. I got the
kit from Shop4Autoparts. The kit was nicely packed and the bits
seem well machined... well they ought to be for £366! :O but I
did have a lovely keyring and light up pen in the box. How nice!
The shortened input pinion
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1222_zpse063f842.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1222_zpse063f842.jpg[/img][/URL]
I broke the oil pickup ring which is by 5th gear (i think), This
was from fiddling around trying to get the piggin’ input pinion
out! :@ a replacement was £34 :( originally made from some sort
of graphitey plastic I expected the replacement to be made from
it too, but it was made of Tufnol which I could have just turned
out on a lathe in work! :@
Here’s the gubbins of the R380, here with the original long
pinion on:
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1185_zps2caaf022.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1185_zps2caaf022.jpg[/img][/URL]
I found that to get the pinion off, you need to take both
‘covers’ off the gearbox (front and rear), and hold the plate in
a soft gripped vice... then I undid the big nut on the end of
the layshaft and slid the cog off just behind the nut. The oil
separator piece then need to be carefully pulled off the end of
the mainshaft... I just made very long arms for my old bearing
pullers which worked very well!
the layshaft and mainshaft will then splay enough to get the
input pinion off.
i bought some ‘proper’ Hylomar sealant for fitting the gearbox
halves together again, for peace of mind.
I didnt take many photos here because i was short of time.. I
wish i did now though!
Some time later: the new bellhousing on: the machined faces are
111mm instead of approx 245mm for the longer discovery housing,
as far as i can remember!
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1246_zps67cf3382.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1246_zps67cf3382.jpg[/img][/URL]
OK, a few notes: the gearbox mounts are now lined up with the
original gearbox crossmember! I made some simple mounts that
bolted on to the original holes in the chassis for the series
gearbox.
The engine mounts need to change though... I carefully measured
where to cut the Left hand/longer mount, so that I could re-weld
it further back on the chassis and it would suit the 300tdi
which has its mounts further apart width-wise than the 2.5NA
engine that was in it.
The RH mount (the side with the exhaust) basically sits against
the vertical chassis wall and has quite a small mount. I wanted
to use discovery 300Tdi rubber mounts on both the gearbox and
engine, which i have managed to do :) the cab doesn’t rattle
when ticking over now.
Here’s one of the very few pictures i took at this stage: a
standard discovery gearbox mount with a small bit added to bolt
the gearbox mount on a bit further down... its slightly squashed
at one end because the angles aren’t completely parallel.
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1254_zps3af4cd5f.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1254_zps3af4cd5f.jpg[/img][/URL]
The engine, as it now sits:
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1138_zpsd4005f81.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1138_zpsd4005f81.jpg[/img][/URL]
The original short engine mount getting in the way of the
exhaust!
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1142_zpsfaf2aa60.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1142_zpsfaf2aa60.jpg[/img][/URL]
Another note: a series 2.25 diesel system IS too narrow for the
300tdi! The series system is something like 43mm whereas the
disco exhaust is 60mm diameter. Even with the rear backbox
completely removed, my engine wouldn’t rev much above half way!
I learnt this the hard way... but still it was good welding
practice making up a nice downpipe for it. The Exhaust is tucked
up out of the way of rocks/ bumps which i’m very happy with.
I have since made a 60mm system by buying and modifying a
discovery downpipe. I made a rear pipe and ‘silencer’ (although
it doesnt silence much) from 60mm pipe and what was left of the
series backbox:
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1267_zpsa83aec78.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1267_zpsa83aec78.jpg[/img][/URL]
This exhaust isn’t going to be on there forever! I am now saving
up to have a ‘proper’ exhaust made up for it, or I will
experiment with backboxes so I can have the exhaust exiting from
the correct place. I don’t like it coming through the propshaft
hole at the moment, plus it is really loud when you’re cruising
along on a dual carriageway etc.
On to the intercooler end of things... I have basically run out
of room! The pipes were chopped off a standard discovery
intercooler and refitted on to the ends. Hopefully you can see
what i’ve done here:
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1262_zps79a6da05.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1262_zps79a6da05.jpg[/img][/URL]
I made two upright supports for the intercooler, so that the
radiator will hold the intercooler in place.the intercooler and
radiator are separated by foam to stop them rubbing holes in
each other.
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1263_zpse6713892.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1263_zpse6713892.jpg[/img][/URL]
I then painted it black (spraypaint) to make it blend in a
bit...
[URL=
HTML http://s10.photobucket.com/user/tomfarm12/media/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1265_zps6ba414ac.jpg.html][IMG]http://i10.photobucket.com/albums/a140/tomfarm12/Series%202a%20Rebuild/300TDi%20Conversion/DSC_1265_zps6ba414ac.jpg[/img][/URL]
The intercooler is very close to the front grille now but it all
fits! :) the pipes go up over the radiator via a carefully cut
hole above the RH headlight. I need better intercooler hoses as
mine are only the aluminium covered in cardboard jobbies that is
used on VW camper vans (my mothers pride and joy... a 1974 Type
2 ‘late bay’ if anyone’s wondering!)
The water pipes were made up of offcuts and scrap bits that we
have lying around in the shed. The setup is roughly the same as
what you’d see on a discovery 1.
The oil cooler pipes fit after a bit of gentle bending: be
careful and take your time with the bends and they won’t kink.
I had to cut the seat box slightly, and make a new transmission
tunnel, more or less! I would have liked to keep these but I did
the job carefully so i’m pleased with it.
I have converted the handbrake to a defender one, so i have had
to lose the series handbrake. I’ve tried to make the cable work
with the rod-style series setup but my handbrake just wasn’t
having it! A nice strong bracket supports the defender lever
from under the seatbox. I also clocked the drum assembly so that
the cable exits at a more convenient place for the handbrake :)
So there we go... apologies if i have typed too much or not made
sense: I’m more of a ‘describe it when its in front of you’ kind
of bloke... :) I would have liked to have taken more pictures
but once you’re on a roll you don’t think to stop and wipe your
hands clean, and take a photo, etc!
I’ve tried to do this conversion so that I keep the series looks
as much as possible... hence wanting the exhaust to be in the
proper place! I miss my red and yellow knobs but this vehicle is
my only car, and i do a lot of miles in it! I’d rather have a
landy that’s lost some of its originality and be driveable at
todays higher speeds than something that has to fall second
place to a ‘sensible’ ford fiesta or something!
I already have the bigger LWB brakes & dual circuit servo
fitted, it’s not like i’m doing 300mph everywhere – it was hills
that were the big problem before now!
If you’d like to see the land rover, I will be at the Eastnor
landrover show all weekend, please come and say hello. You can
have as much of a look over it as you like.
Hope to meet some of you soon,
Tom
#Post#: 71008--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: gp3trainee Date: August 16, 2013, 6:09 pm
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I feel humbled. Extraordinary skills and dedication for one so
young (that's not meant to be patronising - I just look back to
how little I knew when I was 25)
Thanks for the great account.
G
#Post#: 71029--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Joskin Date: August 17, 2013, 4:41 am
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Kwality job Tom , fair play to you chap :thumbs:
#Post#: 71049--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Tom Date: August 17, 2013, 9:36 am
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Thank you :thumbs: It was quite an effort to do, but I love the
way it drives now! it's a bit more bouncy now because the 300tdi
is a lighter engine than the 2.5NA judging by the effort needed
pumping the engine hoist :eek:
I've been brought up around spanners and welders and everything
like that, so I haven't had a choice! plus I'm a
electrical/hydraulic engineer in the week so I really can't
escape the oil haha >rock<
Cheers,
Tom
#Post#: 71072--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Landyphil Date: August 17, 2013, 2:26 pm
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Nicely done sir!
#Post#: 71074--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Arjan Date: August 17, 2013, 2:36 pm
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Very inspirational Tom - very well done and a lot of hard work
that has been.
Love to see it in the metal as I have a 2.5 Series Hybrid here
in need of another engine..
#Post#: 71076--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: chally2 Date: August 17, 2013, 2:53 pm
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Looking good. Keep us updated.
#Post#: 71082--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Dave Date: August 17, 2013, 4:06 pm
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I wish I could do even half of that stuff. Well done :thumbs:
#Post#: 71085--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: welshlandy Date: August 17, 2013, 9:17 pm
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Well done. What sort of speed does it cruise at now?
#Post#: 71091--------------------------------------------------
Re: My S2A 88" with 300TDi, R380 and LT230 gearbox
By: Boris Date: August 18, 2013, 2:47 am
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Very tidy Tom :smilewide: loving your work :thumbs:
Gary
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