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#Post#: 100237--------------------------------------------------
Margaret's second (unfortunate) rebuild
By: samc88 Date: December 27, 2015, 6:32 pm
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Margaret my 1975 88" series 3 was involved in an accident with a
tractor the other week and so I decided to rebuild her for a
second time. Below are a couple of pics of the damage sustained
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/12244212_761646623945666_1675880807_n.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/12244212_761646623945666_1675880807_n.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/12277288_761646583945670_1748287028_n.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/12277288_761646583945670_1748287028_n.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/12248859_761646597279002_1993104254_n.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/12248859_761646597279002_1993104254_n.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/12272872_761646607279001_298914889_n.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/12272872_761646607279001_298914889_n.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290557.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290557.jpg[/img][/URL]
Day 1 of rebuild:
Started by removing the bonnet, and disconnecting the wiring
loom for the wings (Its usually hidden in conduit which was
removed before taking the photo
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290559.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290559.jpg[/img][/URL]
earth block removed (Ex Disco1 item)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290563.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290563.jpg[/img][/URL]
Bonnet stay removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290564.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290564.jpg[/img][/URL]
Then removed the drivers side wing (Below are a few pics of the
fasteners holding the inner wings in place).
Bolts going into footwell (13mm)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290566.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290566.jpg[/img][/URL]
There is also a small bolt above the steering box mudguard
holding it on too (11mm)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290567.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290567.jpg[/img][/URL]<br
/>
The bolts going into the J clips are 11mm
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290568.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290568.jpg[/img][/URL]
11mm nuts going to front slam panel (The bolts are captive)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290569.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290569.jpg[/img][/URL]
The drivers side wing was a right PITA to remove because of how
it had buckled, I had to cut an access hole out the side to get
at the bulkhead bolts. The passengers side one came away lovely.
Im glad i copper slipped all the bolts last time, everything
came apart easily.
A shot showing the buckled dumbirons, this is the only chassis
damage and it has resulted in the axle being misaligned giving
me tracking issues. you can't see the damage looking head on or
from above, only if you look from the side
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290570.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290570.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290571.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290571.jpg[/img][/URL]
Shot with the passenger side wing removed.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290572.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290572.jpg[/img][/URL]
Drivers side
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290573.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290573.jpg[/img][/URL]
Next the front panel was removed, first I disconnected the
bottom hose and drained the coolant into a tub. Whilst this was
happening, I removed the earth wire which was attached to it
with P-clips.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290574.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290574.jpg[/img][/URL]
The 3 13mm bolts holding the panel to the chassis were then
removed and the panel lifted out of the way
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290575.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290575.jpg[/img][/URL]
I was a bit bored so decided to tidy the engine up a bit, I
removed the fan and the alternator and gave the front half of
the block a quick first coat of eau-de-nil engine enamel (The
colour I originally wanted). This is much brighter with a better
finish and gives a nicer contrast to the marine blue
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290576.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290576.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290577.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290577.jpg[/img][/URL]
A couple of pics showing the axle issues
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290578.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290578.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290579.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290579.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PB290580.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PB290580.jpg[/img][/URL]
I dropped the front of the axle down giving me better access to
the dumbirons. Doing a mesurement between front crossmember and
end of dumbiron revealed that the one dumbiron has crumpled in
by 20mm which has pushed the axle back on that side which is
what sent my tracking out. Also measured between the chassis
spring bush and the front hangar and that measurement confirmed
this so luckily no damage aft of the crossmember.
Also took off my track rod and drag links, these will be
replaced by HD items I purchased. They seem much more
substantial. checked all the swivels and brake bits and they all
seem fine, no play anywhere and all moves freely as it should so
I should be able to put the new drag links on, give everything a
coat of paint and then put it all back together once i get my
replacement dumbirons on. Also come up with a mighty fine idea
for a jig for the replacement bits!
Pics to follow tomorrow hopefully as will get the steering relay
out as well as maybe putting some new bits on but we shall see!
Also sorted wings out so all i need for the rebuild now is to
buy a new screenwash/ wiper switch and dumb iron replacements.
I took the damaged door and sill off
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060550.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060550.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060554.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060554.jpg[/img][/URL]
Pic of the bulkhead damage, the outrigger isnt affected (its
sort of bent above that)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060551.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060551.jpg[/img][/URL]
Also fitted some new stuff today, my filler plate from rocky
mountain for the transfer box
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060553.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060553.jpg[/img][/URL]
I do have the dipstick to go with it but i couldnt get the
filler plug out. I'll do that when i sort the rear oil seal on
the transfer box which has given up all hope of retaining fluid.
While Im at the improvement for easy living stage Im debating
about making a similar dipstick/ filler arrangement for the main
gear box. Will make transmission oil changes so much quicker and
easier.
also as promised a pic of the front of the axle dropped
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060556.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060556.jpg[/img][/URL]
all the axle mechanical bits are fine. I even had time to run
the new TREs in the new drag links to clean the threads upp. In
the pic below you can see the difference in thickness between
standard and HD. I bought the HD set from paddocks which
includes all 4 track rod ends for £65 which i think is pretty
good
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC060557.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC060557.jpg[/img][/URL]
At the minute its looking quite good for being back on the road
around new year, every cloud has a silver lining and that will
be that the landy will be much improved as a daily driver than
it was and its given me the chance to cary out all the jobs ive
been meaning to do over the last year.
My gauges came from America this week so I set about fitting
them. I cut the vinyl cover out with a stanley knife (I still
have it so can always reuse it later if i want to. I discovered
that although they were a perfect fit in the holes, they wouldnt
sit right due to coming into contact with the switch panel above
so I took that off and cut the bottom off it, result a perfect
fit :) I will make a proper switch panel out of aluminium to go
there eventually which is why it doesnt look amazing at the
minute but the gauges look smart :)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC190001.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC190001.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC190006.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC190006.jpg[/img][/URL]
I also got around to fitting my new transfer box sump plate
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC190007.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC190007.jpg[/img][/URL]
Also finally made a start on the dumbirons. The passenger side
ones getting done first as that was the worst one. As Baldrick
says, I have a cunning plan for aligning everything up
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC190008.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC190008.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC190009.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC190009.jpg[/img][/URL]
Apologies if it all seems a bit jumbled up but I copied and
pasted the thread from the other forum Im on to keep you up to
date. It will be bak on the road soon and will be much improved
to live with day to day over what it was (and it wasnt bad then)
#Post#: 100238--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: D4B Date: December 28, 2015, 5:13 am
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Sorry to hear of your encounter with a tractor!
Very interesting, great work!
Thanks for posting....
Didn't know about the HD Track Rods so will add those to my
shopping list 8)
Cheers Steve
#Post#: 100239--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: kev Date: December 28, 2015, 5:49 pm
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What bad luck. :-\
Fair play to you for cracking on with it! :thumbs:
#Post#: 100247--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: CaptainSlow Date: December 29, 2015, 7:25 am
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Must have been heartbreaking to think you'd have to rebuild her
a second time, but you're making excellent progress - its
looking very good so far! :thumbs: Very lucky with the chassis
- it was a big hit looking at that bumper :o
#Post#: 100258--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: samc88 Date: December 29, 2015, 3:11 pm
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Yeah was gutted when it happened but i suppose it gives me a
chance to get on with jobs ive been putting off for the last
year.
Finally with help from my Dad the new dumbirons were fitted.
Used a bit of angle with 4 holes drilled through to replicate
the bumper and rested the spring hangers on axle stands with
blocks on top to give me the exact measurements I needed to get
it spot on. Also clamped a bar to the front crossmember to act
as a centerline. Simple to work with but needs a lot of double
and triple checking after tacking that everything is in the
right place.
will paint them black tomorrow and hopefully will be able to get
the axle back on on thursday
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC290018.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC290018.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC290019.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC290019.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC290020.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC290020.jpg[/img][/URL]
#Post#: 100260--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: hippydave Date: December 29, 2015, 3:24 pm
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you will riding about and smiling again very soon i hope,
#Post#: 100262--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: samc88 Date: December 29, 2015, 3:28 pm
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The MoT's due at the start of February so thats my deadline for
getting her going again but hopefully I'll get it on the road
again by around mid January :)
#Post#: 100291--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: samc88 Date: December 30, 2015, 1:47 pm
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Right then, more progress done today and im a bit ahead of
schedule. Managed to singlehandedly refit the axle which was a
faff as the passengers side had been shoved back but with use of
a bottle jack, prybars and screwdrivers managed to get it all
lined up nicely and fitted. All looks square again now so Im
happy that my dumbiron repair has worked out :) Also got round
to fitting the other track rod and set the tracking up. I will
have to do this later on again when the wheels are on to set the
toe in. Everything looks good so far, was very lucky with the
chassis damage being so limited. Oh also painted everything
gloss black so looks better now :)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC300023.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC300023.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC300028.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC300028.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC300029.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC300029.jpg[/img][/URL]
I also started on a bit of bodywork by straightening out my
front panel and giving a coat of grey undercoat
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/PC300030.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/PC300030.jpg[/img][/URL]
So tomorrow I'll probably refit the new shock absorbers (Procomp
ES3000s) so will be back to being an almost rolling chassis.
I'll leave the wheels off till ive fitted the wings so I can
have maximum access to everything. Plus it makes it easier to
bleed the brakes.
#Post#: 100361--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: samc88 Date: January 4, 2016, 4:46 pm
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Got the wheels back on to check all the axle bits are
functioning as they should (they are) and the new shocks fitted
tonight. My free Wheeling hubs have been on borrowed time for a
while so as the drivers side one is a bit buggered I'm going to
swap for standard drive flanges. Always had them engaged anyway
so won't feel a difference but less stuff to go wrong.
Also the drivers side wheel bearing needs tightening up due to
play so will be sorting that tomorrow evening as well as making
a start on the passenger side wing hopefully
#Post#: 100400--------------------------------------------------
Re: Margaret's second (unfortunate) rebuild
By: samc88 Date: January 7, 2016, 5:47 pm
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Progress tonight :)
Wheel bearing adjusted and new drive flange fitted. The britpart
dust covers are a tight fit to say the least!
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P1070047.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P1070047.jpg[/img][/URL]
Shocks fitted and brakes bled up. A trick i found to fit the
split pin in the bottom shock mount is to use a valve spring
compressor to compress the bush enough to get the washer on and
pin in the hole
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P1070046.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P1070046.jpg[/img][/URL]
Also found time to fit the front panel. I was just going to
paint the back of it to protect it when the other bits get
refitted but ended up rollering the front and the top as well
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P1070045.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P1070045.jpg[/img][/URL]
Getting there now
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P1070044.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P1070044.jpg[/img][/URL]
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