Restoration

Technical questions and answers
Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat Mar 16, 2019 7:10 pm

Carried on with passenger footwell. Made a piece to replace rot where heater bolts on, and dry fit the YRM footwell.

Cut the rotten bit of the panel away...

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...made the replacement section...

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...then checked it all for fit.

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Next will be to weld it in place, but before I do, I'd better decide on what to do with the A pillar. I have a replacement and new foot so will get that sorted before welding everything together.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat Mar 23, 2019 8:12 pm

Before I started welding, I was reminded to make sure it was going to fit back onto the chassis bulkhead outriggers. After a lot of measuring and re-measuring, I drilled a piece of box section I had to hand so that I could bolt the feet to it and keep everything where it needs to be. The complication I had was that one foot had rotted and fallen off, so I had to work out where the replacement needed to go so that everything would be in the right place when it eventually gets reassembled.

I forgot to take photos as I was a bit focused on what I was doing, but took some when I remembered. I did things a bit backwards really and would definitely do things differently if I ever do it again.

You can see the datum bar in this pic
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With the footwell, A pillar, and foot positioned
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Tacked up
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I then took the tacked together bulkhead and fitted it back on the vehicle and checked it fitted...

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Phew!

Right, now for the other side. I decided the post was sound and it was just the foot that had corroded, so get the foot out and fit a new one. Drilled out the spot welds...

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...and postioned the new foot (lots if measuring and double checking again)...

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...tack and plug it...

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...and leave it there for today

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Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1471
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Sun Mar 24, 2019 6:46 pm

Nice. Good idea about doing it that way. It is how we were taught to do it in our metal classes :)
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Wed Apr 03, 2019 11:50 pm

Work continues. Although superficially, it looked in great shape needing minimal repairs, it has thrown up a few issues. The bulkhead is not the original and whoever replaced it, either repaired the replacement or bought an already repaired replacement. Either way, I've inherited some pretty poor patchwork. So, I find myself trying to correct the earlier work.
Not having an untouched original to compare with, I am redoing what I have in front of me, so originality has been sacrificed. I think that is evident from the first of my repairs as having replaced like for like, I don't think it looks correct compared to some photos I've seen. However, I'm not that concerned that it needs to be exactly as factory anyway since it already has changed chassis and engine.

Cut out corrosion perforated section...

url=https://postimages.org/]Image[/url]

...and tacked in flush patch piece (don't ask about the gap!)

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Stitch welded and rough dressed.

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I need to get some extra tools for grinding and surface finishing and make a better job; I'll have to tidy up later.

This is a previous owner patch repair. It's just sat on top of rot and seem welded all around...

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...so I cut out the patch and the rot surrounding it...

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...and put a new piece in. Forgot to take a picture.

Next up, I discovered that the new footwell was not fitting as it should. The side section that sits alongside the gearbox/bell-housing had been got at with earlier footwell replacement and was slightly out of position; more spot welds to drill out. Got it out and cleaned up ready to refit...

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The YRM replacement footwell is a standard series 3 version I believe, so I have got to modify for 109 V8

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Made a template for the strengthening plate...

url=https://postimages.org/]Image[/url]

...and used it to cut out the steel sheet...

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...and then made the folds to fit...

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And that's enough for today. Time for a beer.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat Apr 06, 2019 10:10 pm

Finished off the footwell stiffener and plug welded it in place

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The poor repairs visible through the rubbish paint job have been niggeling at me, so I decided to strip the paint off and get a proper look at what's hiding. So, out with the paint stripper...

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...later...

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Unfortunately, as I suspected, the old repairs were not done well...

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also, it is apparant that it has been sand blasted leaving the surface quite rough and blown through in places and just covered up with filler...

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Ah well, more work to do.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Thu Apr 11, 2019 11:06 pm

With the paint out of the way and getting a better view of what was hiding underneath, I decided to sort things out. I started with the horrible looking bodgeup in the centre, which had dodgy welding and filler on top of rot.

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I peeled back the overrlap and chipped out the filler

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There was a scrappy looking section of angle welded on the front

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so cut the whole section out...

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Now, Since the PO had seam welded, I wasn't going to get this apart easily so I decided better to make a new section. First I filled in the missing bit...

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...and then set to work fabricating...

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I'm quite pleased with this

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Clamped it in position...

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Ready to plug weld

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Then welded and cleaned up

Image
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Thu Apr 11, 2019 11:30 pm

Next up the small patch.

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Working on the basis that each old repair I've looked at so far has had rot underneath it, I can't really afford to leave it untouched, besides, aesthetically, I find it unbearable to look at even if it will be hidden behind the dash, so out it comes...

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As suspected, rust perforated metal still underneath, so cut it out...

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Neutralise the rot...

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And but weld in new patch...

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I'm a little disappointed with my welding as I don't seem to be able to get thing cleaned up as well as I want. Hopefully some new grinding and sanding tools will help. I'm taking great care to avoid distortion by stitch welding and cooling each weld and going very slowly, but I'm still having a hard time.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1471
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Fri Apr 12, 2019 2:50 am

Well, I am impressed by what you are doing. The folding on the centre repair looks the bees knees.
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Fri Apr 12, 2019 6:07 pm

Well, thank you :)

Thought before I weldup the driver side footwell, best check it still fits. So tacked the footwell in place and carried the whole assembly to the vehicle.

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Well that's a relief, still fits.

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Ah well, back to welding then.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

Fish
Posts: 12
Joined: Fri Dec 28, 2018 7:35 pm

Re: Restoration

Post by Fish » Mon Apr 15, 2019 3:33 pm

Looks like it is coming along well.

I can't start mine till July then I'll see what state mine is in...

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Fri Apr 19, 2019 1:09 pm

This is like a never ending nightmare, the more you do; the more you reveal, and the more to put right. I'm having a rest this weekend as I've been lost in the land of bulkhead for too long without coming up for air. I'll just write up this weeks work before I put my feet up.

Having test fitted the bulkhead back on the chassis, it was time to weld up the drivers side footwell in place, so plugged and dressed and all nice and solid. Next, I turned my attention to the top corners and top rail. Although it feels pretty solid, the badly patched-over top left inside corner is no doubt hiding rot and future problems.

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Also, the inner top lip of the vent opening is rotten in several places. This was obviously where the rust flakes had come from when I first inspected. It's quite amazing how much you struggle to see when hidden from plain view. It had the vent panels in the filter screens in place of course as well as paint.

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After cutting out the patchover, sure enough, rusty old steel...

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...and the outside looked like this remember

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...so cut that away to reveal this

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Cleaned up and a bit of rust converter

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I cut a piece of steel to strengthen it up...

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...and plugged it in place. I'm a bit nervous I'm adding a moisture trap but hopefully, after hot dipping, it will be good. Did the other side too.

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I had cut out, cleaned and treated the inside area...

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The end concave section retained temporarily for reference.

Next, was to fabricate a piece to fit in place of the cut out steel. This took a while and I didn't photograph progress as I made it. Ended up with something that should work

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Rescued the captive nuts (I could have used new rivnuts but nice to keep the look authentic)

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...and plugged it in position

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Finally, fitted in place.

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Not finished it yet, but had enough for now. Back soon.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1471
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Fri Apr 19, 2019 7:37 pm

What did you use for the complex concave curve? Just a hammer and anvil or a press of some sort?

When you have it galved, will you stick a bolt into the captive nuts?
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Fri Apr 19, 2019 10:25 pm

I just hammered away against an section of rsj I have, not quite an anvil as such but kind of. That's why it's a bit rough and ready. As for galvanizing, well, first of all I have to find somewhere to get it done, then I guess I will have to do something about threaded holes etc. I'm open to suggestions and advice on that one never having done anything like it before.
I could just epoxy prime the thing I suppose and not galvanize it at all but then all the inside surfaces will stay untreated.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1471
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Sat Apr 20, 2019 3:36 am

Good effort, regardless.

I've never galvanised something like that before, so I have no suggestions. But it seems sensible to slip a bolt in there. But I am sure someone with experience will tell me why it's a bad idea. :lol:

Here's some useful advice on the subject. http://az276019.vo.msecnd.net/valmontst ... ctions.pdf
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

Cliff4WD
Posts: 75
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat Apr 20, 2019 9:08 am

Thanks Alan, useful info. Most of what I've read from others after having galvanised their bulkheads described re-tapping threads and drilling out holes. This may actually be preferable to trying to remove bolts now trapped in place, I don't fancy struggling to remove bolts that won't turn and possibly shear off and need drilling out etc. Tapping out the zinc layer seems like far less aggro.
As far as I'm aware, it's just the 4 nut threads at the top corners for the windscreen locks and the bonnet vent flap hinge pin holes that are exposed. There may also be a few small threaded nuts on the footwell tunnel side for mounting throttle pedal assy etc. I need to check it over. Hopefully the galvanisers will give me advice when the time comes. Frankly, there are a lot of holes and seams that I hope will seal up solid! :D
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

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