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 » Fri Feb 22, 2019 11:24 pm

It's been soaked in penetrating oil and I've rock n rolled the wheel; it's seized solid. I've been trying for 2 days now. Will have another try tomorrow.
I think it was overtightened and then the splines have rusted together too. The oil doesn't seem to be able to find a way in, there's no visible line where the spline tops should be visible.
Can't believe it's the bl**dy steering wheel that is holding me up and making life difficult. :(
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 Feb 23, 2019 2:17 pm

Got straight back on it today. First off, make a second plate to double up and spread the pulling force. It will now wrap around the column below the wheel and bolt the two halfs together.

Image

Put it in place and on with the bearing puller...

Image

Started to tighten up and watched the steel begin to bend under the strain. My heart sank as this was really beginning to get ridiculous now. However, I persevered and just as the puller was on the verge of coming off the bending plates, donk! Movement at last. I quickly reversed the plates, refitted the puller, and began to crank. Slowly the wheel finally eased up off the shaft.

Well, what a relief. Can't believe such a stupid problem could cause so much grief. Loads of time and effort spent trying to undo something that should have come apart far easier.
As I suspected, the splined shaft and bearing surface is corroded...

Image

I was also correct in doubting the penetrating oil was getting in; it clearly hasn't. Tip for anybody re-assembling or putting nuts on bolts; put some bloomin grease on!
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 Feb 23, 2019 7:24 pm

Right, now that the steering wheel is out, I could crack on. Stripped the remaining bits still attached to the bulkhead, pulled the loom through, speedo cable freed, brake pipes, clutch pipe, choke cable, throttle pedal, freed the feet from seals, removed the two bulkhead to chassis bolts, and out it came.

Image

Image

Next up, the seat box.
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 » Mon Feb 25, 2019 6:06 pm

And the seat box and side seals are off. Sprayed a can of degreaser on the greasy dirty bits and gave it a bit of a scrub. Needs a pressure wash now.

Image

Getting a bit daunting now. Taking stuff apart is relatively easy; repairs and reassembly takes a bit more effort.
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 » Mon Feb 25, 2019 6:52 pm

Apart from the few bits of rust, it's all looking pretty good really,
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 » Tue Mar 05, 2019 5:36 pm

While I'm waiting for an order of bulkhead and seal replacement parts to arrive, I made a start at removing the rot from the bulkhead.

I'm not the first one here. This bulkhead already had repairs done in the past. Shame the work wasn't done well enough to prevent the problems I now need to resolve. First of all, drilled out a number of plug welds. They were all over the show.

Image

As I suspected though, the rot extends all the way underneath...

Image

...so removed the piece further across to reveal clean metal...

Image

...and cut the piece off. I'll have to have a go at fabricating a replacement

Image

That will have to do for today. To be continued...
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 Mar 07, 2019 7:50 pm

Back on it again today and removed the passenger footwell

Image

Lots of spot welds and plug welds to drill out

Image

Eventually got t it out in one piece

Image

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

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

Re: Restoration

Post by disco2hse » Thu Mar 07, 2019 8:10 pm

Loving your work. Lots of little areas that would hae spread if you had not made the decision to do a major strip down :)
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 » Thu Mar 07, 2019 10:21 pm

I'm trying to be methodical and thorough. Could have just patched it but I'd rather get it as sound as I can and then It won't have to to be done again.
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 Mar 08, 2019 2:08 am

Ayup. Do it right, do it once.
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 Mar 09, 2019 5:56 pm

Got the driver's side footwell out today.

Image

The deeper I get into this, the more I find. Seems there is a lot more rot hidden away than I first thought.

Image

I'll just work my way through slowly, find the rot and get rid of it. All a bit mundane and not particularly exciting or interesting.
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 Mar 09, 2019 6:23 pm

It is interesting to see where the rust is appearing.
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 Mar 09, 2019 11:15 pm

All the usual places really. I shall be doing my repairs utilising copious amounts of weld through seam sealant. It should last at least as long as I will that way :shock:
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 » Fri Mar 15, 2019 7:53 pm

Took delivery of a panel beating hammer and dolly set today, so got straight to work and made my first hand crafted replacement piece.

I need a new one of these...

Image

...so cut out a piece of steel...

Image

...and hammered it into shape...

Image

...and checked for fit...

Image

It will need a bit of fettling yet, but quite pleased with my first attempt.
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 Mar 15, 2019 8:18 pm

Nicely done :)
Alan

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

Post Reply