The 110Posted by Nicky Smith Thu, January 05, 2017 13:51:40 It felt like I was slipping backwards, all of the hard work putting things back together seemed to be coming back off The 110 in droves. One step forward seemed to lead to four steps back. This though it would seem is all part of the fun of Land Rover ownership.
After the initial run up of the engine and the modification of the radiator brackets I had to actually mount the Header Tank in a proper permanent position. Now this should be a straight forward affair really but the 300tdi header tank I had bought fouled the suspension cone turret. "Not to worry" I thought to myself "I am a resourceful fellow, I shall make a bracket up" So that is exactly what I did. I dug out some metal and made up a bracket. This fitted easily and before I knew it I had the header tank fixed into place.
A little later I got talking to a friend about the turbo issues that were going on when, after I had sent a picture of the days work, he pointed out that the header tank was probably far too low to work properly. Hmm...back to the drawing board then. I set to seeing what could be done I mean I am not that daft to only come up with one solution to a problem so I sat back with a brew and pondered the issue. A new bracket then but I only had the metal that was already used but not to stress a bit of bending here in the vice and there with a hammer along with some gentle persuasion soon saw it all remoulded for a higher mounting.
Now that header will sit above the radiator and the coolant can now circulate around nicely. As the tools were out I quickly popped the rad and front panel back into place so The 110 will finally once again start to look like a Land Rover.
One thing I am not looking forward to doing is wiring those lights back up. I hate Land Rover wiring...
The 110Posted by Nicky Smith Mon, January 02, 2017 14:58:07 Here we are again then folks, we made it into 2017 alive and kicking. Some friends and family were not so lucky but that drives home the fact that we should live our lives to the max every day doing what we enjoy. With that said I have done bugger all for the whole of the festive season on The 110 and that I did enjoy! But all good things come to an end eh.
Before work today I decided that I really had to sort out that issue with the bonnet sitting too high and resting on top of the Discovery Radiator and oil cooler housing.
First things first I had to drain the coolant out from the radiator, luckily i had only put in just enough anti freeze to keep the whole thing from freezing so no great expensive loss there. Once all of that had finished dripping its way out I disconnected all of the pipework forgetting that the oil cooler pipes would have oil in them...that was messy.
A few minutes cleaning up an oil spill later and I lifted out the whole rad/cooler set up popping it into the garage then covering it up with a plywood board. Yes I am paranoid about putting a hole into another radiator!! It is an expensive mistake not to be made twice. Obviously I had already measured the gap between the wing and bonnet so it was just a quick mark up on the existing bottom brackets before cutting through them then cleaning them back to bare metal ready for welding up.
A few minor adjustments with a lump hammer saw the newly trimmed brackets dropped into place with all of the body panels then offered up and hurrah! the bonnet now closes like it is supposed to. I dug the welder out which didn't want to play with the feed coughing and spluttering away giving me just enough cooperation to get the brackets welded permanently into place.
I have left all of the radiator bits off for now as I want to position the header tank properly and get those oil pipes made up and fitted into place, this will make access just a little easier. When I stand back though I cannot help but think The 110 is starting to look like it wants taking apart again...
***A quick follow up note. At the beginning of this post I mentioned doing what you like every day and a memory came to me yesterday as I ran through the torrential rain with my coat held on only by being hooked over my head that when we were kids we did just that, hooked our coats onto our heads whilst pretending to be superheros. I was always Batman of course and I have to admit running through the rain yesterday made me feel like I was seven again. And it turned me into Batman...I am the Batman.
The 110Posted by Nicky Smith Sat, December 24, 2016 18:04:56 It's amazing how quickly things end up coming together in the end. After spending as much time as I could on The 110 recently it has got to the point where I am easily putting things back together surging head long towards getting an MOT put on it. With that in mind I decided that I was getting a little fed up with falling through the gaps where the floor should be whilst clambering over two seats that moved around more than my teenage daughter. So the first point of call was to get those seats secured for now. They will be coming out again once the motor is on the road to soundproof it better but for now I am happy to keep it nice and functional, just how it was originally designed.
I soon made short work of popping the main tunnel and floor pans back into place. These for now are just resting there incase I need a little better access to the gearbox or transfer box whilst getting the final set ups sorted out. A freshly charged battery was grabbed from the garage, fitted and secured into the recently welded up battery box. The exhaust was now fitted so with no fear of being gassed once again I climbed into the drivers seat and turned the key in the ignition to be met by the 200tdi engine bursting into more or less instantaneous life. This was accompanied by the usual grin from me but now was the moment of truth seeing if everything I had refitted would work making the car once again move under it's own steam.
I dipped the clutch pedal that gave enough satisfying resistance then gently tried to engage reverse gear. It slotted perfectly and smoothly into place. I let the clutch pedal up a little and was soon met by the biting point. I grinned like a nut case once again and let the clutch gently start to bite and the whole 110 began to move slowly backwards along the drive. To say I was preoccupied in my amazement that I had actually put everything back together correctly would be an understatement and only just in time did I realise that I was about to reverse into the fence that The 110 had been tightly parked up against! In fact I am not sure how I managed to move the fifteen back that I did without bumping into the fence already.
This though gave me the opportunity to see if it would move forward as well as backwards so I selected first gear and smoothly drove forwards with no issues.
I soon had it all the way up and off of the driveway as far from the house as I could to let it tick over warming itself through for the first time in years just incase something went bang or caught fire.
To say I was happy is an understatement. My creation has proved itself by moving at least fifty feet under it's own steam! Yes it smelt a little burning oily but I just put this down to it being sitting around for years along with the odd spillage here and there when I changed all of the fluids before firing it up. Nothing to worry about. Well nothing for about five minutes until I noticed the alarming amount of oil that was dripping out of the Turbo itself... I literally hopped back into the drivers seat, drove it over the hump of the driveway then killed the ignition letting gravity on my downhill driveway pull The 110 back into it's semi dry working spot under the car port.
I felt really disappointed. Talk about one step forwards then two steps back. Add to that I am skint and it will take me several months to save up for a replacement turbo I could have cried a little. I was literally ready to throw in the towel proper then, just sell the whole damned thing and buy myself a facelift Discovery 2 instead because at least then I would have something I could use straight away.
Time for a cup of tea then.
Twenty minutes out had seen me take a few deep breaths, go back to this expense peice of scrap I owned and refit the drivers side wing. I wanted to offer up most of the front end because the radiators seemed to be sitting a little high for the bonnet. I was right there too. I need to adjust the mounting brackets lowering them by about 30mm so that the bonnet will actually close.
I also had to trim the outer brackets off of the radiator cage as well as these were fouling the wings.
I popped the front grill back into place so I did not have a repeat of the whole sticking a ratchet through the radiator performance. All in all though things are still heading in the right direction. There is still other work to be completed while I save for a turbo but I was hoping to have it on the road in about a month. Hey ho things can always be worse eh.
Christmas time is once again upon us! It seems to come around quicker and quicker each year. My home seems to resemble Santa's grotto more as each passes but I don't mind that at all. I would just like to Wish all of you out there a very Merry Christmas! May you all have the best one you can and remember it's not about what you get given but trying to enjoy time with Family and close friends, then congratulating yourself at the end of the day when they have all left without you killing them...
The 110Posted by Nicky Smith Tue, December 20, 2016 18:27:24 After yesterdays success I would quite like a repeat performance of hearing the engine running once more but without the rather excessive black smoke that was like smoking a couple of thousand cigarettes at once. The first order of business was to get the exhaust fitted. The rear and mid sections were no problem at all of course but the front had to be cut shut and welded up once more to make it fit onto the 200tdi Disco engine.
That done I started to drain the old thick black oil out of the engine. Whilst that was happily dripping out the oil filter grabbed my attention. This had to come off and I had my trusty oil filter grips to use. It did not want to budge. I managed to crush the bottom of it then dent the middle but still no movement. Time to take a breather. I lay there under the 110 resting up my arms for a while before putting the grips towards the top of the filter and with all of my might twisting hard it finally budged a few millimeters. That came with the feeling of relief so I gripped hard and twisted again. It moved more easily this time, finally coming loose and dribbling as much oil out of it's housing as seemed to be coming out of the sump.
I left the whole thing to drain for twenty minutes or so before refitting the new filter then topping the engine up with new oil. Tomorrows plan is to tidy up the floor well then start to refit the seats and floors themselves. Then I can start it up properly and run it up to temperature seeing if we have any issues with what has been refitted...
The 110Posted by Nicky Smith Mon, December 19, 2016 21:27:27 What an eventful day! I literally just popped out under the car port for a bit of a potter on The 110. As always I quickly ended up in my own little world tinkering here and pottering there. First off I had to attach some ends to and ground the two Earth wires that were on the engine onto the chassis after a few good minutes sanded back the underseal to get to clean metal.
Then I figured I may as well top up all of the oils in the gearbox as well as the transfer box. Four litres or so later that was done up and put to bed so I got to looking at engine itself. I really wanted to start it but I knew I probably should change the engine old fist but I have to admit that after all this time getting the lump into place impatience was getting the better of me. "Sod it" I thought to myself and headed off to get a can of diesel. WHen I got back without anything but excitement in my mind I filled up the fuel filter and using the lift pump primed up the fuel system as best I could. There were three old batteries in the garage that were ok when I put them in there but I had topped them all up last week. With a grin on my face I hooked up the first one then with excited anticipation I turned the key...the engine turned over twice before the battery died. Hmmph. Right not to be phased I grabbed the second one. Same thing, two turn overs before the starter ground to a halt. OK then it must be third time lucky. Nope, dead from the outset.
I was beginning to suspect that my very old battery charger might just have given up the ghost. A quick conversation with a neighbour and I had a boost pack in my possession. This was duly hooked up and left for a few minutes to force some charge in. Then with bated breath I clambered once more across the two seats, sat down and turned the key around.
The engine fired up instantly into life and I learnt two things...
1) You really should change the years old oil in any engine before you try to start it. 2) Make sure you have fitted the full exhaust system as well as replacing all floor panels so the inside of the cab does not instantly fill up with thick black smoke leaving you fumbling for the keys in the ignition to switch the engine off.
So GOOD NEWS!! The engine runs!! It's alive!!! I have no idea if it drives yet because I could not see my hand in front of my eyes when it was running so a quick oil change along with fitting the exhaust and floor pans back into place should put that right.
Those dreams of heading out onto the open road could well soon become a reality...
The 110Posted by Nicky Smith Wed, December 14, 2016 12:50:51 Right I need to go to work soon add to that I am full of cold again this is going to be a hard and fast update and not in a fun way!
I started with the power steering. I stood wondering what pipe went where but it was pretty obvious once all of the bts were out as they would only go so far lining up with the correct holes just begging to be plumbed in!
Once done I cable tied the fluid reservoir in an upright position and promptly filled up as much of it as I could with power steering fluid. I will bleed it properly once the engine is running.
With all of that done quite easily I decided to set up and support, with cable ties of course, the coolant system and expansion tank. Again literally took minutes.
And when I stood back looking at the magnificence of my complete creation it brings rather a large smile to my face!
That left just one more thing I wanted to tackle today...the exhaust. Well the down pipe from the manifold. I bought one of those James Parkin (I think that's what the name was anyway) Discovery 200tdi to Defender conversion kits. It hit the footwell. So I had to modify the footwell. Well I need to modify it, all I did today was cut piece of the footwell out so the exhaust wouldn't keep knocking as I hopefully drive around.
It wont take long to fabricate an extra piece of metal to slot in there. I did have to modify a 17mm spanner to fit in on the back bolt of the exhaust (I just cut a spare spanner down in length) so it wouldn't foul on the engine block. It was soon all in place though.
Next up will be fitting the exhaust in place and making up some brackets to keep it there. I need to pick up some engine oil and do a quick change before I try to fire it up and I think I have some EP90 kicking around somewhere so the rest of the fluids can be sorted out at the same time. That's going to be it for a few days folks as the retail madness of Christmas kicks in at work, I don't think I will have much time to be doing much of anything apart from work then sleep for a few days!
The 110Posted by Nicky Smith Mon, December 12, 2016 16:26:00 Are there any other Males, especially Dads, out there that have any idea what Christmas presents have been bought for their daughters? I have to admit I don't have a clue before hand but as I informed my youngest daughter last night when she brought this up that I personally vet each and every gift when it is unwrapped on the big day,. If I am honest it doesn't stop with my daughters either, it runs out to our friends and family who when tell me "thanks for the present, it was just what I wanted!" I tend to reply "That's great, I am really pleased that you like it. What did I buy you?" Some would say that I this is really bad not having a clue what has been bought and leaving all of the festive cheer for my ever suffering Wife to sort out, but not really it is for the best. I am rubbish at buying gifts and even worse at wrapping them! Luckily the girls are now older and tend to (Always without fail) wrap their Mothers gifts from me vetting them as they go and handing back with receipts in bags the ones I need to change along with a list of what I should change them too. Then they look at me for about two seconds, take the bags back off of me and just put their hands out for my debit card usually muttering "Just give it all here, I will sort it tomorrow." You see it's not for a lack of trying...I am just a little bit rubbish at the whole thing! I did buy a few extra gifts for my Wife today and they are currently sat in hiding waiting for my youngest to get home to tell me how well I have done but one thing is for sure, if the crowds (more like mobs) I saw out today were like that on a Monday I do not want to be anywhere near any sort of store until about February! Then it needs only to be a car shop.
After that little swaray (I'm sure I have spelt that wrong) venturing into the great retail world I decided that seeing as I am on such a roll with The 110 I may as well have a stab at a few of the little jabs that are outstanding. I had nipped into Paddocks on my way around earlier so the water pump bypass hose along with the top intercooler hose were just itching for fitting.
The bypass hose was soon out of it's packet and into place along with a couple of shiny new Jubilee clips.
The intercooler hose though would need extending and seeing as I had just spent what was left of my bank account on Wifey for Christmas I was going to have to be a little creative here. Off to the spares shed I pottered with the beginnings of an idea forming at the back of my mind if the part was still in there. After a minute of moving things around, I really need to tidy up in there, I found a shiny new V8 exhaust down pipe that was exactly the right width! Now this had been part of a job lot bought a long time back which I had already made my money back on so chopping it up was not going to be an issue. In my nice dry garage I measured out the length that I needed, chopped it off and fitted it in no time!
The bottom hose is on back order so that will be done later in the week. I decided that as I was already in my dirty work clobber I may as well bleed the clutch. The old fluid was really dark so who knows how long it had been sitting in there! I have a non return bleed pipe that cost me about two pounds a lifetime ago which still works wonders when you are doing this sort of job alone. Again it all went really smoothly with me getting the correct pressure build up nicely on the clutch pedal very easily and quickly.
Another few jobs down then. Feels like the reality of driving the bugger is actually an option now in the not to distant future. I did realise whilst stood back looking at it (as you do) that I still need to plumb up the power steering pipes before I fire it up as well. Not a problem as I have those pipes but not today, I need to do the whole Dad breakdown and recovery thing for my eldest daughter who managed to crash her motorbike once again today. Thankfully she is ok but as for the bike, well, that remains to be seen.
The 110Posted by Nicky Smith Sun, December 11, 2016 19:54:23 Well I have had a busy couple of shifts on the 110 over the last 24 hours and I have surprised myself at how many loose ends I have managed to get tied up. It was all nearly scuppered early on last night when the rain started to fall heavily. Now in the last house it would have been game over but with the car port covering most of the land rover and the shiny new garage roof keeping all of the water at bay outside where it belonged, I was happy as a pig in the proverbial pottering about with the dark winter nights being held at bay!
I have been sitting here for the last few minutes since finishing the first paragraph trying to remember exactly what I have done in what order but I am giving up with that! I will just pop in what I do recall as there has been quite a bit! Firstly I put jubilee clips on the pipes I fitted last week, I had bought a large box off of the internet of the mixed sized ones and they have been a godsend, then it was onto getting the alternator and power steering belts. I changed a couple of the bracket bolts over so they actually tightened up then after a ten minute mild panic hunting for the belts I knew I had bought in the garage then the spares shed, the belts finally turned up in the back of the 110 where I had put them so they would not get lost. It took a mere couple of minutes to pop the into place and getting them tensioned up.
The top along with the bottom coolant hose were then fitted but the water pump bypass hose was a no go because I had bought the wrong one. I am off of work tomorrow so I will nip out and get the right one then. I had bought a pair of intercooler pipe hoses thinking they would be long enough but after messing around with them fitting new O rings it turned out that they were exactly the same length as the ones I have already fitted.
Hmm what to do because I would really like to have a stab at getting the engine running this week and without these pipes I would quickly end up with all of the engine oil coating the garage and driveway, I don't think Wifey would be too impressed with that and cleaning up could take a while... As a temp measure I sliced into the old pipes and extended them with metal pipe for now so I can at least get the engine fired up and will once again be able to move the motor about.
What now then? As I was still protected from the weather along with my new under car port lights creating a false daytime I decided that I may as well dig out the new radiator and get that lot fitted. Out came the old one still in its frame along with the cooler and after a little more rummaging around I found the shiny new one too!
It literally took ten minutes to switch them over and drop the whole caged lot into place with the pipework plumbed in.
It's amazing how these little jobs take next to no time but make a huge difference! That was enough for the evening because I was getting a bit cold and tired...the things that my shiny dry well lit work area could not help me with.
The following afternoon though I was in the mood for a little more titillating after all there were quite a few little jobs that needed finishing the majority of which were centred around the transfer and gearbox. I had to dig out the transfer box linkage out from where it had become trapped somehow between the transfer and gearbox. It again was surprisingly easy...surely my luck could not hold here?
Then I swapped some of the bolts holding the transfer box onto the gearbox around as they had been put in in the wrong places...literally took minutes.
After a quick clean up I remembered that the handbrake cable would need to be attached and with the way things are going it should not be an issue. Yep this is where it started to get a bit more challenging. Firstly I had fitted a Discovery transfer box to a Defender so the handbrake cable mounting was different. Ha! No problem there because I had the foresight to remove the one from the 1:6 ratio transfer box I removed. With a slightly smug grin I removed the Disco one and it became very obvious that two of the bolts went into different places. Humph, I am on a roll at the moment so I would not be out off here. Now don't get me wrong I wanted to cry a couple of times as I tried to modify the defender bracket but after destroying three different drill bits, and I am also pretty sure I have broken my drill, the old bracket now sat proudly in place all adjusted up with the handbrake working.
After sitting back with a brew in hand I wondered at the speed that the whole project seems to be coming together all of a sudden. There seemed to be months when all I seemed to be doing was constantly working on the old boy but seemingly getting nowhere but in what amounts to a couple of days the whole thing seems to be accelerating at a crazy pace towards completion. All of these little jobs are ticking the big jobs off of the to do list which is getting smaller and smaller by the day and it feels great!
So I will be picking up the bypass hose tomorrow which will leave the exhaust to try and get fitted, the clutch needs bleeding then my friends it will be time to to get this beast started...
MusingsPosted by Nicky Smith Sun, December 04, 2016 15:28:24 As most of you already know we bought a house in the spring of this year, lets say it needs a little work. Not to worry because the price we paid for it was more than fair but lately most of what I have been doing is just getting it to stay warm once the heating goes off. This entailed mainly putting more of that itchy loft insulation down along with fitting floor boards so Wifey has all of the storage her heart requires because "this house has no storage" I am told regularly. Lots of sweaty hard itchy work that cost enough and literally leaves me walking away looking like nothing has really been done! Still has to be done and I wont have to do it again for a long long time after the stud walls have been insulated.
Enough of the house though because there was a much more pressing construction issue on the house...my garage roof. The garage roof leaked like a sieve through old asbestos/cement roofing sheets, this was so bad when raining I had to put down eight different buckets and pots to catch the worst of the water coming in. They did not catch everything just stopped the place flooding. Seeing as my tools, motorbike and electrical's are kept in there I was more than a little concerned with the worst of the winter yet to come with cold rain and probably snow.
I managed to source some reasonably priced roof sheets and seeing as the day was forecast wall to wall sunshine it seemed like a good time to get stuck in. I had soon dug out a set of ladders and a pair of old scaffold boards so I could climb onto the old roof and see what I was up against getting that awful sheeting off without falling through on top of everything I wanted to protect.
Luckily all of the old bolts came out easily enough and before I knew it the sunshine was covering the inside of the garage for the first time in forty odd years.
These old concrete sectionals are not designed to last for ever but I need a few more years out of this one yet before I can afford a newer larger purpose built garage for my toys. The old sheets were brittle and heavy but happily they all came away without breaking and I was soon putting the new metal sheeting up there, then using the boards screwing them all into place without falling through the roof or damaging the sheets.
There is a decent overlap on each one along with more than liberal doses of silicone sealant along the joins...I used just about every tube of this I had in the place!
The result though is much better.
I now have a water tight garage that kit will actually stay dry in! Now you may think that that would come as standard with a garage but I can assure you from bitter experience it does not! I'm off for a lie down now though, this physical exercise stuff is exhausting!
MusingsPosted by Nicky Smith Sun, December 04, 2016 08:35:32 There is a Teabag Mountain challenge in my house at the moment. When the lid falls off the loser has to take it all out to the compost bin...
The 110Posted by Nicky Smith Sat, December 03, 2016 20:29:46 Sometimes I am amazed by the kindness of strangers. Now this may sound stupid but I have, along with my ever suffering Wife, for a great number of years tried to make someone smile everyday. That person can be someone I know but more often than not it's a stranger. Sounds daft eh but a kind act or daft joke normally aimed at myself can make a huge difference to a persons day. I work on the proviso that you don't know other peoples stories so have no idea on what they can be going through, good or bad.
Turns out it's not only us that do this. A couple of days ago I put out a request for help on teaching me how to change the cambelt in the 200tdi engine. This is something I had never done before, I had read up on the do's and don'ts which seemed pretty straight forward but really wanted someone around when this was put into practice so I did not bugger the engine up before I had it out for an actual drive. There were a couple of offers for which I was thankful but after my last blog post went out a chap called James contacted me again to say he had some time straight away if I wanted to get stuck into it! Now until we met today James was a complete stranger so to say this was a kind offer is probably an understatement but you have to love the fact that there is still this sort of generosity out there.
He turned up in short time along with a great deal of tools then ran through what he was doing as the cambelt was slowly exposed behind the cover. First out was a pully to remove the wheel.
Then the cover was whipped off.
The tensioner was next off as was the other wheel (forget the name, it's late and I am tired) leaving the cambelt just dropping out. Some cleaner was applied then all of the timing lined up.
A locking pin was popped into place before most of that (yep I am getting tired and forgetful here) and soon enough the new cambelt was put into place. A couple of rotations and a check later, all was sitting well and where it should be :)
A couple of brews later along with some very good guidance on the transfer box linkage issues I am having and James was off! I then set to getting the cover back into place along with the new water pump fitted. First up was cleaning the two mating surfaces off. I spent a bit of time here making sure all of the surfaces were flat and free of any old gaskets and contaminants. That done I popped on a bit of instant gasket around to help hold the new gasket in place.
Then I cleaned each and every bolt back to a muck free condition and liberally applied some copper slip before putting them back into the holes that they came from through the cover. Once all were set into place neatly through the gasket I ran around them all a few times gently tightening them all up. Then out came the new water pump (seeing as the old one was in such good condition I have cleaned it up and kept it as a spare) and that along with its replacement gasket were soon set into place.
I do still need to check that I have tightened up the came pulley bolt enough so I have marked this down on my to do list so I don't forget. Due to the act of kindness from someone who started the day as a stranger I am now so much further on than I thought I would be for a few weeks. Looks like I may have found the hoses I needed for the oil cooler from another friend as well so I may just have this motor running within a week or so! Is it me or are things starting to get exciting all of a sudden...
The 110Posted by Nicky Smith Sat, December 03, 2016 12:54:51 December has arrived. That means, in my house anyway, all of the decorations that have lain boxed up in a dusty loft for eleven months of the year now see the light of day once more. What that means for me is a great deal of work putting up decorations, hanging lights on trees and this year it comes with the new experience of putting lights up on the outside of the house. The only problem with hanging lights up on the outside of your home is the fact that you have to get right up the outside wall balancing on a ladder whilst holding onto the long length of dormant lighting simultaneously hammering in the wall clips to keep it all in place.
Ten years ago this would not of bothered me but these days I am not overly keen on balancing on one foot on the top rung reaching as far as I can with a hammer wondering why I don't have two pairs of hands because that would make the job so much easier. My daughter asked "Are you scared of heights Dad?" to which I answered "The heights don't bother me kid, it's the falling from them that does" Funny how as you get older you realise you would much rather not do some of the things you used to do without thinking. I recall running up and down the same extended ladder cleaning windows on three storey Victorian houses in the wind without batting an eyelid. You literally could not pay me enough to do that now! Still the lights are up and it will be at least a month before I have to climb the ladder again to take them down again, or I could just leave them up until next year...
Progress is being made again on The 110. This week has seen me still focusing on the 200tdi lump I popped in earlier. I decided to have a stab at re-piping the fuel lines and it is here that I must admit that I got it completely wrong. It looked good with all bases covered but there was just one snag, I had not run in the from and returning to the fuel tank. This may have caused the odd running issue so I posted my bad pipe work online with a big help attached to it and quickly got a large number of responses. I seemed to keep getting this relatively simple task tangled up in my head so I popped around to have a look at a friends motor and as soon as I saw underneath the bonnet I had a "Of course you tool" moment. It was a tad dark and cold when I got home so the following morning I rearranged the spaghetti pipework and it all now proudly sits where it is supposed to.
I could not find a diagram to easily explain it so I have tried to make one up. Feel free to tell me I have got it wrong!
As I stood with my wolly hat on drinking a brew convincing myself that it was not quite as chilly as my body was trying to tell me I was getting I thought I may as well tackle plumbing the the meagre heater once again. Lets face it some heat is better than no heat at all! I knew I did not have the correct 200tdi pipework but what I did have was a tub full of old pipework, so I dug that out and soon mackled together a system that would work. Its not the prettiest looking set up and I no doubt will return to it in the future to redo the whole system but for now it is functional and lets face it, you don't look under the bonnet when you are driving along. That and this old beast is not going to be winning any beauty contests any time soon.
The only thing left to do really on this engine is to change the cambelt over. Now I have never done this before and there have been offers of help that I will happily accept as not to bugger up the lump before I begin using it. First up though was to remove the water pump and those swine bolts that like to snap off inside the engine. Lessons have been learnt in the past of trying to force rusted bolts then ending up weeping quietly in the corner before having to drill out and re-tap the threads, so caution was the buzzword of the day.
Nearly all of the bolts cracked off and out easily enough but there was of course the two that did not want to move, at all. Off I toddled into the garage to get the long bars and with more force put onto the bolt heads than I ever wanted to use they started to move slowly. I then kept gently moving them back and forward clearing their threads of the rusty crud that was helping to keep them in situ. Patience was the name of the game even when I started to get a little bored with this game but I was rewarded ten minutes later with every bolt having come cleanly out of the water pump! A rarity indeed!
I did put all of the different length bolts in a piece of cardboard so as to recall where they all go back into so as not to repeat the transfer bolt mix up!
The ease of teh bolts coming out and the fact there is no play at all in the water I have just removed leads me to think it could not have been on the engine for too long before the whole lump was removed. I will still replace it with the shiny new one I have bought though just to be on the safe side.
It really is nice to be on the service and put back together side of things now. It feels like the project is running towards getting an MOT which should only be a few months away...
The 110Posted by Nicky Smith Sat, November 26, 2016 18:26:57 My youngest was at work. Wifey was out Christmas shopping with her friend for the day, so what does a chap do when the day that lays before him is his own to do with as he pleases? Well what he does is go and grab his friend who's Mrs was out shopping with mine and head off to look at boys stuff all morning! We hit an Army surplus store then headed off to get the bugs for my Dragon looking at all the other impressive reptiles while we were there of course and to top it off we headed to KFC to have a fat git bucket meal for one as lunch!
We were home soon enough though so my attention was soon attracted back to the 110. There are a pile of parts kicking about so in the continued fashion of working from the front backwards I dug out some of the easier parts to fit to the engine. First up was the thermostat change over. It has been known in the past that anytime I touch the bolts on a thermostat housing, they tend to just snap off leaving half the stud behind.
Today though was a good day! They all came lose with a satisfying crack! I soon had them out and the thermostat looked a little past its best.
While this was off I took out the Discovery temperature thermostat then cleaned up the whole area scraping off the area to give a good surface to mate up too.
It is nice when you line up and look at the new and old bits you are about to fit...
Or is that just me? Everything soon dropped back into place so job one was finished.
Next up was the old fuel pump. I don't know what was going there before I bought the engine but an old style series engine fuel pump was loosely bolted into place. Off that came and I quickly fitted a shiny new 200tdi one. I found the easiest way to do this believe it or not was to stand on top of the bumper with one foot on the front wheel reaching in with the spanner and socket from above.
Now seemed like a good time to start to reattach all of the wiring to the engine so I steadily worked my way through them adding the odd new end here and there to tally things up nicely.
I have come across one problem though. You see I meticulously put tape onto each wire and wrote on it where that wire went to so as to save confusion much much later on when I came to refit them all. Well there is just one left over on the nearside that still does indeed have its hand written label on it but the problem is that it has got more than a little mucky. I cannot know read what it says so feel free to have a look at the picture and see if you can decipher it.
I will be needing an alternator plug for the loom as well because the old one disintegrated when I took it off of the old engine.
As I sat back warming myself with a well earned brew I decided I may as well hook up a battery and see if the old unit would turn over. So I removed the seat then opened up the battery box, in dropped the battery and I pushed the keys into the ignition. At this point I thought how disappointed I would be if nothing happened here. It would mean that I had done something wrong with the wiring or the starter was past it's best. With a shrug of my shoulders to myself I turned the key around. To my immense delight the engine turned over without hesitation, what a sound! I don't think I have ever been so pleased to here an engine not starting before!
This feels like a huge milestone to me. I have had this motors guts out and replaced them with the spec I wanted and blow me it seems to be working! I am so much closer to the end of this project than the beginning it is starting to feel like it may be finished sometime soon...
The 110Posted by Nicky Smith Thu, November 24, 2016 23:18:33 Unfortunately The 110 is not my only project, you see Wifey did insist that we bought a house now so we could hopefully grow old and grey in it as the years go by. The thing is that she does insist on putting her own mark upon this new home we shall spend out autumn years in so there is now a "list" of improvements that need to be done. She is one in a million though and is in no great rush to get it all done particularly quickly. That said would not want to impose upon her good nature and just focus upon my own toys all of the time so this afternoon I set to taking down the last pair of 1970's dark brown and shiny doors off of the living room and study. I wish I had taken a picture of them in situ but I forgot if I am honest and trust me here you are not missing anything at all. These types of cheap formica doors were all of the rage with their highly modern smooth mass produced surfaces. The ones in this house have been here since the place was first built.
It didn't take long to get to get them down and in all fairness it was no time at all before the replacements were up in place. As always it took longer to sort out the catches and door furniture than the time to hang the actual doors but the overall effect is quite pleasing, even if I do say so myself.
It is nice to keep doing these little jobs putting our own stamp on the new home.
That done along with a hearty dinner in my belly and I sat down to chill out for the evening. Yea that lasted all of thirty minutes. I am not one to sit around just looking at the TV so I pondered what to do next. Well I have had some shiny sun shine bright LED lights fitted under the car port so I could work on The 110 these long dark evenings. Best try them out then eh!
If you recall I was about half way through sorting the steering out on the Land Rover so why not get on with getting it finished? I had popped out at lunchtime to pick up the steering damper so best get on with it eh! I grabbed the front steering bar, fitted it then attached the damper. I had to go back around all of the front end including the replacement steering box to make sure I had tightened all of the bolts and fitted all of the split pins. Would not want any nasty surprises once we get the old bugger back on the road.
The only drawback I can see at the moment with working outside in the evening in Winter is that it is damned chilly to say the least! Best dig out that thick old babygrow of mine eh!
The 110Posted by Nicky Smith Fri, November 18, 2016 16:38:31 After feeling sorry for myself for a while after realising that I was going to have to make some structural alterations to the passenger foot well so the 200tdi's exhaust does not hit it constantly I wandered back outside to have a look at the motor that seems to be the project destined to last for ever.
The steering is sort of half replaced so I took a closer look at what was left to do. As I was hunkered down I recalled that the front wheels needed setting up straight before I would be able to do a great deal. This would save me having to take off/adjust the track rod ends later on in the rebuild. Now I do not own any fancy wheel alignment equipment but what I do own is a long length of rope. I tied this around the rear axle then ran it down the side from wheel to wheel which showed me which way to adjust it.
With the first side done and wedged into position I made short work of the other. Afterwards I did a quick double check and great stuff they are both nice, straight and in line now.
Then I set the steering box to its centre position and started to fit on the new drop arm. I was advised to do a bit of a mod here so the drop arm is a Discovery one and the new front steering bar I bought did not have any fittings for the steering damper.
A quick search on the internet showed that although opinions are split on whether a damper is needed or not it does make the drive a bit better when hitting pot holes etc. Looks like a trip will be needed to exchange some parts that have already been bought but there was a niggling at the back of my mind to check the spares shed out. A quick rummage through a shelf full of junk and a heavy duty front steering bar that came as part of a job lot of stuff was soon found complete with a damper mount already welded on!
A quick rub down, removal of the old tired track rod ends then a coat of black paint and shiny new ends is problem solved for me.
I do still need to pick up a Discovery 1 steering Damper to fit but the parts I have to return to Paddocks will more than cover the cost of that! All in all it has been a productive day on the old boy.
The 110Posted by Nicky Smith Fri, November 18, 2016 13:00:06 Isn't life a strange thing. You head off in one direction thinking that a small job will take no time at all but within moments of starting you realise that now it's going to head off in a completely different direction taking up hours of time stood outside in the cold. I headed off this morning to Paddocks to buy a single nut for the steering box so I could get the front end finished only to find that that one singular bit from the hole of a Land Rover is not in stock. A quick change of mind and plans saw me buying the whole of the 200tdi exhaust system as that should be an easy job to chuck on seeing as the conversion down pipe was already purchased and sat on a shelf at home.
It was not until I got home that I realised that I had not bought the manifold to down pipe gasket but figured "hey ho" lets get it all offered up to make it fit. I did not get past the conversion down pipe in this.
When this pipe is flush to the manifold it still rests on the passenger foot well which will not bode well when I am driving along, so what to do? Well it bloody well looks like I will have to modify the foot well then. I will have cut it out and then make up some new shaped box that will give some clearance for the pipe work when the engines running and moving on its mounts under acceleration.
On a more positive note I had a tow bar fitted to my daily runaround by the tow bar chap (because I needed an invoice to keep up the warranty) and this was done in ninety minutes with no fuss at all. I didn't have to lie under it in the rain like he did getting cold as well as soaked to the skin.
So what I have done in light of this is buy a ticket for the Euromillions in the hope that I win enough money to either get someone else to finish the rebuild or so I can go and buy an already finished motor and then take great pleasure in burning this one.
The 110Posted by Nicky Smith Thu, November 17, 2016 10:51:58 As you can all see from my delays in writing anything I have been more than a little busy of late with life in general as well as family illness including my own, that bug that's doing the rounds is a doozy! Whilst lounging around the house generally feeling a bit rough and sorry for myself I became aware once again of the odd moaning and creaking noises it makes. These sounds worried me sick when we first bought the place as I was so damned sure inside of my crazy head that something would fall down or break but now it is a different story. Those sounds are just the house itself as it warms up and cools down. It's about the same age as me so it's bound to have the odd moan here and there, I mean the poor bugger is getting on now you know! But now those sounds that once sent me into a quiet worried despair thinking I had bought a lemon now bring a quiet sense of homely comfort. They go mostly unnoticed as such but when they do reach the surface of my mind, I know I am home.
There has been the odd hour here and there on the 110 though so some progress is being made with my main focus being on the steering box. This really is a straight forward swapping over procedure. Firstly I removed the nut and bolt from the steering column UJ. Then came off the front steering bar on the box's drop arm. Four bolts that run through the chassis came undone without too much of a fight and the box then literally dropped off.
I slid the replacement power steering unit on and much to my surprise it bolted straight into place without any messing around with the holes on the chassis.
I do need to go and pick up a new bolt to hold the steering box arm in place though.
It will be nice to have power steering on the motor. Seeing as it will be our camper/overlander I want it to have as many of life's little creature comforts as I can fit!
There has been a great deal of pondering on what I would like to do seat wise. I have gone from outlandish captain seats through to RX-8 seats in my mind, but after even more contemplation I decided why mess with design and started a bit of a hunt for some standard Defender seats. What I did come across in the end was two separate pairs of seats. One had a good drivers seat and the other a good condition passenger one. The money was right on both sets so I bought them and made myself a good pair.
They are not fixed in place yet as there is still far too much to do on the inside but once recovered they will be spot on. It is damned good to see a pair of seats in the old boy once again though!
The 110Posted by Nicky Smith Fri, November 04, 2016 13:02:29 Well I am a man who is happy to put his hands up and admit when I got it wrong. And I did get it wrong. When i refitted the rear propshaft yesterday I put the damned thing on the wrong way round and to say I got a few emails about it would be an understatement! Happily though all were in a good natured tone and none were mean enough to call me outright stupid!
This morning then was spent doing my favourite job of taking off then putting back on the fiddly little propshaft nuts. In the end it took about forty minutes of messing around but happy days it now sits correctly as it should!
Seeing as I was dressed up in my mucky clothes I then set to removing the pan hard rod on the front, treating the metal whilst it was exposed then refitting the replacement one with the new bushes in.
Not a bad potter for a Friday morning before heading off to work. This is the way I like it, two little jobs done instead of just hanging around waiting to start the work that we have to do to pay the bills. Hopefully I can carry on in the same vain...
The 110Posted by Nicky Smith Thu, November 03, 2016 19:16:50 It has been an interesting sort of few days. The Disco has gone which has left me to focus just upon the 110 which is a good thing really. You see I have been stretching myself rather on the thin side. The problem with pushing yourself too far with too many things is that you start to lose your focus, my perspective has shifted between too many things like keeping several motors running as well as doing up the house. Add to that the hours at work well things just mounted up. With the disco gone it's one less issue to look at and I do feel a damned site better for it if I am honest.
The next thing though is that my focus has turned towards the 110. I hopped back on board yesterday morning with a pair of spanners in hand to get the propshafts reattached after the engine and transfer box swap. The front one just kind of fell into place and was soon all tightened up.
For the rear I dragged it all into place along with myself to offer it up and wondering why it was all of a sudden too spacey? I lay there on back trying to figure out why the bolts met both ends but what was that space??? Then the penny dropped. I suppose I had better put the handbrake drum back into place first. That didn't take long either but doing the nuts and bolts up seemed to take an age with me ended up jacking up one side on the front and rear so I could turn propshaft around making access a little easier.
With that done it was time to write a big list of what I needed to buy to get this project up to MOT status. The list was indeed a long one.
A trip to Paddocks it was then because I have sold a few bits this week so the kitty was sitting pretty, well until I got there. My poor little car was weighed down with a full boot as well as the back seat being covered. I have a great deal of parts now that will take me almost until the end of the build. There are still a few things like an exhaust system that needs to be modified and fitted along with the pipework for the coolant system but I will get to that. I also need a pair of seats and I will go with the RX8 ones I think.
There's a few things coming in the post as well so I have no excuse not to pull my finger out now. The jobs that are ahead are all smaller in nature, which I like. It means I can potter about with different jobs that have different timescales. Nothing else will be really forced to completion, I can step up and step out at any point so hopefully the build will be plodding along nicely now...
The 110Posted by Nicky Smith Tue, November 01, 2016 09:05:31 Being a father to four kids I am not easily surprised these days to see one of them sporting the latest trend in fashion or head wear styling. I have learnt over the years to keep my inner thoughts to myself so as to not upset the little dears or sound all old and grown up like my parents did. Well, hang on a moment I am being unfair here to my parents because my Dad just used to rip the mickey out of me for sporting the latest trend with literally no holds barred. Maybe I am just a little more diplomatic with my children... No that's a lie as well I do tend to rip the mickey out of them just not to the soul destroying level Dad did it to me. I think the official term is character building.
So to see something several times in one day that makes me stop stop and think "What on earth is that on your head?" is unusual. When I first noticed this new fad I was walking down a corridor at work when a young chap with reasonably long hair came bouncing towards me from the other direction. I did a second snap of the head look take at his head because he was wearing a plastic hair band keeping his mid length locks back in place. Straight away the Dad in me wanted to take over with a dozen, in my eyes, witty quips but as soon they nearly came out I realised I was at work so I had to hold them back. This though did not stop me staring and grinning at the poor lad like some lunatic keeping back the roars of laughter that wanted to escape my insides. Now this young fellow is not alone in his funky personal styling with a £1.99 plastic Alice band. Oh no I have now seen at least a dozen pillocks I mean young men wearing these. I may well be into my forties now but I don't think I am that "Old". I am all for living life and expressing yourself but come on guys you are really letting the side down here I mean, this must be on a par stupidity wise as the "Man Bun" where you stuck a fresh roll on the back of your heads and covered it with hair! Still each to their own I suppose and many will think me mad for wearing a babygrow then working on a motor that should of hit the scrap heap many years ago.
Speaking of the scrap heap I have spent a little time playing on the 110. The stage that I am still at is the putting it back together one from the engine and gearbox swap but headway is slowly being made when I get the time. First up was fitting the shiny new clutch slave cylinder I bought just because I was changing the clutch over and the old one looked pretty damned tired. It was soon set into place after a few frantic minutes of scrabbling around looking for the bolts only to find this nice expensive branded part leaks.
I have nipped it up as far as it will go but nothing will stop the drip of clutch fluid until the reservoir ran dry. It could be the old pipework or the new part but what I will do is replace the pipe first then strip the part out if a good seal cannot be made to swiftly return it to where it was bought from.
It was then onto popping the crossmember back into place. This is an easy job providing you do a couple of things before trying otherwise it becomes a struggle you will not win. Firstly try to just fit it back into place without any prep work. Secondly get the damned thing stuck dry metal to dry metal after hitting it with a large hammer to try to make it move upwards. Thirdly hit it with a hammer and large piece of wood from the top to get it to drop back onto the floor.
After removing it from under the truck give it a good rub down removing any rust build up and grease the hell out of it. Do the same thing to the chassis it is supposed to fit onto. Then my friends it will be able to be gently knocked into place with no struggling, swearing or pulling of shoulder muscles when trying to swing a large lump hammer whilst lying down underneath it.
Next job will be refitting the propshafts now I have pressure washed the 30 years or so of muck build up off of them. Then I best get the transfer box linkages put back together if I can figure out how to do it!
The Discovery Project...Posted by Nicky Smith Mon, October 24, 2016 15:53:44 Today I found myself running the Dad errand of taking my youngest daughter to her first job interview. Seeing as the old Disco that has been sat for a week that was my chariot of choice for this small run. All was going well, in fact the old girl was running just fine as I sat there chatting with the baby of my family, until something caught my eye in the rear view mirror. There were plumes of thick blue smoke pouring out of the exhaust. Hmm that shouldn't have been happening of course so I looked down at the temperature gauge which was sitting quite unhappily in the red.
At this point I had two choices. On the one hand if I kept driving I doubt much good could come from whatever was happening to the engine but on the other if I stop now in what is essentially my back up motor that has been slowly falling apart my daughter would miss her interview. No brainer really, I kept going. It was only a few more miles and the old boy made it no problem. As she trotted off to see if she could get a job I popped the bonnet and had a look to see if it was anything obvious. The coolant was low so I topped it up after the engine had cooled down. With a shoulder shrug to myself I dropped the bonnet down and decided not to worry about it. When my daughter returned with a smile and a "It went alright" we started to head home.
It ran hot once more but to add insult to injury the nearside front brakes started to play up again. Every time I braked the Disco tried to shake itself apart. If you imagine a warped disc that had cracked and each time the pads go over that crack the wheel tries to break free of its nuts...yea it feels just like that. This would be coming from the side that has been rebuilt several times now so that along with the now warm engine means I am done with it.
No more money will be spent on an old Discovery because I now have to make a choice. I can spend my money on trying to fix an ancient Discovery that has done over 200,000 miles or on the 110 that is months away from completion but any further delay will in all honesty will leave me with such a distinct lack of enthusiasm that the project may never be completed.
So now I own two Land Rovers that don't really work. Typical eh...you have to love the green oval reliability. Now then do I strip it or sell it scrap???
MusingsPosted by Nicky Smith Wed, October 19, 2016 13:11:04 I have always enjoyed taking photos. It helps to focus the mind as well as en-capture the wonders of the world we live in. There is great beauty all around us to be found in the smallest of things. Most of us do not take time to just stop and notice these things, myself included a great deal of the time but to try and capture this essence of nature and the world around us has always been a goal of mine. To look back upon photos taken that boost the memories of enjoyable days past. This has always been done with my phone camera and not too shabbily if I am honest but I have always hankered after a nice piece of equipment to play with funds though along with a growing family had always put pay to that idea.
Now though, well I came into a bit of an unexpected windfall so I have treated myself to a Nikon D3300 AF-P. That's a fancy way of saying "A nice camera" that has more buttons and information on screen than I have a clue what to do with yet. So I charged up the battery, confused myself a great deal with the instructions and took it out with myself and the dog this morning to have a play with it. My main aim is to get up into Derbyshire on a regular basis taking the camera along on our hikes to get some interesting pictures from up there then starting to get into night shoots as well as daytime ones. But firstly I shall learn to crawl with it. I can't say that I can even walk yet as I wander around randomly changing buttons around but I shall read up some more and get talking to like minded folks seeing where this new hobby will take me.
I need to shrink the size of the pictures before I can get them uploaded on here but I will try to figure out how to do that later today!
The 110Posted by Nicky Smith Mon, October 17, 2016 19:18:53 My new approach is definitely "Do a bit when you can" where the 110 is concerned. There is still so much to do on it that the only way I do not get fed up with it all ending up selling the damned thing is to look at one job at a time. I fell into the frame of thinking that when I worked on the Land Rover it had to be a whole day at a time. But I find myself just getting back into the pottering type of do a bit at a time type of progress.
Today I had a spare hour so I started with popping a bracket into place between the alternator and fuel pump bracket making sure that I had all of the bits that were needed...
With that done in a few minutes I set to popping the wiring back into place on the starter motor...
Then last but not least for the day was swapping over the old type of fuel filter housing for a 300tdi one that will make it easier to change over and service as and when needed...
As I looked at all of the fuel pipes that are littered around the engine bay I realised that I have absolutely no idea where they are all supposed to do. That goes for the linkage on the gear/transfer box as well. If anyone has any pictures please feel free to pop them up!
I did try to adjust the accelerator cable to fit the 200tdi but the outer casing disintegrated so I guess that will now get added to the parts list! A few more little jobs down now though which makes it just a little bit closer to being finished.
The 110Posted by Nicky Smith Sun, October 16, 2016 11:23:06 Wouldn't it be great to have a tail. I was sat last night with my family enjoying a tipple when I got around to watching the dog. She seems to be able to express all of her emotions just using her tail! I just said her name quietly and received a quick flick of the end of the tail that seemed to express a little hope that she had heard right from where she was lying down but not sure enough to yet come running. I repeated her name loudly and she literally grinned jumped up with her tail wagging happily generating enough wind force to run a small wind farm. Admittedly everyone would know what we are thinking most of the time if we had one ourselves but I bet there is something immensely satisfying when you get to wag one!
Back to the 110 then. With these 12 hour shifts at work I am finding it hard to get any sort of decent time in on the rebuild at all but I managed to get an hour in yesterday just pottering around. Seeing as we are at the putting it back together stage an hour here and there can make a fair bit of difference. The gearbox got earthed, the reverse switch put back in then I confused myself as how to make the speedo cable stay in place. One job I wanted to get out of the way was putting all of the studs and bolts back on around the bell housing. This is where it started to get a little weird. If you think of the circle of the bell housing, the top half of that circle has the threads in place for the studs and bolts but the bottom half has no threads at all, as in none. They have never been tapped!? Is anyone else's 200tdi like this? I wish I had noticed before we put it back into the 110 but hey ho it wouldn't be a Land Rover if I didn't have to sacrifice some more blood and skin whilst lying underneath it in a contorted position...
The 110Posted by Nicky Smith Mon, October 10, 2016 18:18:32 After a great deal of pondering about what type of wheels I want to go with on the 110 I decided to go with the 16x7 Black modulars. 2 bought with my birthday money and three to go as and when I have the cash!
The 110Posted by Nicky Smith Tue, October 04, 2016 14:58:52 There were great big heavy lumps of metal everywhere underneath the 110. In fact there was no large metal lumps left at all in the 110 and this left me a little miffed with what lay ahead. But as with all insurmountable chores that lye ahead you really just need to chose a point to begin then take it from there. An old friend was up for the day to give me a hand in what was meant to be a quick change over of the transfer box before popping it back into position. Easy eh? But the best laid plans never go to plan. It didn't take long to separate the transfer from the gearbox and that really was the easiest part of the day!
With that done my friend, who is a mechanic by trade, piped up with "Well lets get the engine in then." "What!?" I said. "Lets get the replacement lump in, then pop the gearbox on and finish with the replacement transfer box." "Err ok then" I replied.
So with that very short conversation the afternoon had changed from a quick swap and lift into place of the gearbox end into a lets get all the big bloody metal lumps back into where they are supposed to be sort of affair. This I was not expecting at all.
Out came the engine crane along with the 200tdi attached and in what felt like a matter of minutes it was dropped straight into position with minimal wiggling.
Before we popped it in I replaced the rear seal behind the fly wheel (I forget what it is called) because I did not fancy having to pull the whole thing out again to change it later and seeing as the engine has been sat around for a couple of years I figured prevention is better than cure. Then I scrubbed up the fly wheel itself before we fitted the new clutch.
It was now time to refit the gearbox but would it just drop into place? Nope. We twisted we wiggled I even called a friend in case I was missing something obvious but after a bit more jiggling as well as turning the engine over by hand slightly we had the whole thing in place. It was at this point that my friend said "Oh you are not going to be happy with this" then he pointed to the clutch release bearing that had somehow dropped out when he was manoeuvring the gearbox around on his legs. So off came the newly fitted gearbox once more and the merry go round started again! It was all good though and before we knew it the transfer box was refitted to boot (along with replacement seals first of course).
After a quick meal we were back out popping on the replacement gearbox mounts. I made that sound easy didn't I but it was a pig of a job to do. At this point we were both getting to the "more than had enough of this point" but we pushed on until they were in place.
It was now that we realised that we really should have kept the transfer box bolts in order because they are all different lengths. This still needs to be sorted but we had had enough so seeing as the whole lot was now securely in place we both walked away to get washed up.
I am now a damned site further ahead than I planned to be around now and I thank my friend for that. I do need to try and find some enthusiasm for the project again though because I am still pig sick to my back teeth of it! Having said that I am now once again at the point that I can just go out and potter from time to time on little easier bits. So forward we go folks pushing just a little further each week to get this old beast back onto the road...
The 110Posted by Nicky Smith Thu, September 29, 2016 16:14:27 As I sit here writing this I have popped the TV on for a change, I fancied some background noise. The programme I managed to find is an old 1950's B movie about a Plasticine monster from Venus that is set to rampage around Rome whilst the rather well spoken Army folks chase it around generally making things worse while trying to kill the poor bugger using whatever the biggest weapons they can find. Our poor women though, bless them because all they can do is stare straight ahead at the danger raising their hands to their faces and scream at the top of their lungs at the horror of it all! I mean it might mess up their lipstick or hair styles for goodness sake...where are all of the strong men to deal with the issue?? You have to love it. I often look back at the simplicity of the past compared to the present. Then I get to wondering if our grandchildren will be doing the same in another 70 years?
Still I waffle on a bit too much about this so as the polystyrene boulders fall I shall make my way back to the 110 and it's gearbox removal. It's out. It's just lying there on the ground looking at me laughing at how long it took to come out and now knowing I am shattered so it will sit right there under the 110 waiting to be dragged out by me and a friend later. Then I will get to fitting the replacement transfer box that I am collecting later this evening.
I got the bugger out using two large trolley jacks in the end. Up went one end then the other. Out came a big crowbar that was used to lever the lot to the left then the right getting clearance to drop it down. Add into the mix some large bits of wood to protect it from the jacks themselves and after thirty long fumbling minutes the damned thing finally hit the deck...out...done.
The 110 then got jacked up on the nearside to give me easier access to try to drag it all out and this led to a bit of an annoying revelation. You see now that its all jacked up on one side I think I will be able to get the engine crane in through the door...that'll make life a little easier getting the whole lot back into place eh.
Oh and if you are wondering what happened in the film, the beast from Venus could not be killed by any weapons but the clumsy bugger fell off of the top of the Colosseum in Rome and killed itself. You would think after travelling all that way from Venus it would pay a little more attention to it's surroundings but the 50's women all climbed into their men's chests for happy reassurance that the world was right once again.
The 110Posted by Nicky Smith Mon, September 26, 2016 14:18:30 Honestly I have been crazy busy with life of late. Family have been coming and going, in fact I have had more family along with friends visit lately than ever before so with all of that good company along with trying to fit in a bit of walking and other hobbies, time has really been tight. Now I will readily admit here that I am on the "Little bit fed up" side of the rebuild at the moment but I still try to get at least a few hours in once a week if I can. Without reading back through my blog entries I cannot recall if I have said what ratio transfer box I was going to go with. It will be the Discovery 1:2 ratio and the box is already bought.
The reason I have gone for that ratio s the 110 will be my cruiser/camper that is going to rack up the road miles like nothing else. There will be no off roading with it apart from where it will be parked up for the night. So with that in mind I have started to remove the gearbox so the transfer box can be changed over and the gearbox mounts replaced.
This is not a five minute process. First things to be tackled were the propshafts and the challenge of getting the very rusty nuts and bolts off.
These off course are quite easy to get to from underneath but what I would not recommend is the following when tackling them. As you lie on your back with spanners in hand do not, I repeat do not put so much pressure on the said spanners that when they ultimately round off and slip off of the nut you are trying to loosen you get to smack yourself with a full force punch square in the middle of your face. Then after the tears have passed and the pain has subsided enough that you can once again see reasonably clearly do not then realise you were wearing your last pair of good glasses that now sit splayed bent outwards on themselves with two broken arms.
After weeping quietly to myself in the corner of the garage for a few minutes I went and got my reading glasses so I could see what I was doing when trying to repair my now rather sorry looking specs. A bend here and a couple of strips of black electrical tape later and voila! A nicely repaired set of bins.
Back to the bonded bolts then. After some muttering along with lots of lubrication both propshafts were soon removed. Once the handbrake, reversing light wires and accelerator cable were removed I drained off all of the fluids from both boxes. But that was the end of my day. I was tired and funnily enough had a headache/faceache coming on in earnest so removing the cross member and then dropping the box out will have to wait until later in the week.
Quite honestly I don't think there is anything else mechanical that I have not removed now! But I can rest easy knowing that once i have put the better engine and transfer box back in and popped the front end back into place, it will look like I have done sod all for the last couple of months!
I am now a forty something who has come through most of my mid-life crisis trying to cheat death by now eating healthy foods exercising more and stopping smoking....I doubt this will work seeing as I have abused (no not in that way) my body with booze smokes and doing sod all for couple of decades or so but hey I feel a bit less mental for trying it!
So instead I rebuilt a Series 3 Land Rover, then a Discover, after that A Defender 110 and now I have decided to head more towards enjoying my outdoor pursuits. In comfort. Yep there will now be a campervan build in progress (as soon as I can find a decent base) for myself and the ever suffering Wifey to head out i ...see there is still some joy to be found in life!
I hope you enjoy my rambling drivel and if you do please feel free to share it around using the cunningly disguised "Share" menu at the bottom of each post I believe it does Facewipe, Twitter and those other places all the cool kids hang out in indoors now a days.