some exotic Stage 1 in Germany

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disco2hse
Posts: 1583
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: some exotic Stage 1 in Germany

Post by disco2hse »

Outstanding! :D
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5
tomo_
Posts: 18
Joined: Tue Jul 05, 2016 11:37 am

Re: some exotic Stage 1 in Germany

Post by tomo_ »

nice!
can't wait to get my engine kick in. im in the middle of the project as well but standard 109 and way behind your progress.
Def 110 200Tdi, work in progress on Stage 1
FBW
Posts: 40
Joined: Sun Dec 20, 2020 10:41 am
Location: southwest of Germany

Re: some exotic Stage 1 in Germany

Post by FBW »

disco2hse wrote: Wed Apr 21, 2021 9:20 pm Outstanding! :D
tomo_ wrote: Thu Apr 22, 2021 4:58 am nice!
can't wait to get my engine kick in. im in the middle of the project as well but standard 109 and way behind your progress.
Thank you very much, I am happy if you like my work.


greeting
Frank



I still had an e-fan in the fund. The placement is due to the fact that, with a little luck, I will get a second, identical one.
The fan mask stays that way.
... yes, yes, there is a strut in the middle!

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... and then the second fan was in the mail.
That is really tight in the fan cowl. But what doesn't fit is made to fit. The black thing is made of thermoplastic :wink:

Sawn out insert

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... warmed up the bottleneck with the burner and clamped everything together.

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The missing millimeters bulge ;)

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The second fan was once installed in front of the cooler. You just have to loosen the clip, pull off the fan wheel, turn it around and clip it back on.

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But the clip is stuck> needle-nose pliers >> ... it's out >> ... pling !! >> ... he's gone :o :x :twisted:
For over half an hour I search the workshop floor on all fours ... in vain Image

Where can I get such a clip from >> O.k. do it Yourself.
It is stupid when the fan is mounted behind the cooler, the load pulls the fan wheel in the direction of the clip from the shaft and thus in the direction of the cooler >> coolers are expensive! The craft solution must be absolutely secure:

„et voila“ Clip made from the turn of a matching spiral spring. The washer is countersunk so that it presses the clip into the groove.
There are also wire fuses. It'll hold up better than the original. Image

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there we have the airy duo Image

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greeting
Frank
FBW
Posts: 40
Joined: Sun Dec 20, 2020 10:41 am
Location: southwest of Germany

Re: some exotic Stage 1 in Germany

Post by FBW »

Hello everyone


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The long wait for the painted tub...


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... has come to an end!



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... you slowly see what it should be Image

There are still too many little things to do. These sometimes take a long time, and when you are done with it you don't see any of the effort. :P
Bulkhead aligned and fixed.

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Bright spots at the rear

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Seat box completed.
The right storage box was drilled out before painting. There weren't any on the left, there was an additional side tank. Replacement has been waiting in the fund for a long time.

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stubborn, pimped up and stapled together.
For that she had to be opened the second pack of 500 cup rivets :shock:

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.. again something for the eye!



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The sheet metal between the upper and lower part of the dashboard is normally black. Like many other things, the thing was painted in limestone.
After thinking about it for a while, the idea came up to leave it that way. So the shelf is not such a dark hole. I like itImage

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You can now accelerate too!

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... but don't heat it up yet. :) . Something is still missing.
E.g. the aluminum pipes from the engine to the heat exchanger. I don't have it, I have to tinker with it.

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Currently there is still a very rare special component installed :o :P

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greeting
Frank
FBW
Posts: 40
Joined: Sun Dec 20, 2020 10:41 am
Location: southwest of Germany

Re: some exotic Stage 1 in Germany

Post by FBW »

Gordian knot also called wiring harness

The thing is in pretty good condition and apparently unencumbered. Which is not to say that everything is OK. is.

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The line running through the frame to the rear is probably torn off when you pull it out of the frame. When looking through whether it got something else, I found a thickening. As a precaution, I took a close look at them.
oha! The cables were lengthened at the factory (!). Image

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... after my surgery it looked like this ...

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And here the "new", ready-to-install cable for the rear.

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It doesn't look much better, but you could say that "the mess now has a system" :D

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Pulling in the wiring harness is not one of my favorite tasks!
You need a bit of variety in between Image

The brake lines between the master brake cylinder and the brake circuit failure valve, or whatever it is called, were still in great shape, so I wanted to reinstall them. Unfortunately, the "in good shape" only referred to 95%. The last two inches to the failure valve were rotty ... too rotty! Since the rest of the brake pipe would not have been enough anyway, I ordered two pieces and replaced the last few cm.

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Then the water pipes to the heating heat exchanger were tinkered.
I got a suitable aluminum pipe at a trusted hardware store. Warmed up with a soft flame until it can be easily bent.


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It is a pity that you will no longer see the beautiful pipes behind the air filter box.

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In most areas, the Landy has a nice, logical structure and is easily accessible.
The developers did not have a good day with the dashboard and the wiring behind it. It is absolutely incomprehensible to me how one can build such a botch in series Image


To compensate, I always have to look for a job that is more fun.

Holder for the AHK socket including wiring harness made from existing material.Image

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The main wiring harness remains unchanged.
>> I had already worked up the engine wiring harness.
>> I had to make all the wiring harnesses to the rear. I didn't want to leave the "original" piece like that. The new main wiring harness to the rear now corresponds to the original, except for the stretched length.
>> At the same time, I tinkered another strand that organized the connections to the gearbox and a separate power supply to the rear.

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A long time ago I installed additional 12V + USB sockets including switches and volt meters on the Shorty. This has proven itself and is also implemented 1: 1 with the Sandy.

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Everything is connected at the back. I think I mentioned it that I put a thick cable with a secured permanent plus to the back. Among other things, it supplies a relay for driving. The original cable now only switches the relay.
It's pretty easy to see what's on it.

2x taillight +
2x license plate lights +
2x taillight on the trailer +
1x license plate light on the trailer

... and the electricity does not only run through the thin cable but also through the light switch, the switch on the steering column stalk and the ignition lock!
The measure relieves all of this and, as you can see, it is secured separately again.

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.. Everything was already fixed..

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... and even here there is a legitimate chance that the lid will fit on it at some point ... Image

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... let there be light

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greeting Frank
disco2hse
Posts: 1583
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: some exotic Stage 1 in Germany

Post by disco2hse »

:lol: :lol:
> It is absolutely incomprehensible to me how one can build such a botch in series Image

It is the delights of British motor vehicle manufacturing.
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5
tomo_
Posts: 18
Joined: Tue Jul 05, 2016 11:37 am

Re: some exotic Stage 1 in Germany

Post by tomo_ »

Is just superb and also comprehensive description
Def 110 200Tdi, work in progress on Stage 1
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