Mud-club

Vehicle & Technical => Series Land Rovers => Topic started by: Saffy on February 06, 2012, 06:48:03

Title: It lives !
Post by: Saffy on February 06, 2012, 06:48:03
My series 1 (aka the garden shed as it full to roof with junk) hasn't been run for over a year.

Wanted to gauge how much work needs doing to because it been laid up for about 3 years or more. There was a dim glow from the ignition lamp and just a 'click' from the solenoid.

Gave it a crank on the starter handle and nothing.

No fuel !

10 litres of unleaded later ---------ah the smell of petrol been so long.

Mechanical fuel pump not priming, so into man shed and pull out a ropey looking 'spare' and fitted it.

Bit of fuel poured directly into the solex carb.

Half a crank with the handle and the 2.25 purred into life.  :grin:

Need wheel and tyres, set of front lights, service and all the junk removed before I can give it a good going over. Should not be too bad as it was tidied up and MOT'd before being laid up.

Anyway I'm keeping it and making it into the fun ride that I want and ditching the Disco.
Title: Re: It lives !
Post by: lambert on February 08, 2012, 05:09:20
Nice one!
Title: Re: It lives !
Post by: Saffy on February 08, 2012, 08:13:00
Quite a bit to do with the oily rag - but not too bad, but limited by weekends and daylight hours to do work at moment. I'm doing the sensible thing and ignoring all of its problems and buying a rag top for it first.

I have a fair amount of spares for the truck, new and old. It's on SIII axles and ex-mod recon 2.25 petrol engine. It has parabolic springs. And the widget thingie that replaces the points which I remember was a God send.

Last time I was using it I was suspecting a blown valve but also the carb could have been issue. I have a serviced carb to put on, if no joy then it may be worth having the head off for a look see... but that's the future as it does run.

This truck was well looked after, serviced regular, and had been refurbed for sale with a new MOT before being laid up. Didn't really want to sell it and wanted to check the valves before I did.... but never got around to it and it's been a garden shed ever since.


Starter motor or solonoid (or both) needs a bit of attention as it's not turning over - clickity click - have to start with handle  :laugh: Have ordered a new solonoid. The starters dog probably needs freeing off.

New battery defo needed.

Need to ditch the oil bath and put the K&N filter back on.

Wheels and tyres..... it doesn't have any that are suitable, it just shod with ropey rolling chassis donuts  :cheesy:

Clutch pedal hits the deck. I have a new master cylinder, and the slave swap is an easy job. Will try some fluid in it on weekend anyway. The clutch plate probably needs freeing off.

Coolant hoses 'look' ok - have spares.

HT leads need new boots. but might as well swap the leads out with plugs, engine oil etc in a service.

Wipers need sorting. I just want to fit an original screen mounted motor to drive side only.

There's no heater fitted, will see how long I can live without as I do not think it going to make a difference.

Front lamps need replacing - have ordered some.

That's the list so far... and I haven't even got to the brakes yet.

This was it in action way back when:
http://www.youtube.com/watch?v=YKCy97i4kbs

and how it looked before begin laid up

(http://www.stonefisk.com/media/users/stonefisk/series1.JPG)












Title: Re: It lives !
Post by: Landy1uk on February 08, 2012, 13:06:21
Looks good that must get round to doing my 2a this year
Title: Re: It lives !
Post by: lambert on February 08, 2012, 14:59:34
i have seen longer lists for asda, you will be out and about in no time!
Title: Re: It lives !
Post by: NiteMare on February 09, 2012, 04:28:28
that's quite a tidy looking truck  :smiley:
Title: Re: It lives !
Post by: Saffy on February 09, 2012, 06:35:49
Its looks more of shed at moment though  :grin:

(https://lh3.googleusercontent.com/-QJQd7lfhVRo/TzNoksXxo9I/AAAAAAAAJhQ/1Z-j0q0Gpdc/s640/photo.JPG)
Title: Re: It lives !
Post by: brixworth-alan on February 11, 2012, 22:07:41
It will look great- Mine's still in bits!
Title: Re: It lives !
Post by: Saffy on February 12, 2012, 07:19:15
Well I have borrowed some plastic teas crates from work and cleared out all the parts of dead landrovers from the inside. The suspension must have the risen about 2 inch once void of the weight :D This alone took most of the morning.

Removed the late wiper motor and mechanism and repaired and fitted one of those single wiper motors to the drive side. The screen can flip down now. Hadn't thought about it or noticed before but the later landies had the wiper set into the bulkhead where as the s1's were set into the windscreen frame. Having a s3 setup on a the s1 screen meant it could not be flipped down.

Removed the oi bath and fitted the filter I used to have on there.

There's defo an electrical problem that I have yet to get to. Seem like there a dead short or no alternator output once when the engine is first running .... flip on the headlamps/wipers/horn/indicators will stall the engine. But a few revs and all is well.  I can't expect much as Battery is ill, starter motor is seized and the solenoid is toast and there was a new alternator sitting in a box in the tub.

Didn't get to tinker much as I had to shoot of to Devon in the afternoon to collect some wheels and tyres.




Title: Re: It lives !
Post by: Saffy on February 12, 2012, 14:39:32
Well, didn't have to touch the starter motor, solenoid or alternator... troubles where due to the battery only. Replaced that with a good one and it starts on the button.
Bled the clutch through but pedal still hits the deck, so will looks like master and slave will need a overhaul/replacement. I have a new spare master and I bet in my spar box  I have a repair kit for the slave  :cool:

http://www.youtube.com/watch?v=eggszRYqsd4
Title: Re: It lives !
Post by: Saffy on February 12, 2012, 17:57:44
scratch all that about the clutch - just needed the mrs's foot on the pedal to bleed it thru...

and now it rolls...

http://www.youtube.com/watch?v=TylFMxEMLjQ
Title: Re: It lives !
Post by: lambert on February 12, 2012, 21:25:19
I know I love my 90 but you are making me envious!
Title: Re: It lives !
Post by: Saffy on February 13, 2012, 21:01:58
I have liberated the S1 tonight. It has been blocked in the garden by 4 tonne of scrap metal that's in a 110 tub and rolling chassis. But I noticed neighbour is away... so I took down fence and drove the truck out via their garden and put the fence back and there's not even a tyre track to be seen :grin:

Brakes seem fine ! 

Now that I can drive it out into the carpark proper I can give it a good going over next weekend. I was always waxoyled it regular when I was using it and it all looks in good nick underneath.
Title: Re: It lives !
Post by: baron von ledwidge on February 14, 2012, 12:17:28
Nice work mate, i will be watching ths closely, making me very jealous too.
Title: Re: It lives !
Post by: Saffy on February 16, 2012, 19:12:30
I insured it today so will be able to drive it to an MOT station when I'm ready . Fully Comp = 112 squids :smiley:

Think I need to sort some wheels and tyres next (the ones from devon too wide)... budget for this month pretty much at an end though. I could try for an MOT with the anconda 235/85 on it as they are fine just as long as there no too much articulation.........hmmm think I used to run with 235/85 colway MT on it before with offset rims... so maybe the anconda with the disco steels would be okay.
Title: Re: It lives !
Post by: Saffy on February 17, 2012, 20:28:58
The rag top and sticks have been dispatched and should be with me next week. I have driven it without the hardtop roof before and was amazed at how much quieter it is with out all the rattles going on, so hoping the rag will be similar.
Title: Re: It lives !
Post by: Saffy on February 18, 2012, 19:17:41
Indicators fitted and fixed (crudded up contacts on selector switch). Thing is the hardtop has a extra pair of indicator lamps fitted, so now they are disconnected the rest flash really fast - not sure if too fast for MOT.

Have taken the bolts out of the roof panel so it's loose and easy to remove next week.

Fixed the wing mirror I broke off last week.

Had a look at the birds nest of wiring behind fuse and instrument panel...... scary bad.

Removed the oversized SIII hinged middle seat, going  to fit something more S1'ish in it's place.

Still need to sort:
wheels/tyres
Fit rag top n poles.
Free up the windscreen hinges.
Replace wiper blade.
Fix the screen squirter.
Remove seat belt stalks (now the roof is going there going to be no seat belt option)
Do middle seat.
Sort out the carb.
Service engine.
Replace all the oils.
Get an MOT
Title: Re: It lives !
Post by: bravo669 on February 18, 2012, 20:55:09
it'll be ready next weekend then?lol, i love projects like this and would love one myself but wifey says im not allowed one! :shocked:
typical!...
Title: Re: It lives !
Post by: ukmudmaster on February 18, 2012, 21:10:34
If mine looks as good as that when its finished, I will be dead chuffed!!!!!
Dave
Title: Re: It lives !
Post by: Saffy on February 19, 2012, 20:10:06
it'll be ready next weekend then?lol, i love projects like this and would love one myself but wifey says im not allowed one! :shocked:
typical!...

I wish I could put some solid time into it but other life crap keeps getting in way. Just need to get to MOT standard and then I can spend when ever I can tinkering with it in my leisure. Maybe I need to book couple days off work.
Title: Re: It lives !
Post by: Saffy on February 21, 2012, 20:54:08
The bikini hood and stick set arrived at work yesterday so I raced home and so by the light of my coleman northstar lamp I took the hardtop off and fitted bikini...... rather exposed now !

(http://farm8.staticflickr.com/7202/6918135495_fa7cb55afc.jpg)

Going to ditch the rear bench seats and tart up the rear panels a bit with something that will cover all sins.

Also probably will end up making myself a fume curtain affair that I can roll down and keep the weather out of cabin when truck is not used.

Can't wait to take truck out--- wonder if my dogs will jump out  :shocked:
Title: Re: It lives !
Post by: Saffy on February 23, 2012, 19:32:42
Had an hours daylight when I came home from work so removed the bench seats. Fitted some rubber stops to the bulkhead for the folding cabin seat backs... dunno why I never bothered fitted them before. The stonechip stuff arrived today which I am going to coat the tub in. Have booked 3 days off work next week so that'll be me taking it for an MOT.\

Still need to swap out the carb and set it up.
Fit base to middle front seat.
Remove seat belts.
Check how bad the wheels/tyres rub if I can't get a set before next week.
Remove the door tops.
Sort the screen washer out. It got an electric washer but I want to fit a hand pump one but not got one :D
Title: Re: It lives !
Post by: Saffy on February 25, 2012, 18:19:37
wow - nice sunny and warm in Wiltshire today.

(http://farm8.staticflickr.com/7202/6782639540_b8c796886b.jpg)

Fixed the screen washer hoses so now get a jet of water on the screen rather than a dribble inside the engine bay.

Fitted a new blade insert to the one and only wiper  :cheesy: It wish washs back and forth as it should.

Did a do-for-now repair of the bulkhead galv top rail behind the drive seats which has a split, repair stops it getting worse anyway. Think the stress of a spare wheel being mounted there once was too much for it.

Set the end stop things on the steering. The anaconda extreme muds on disco steels are waaaaaaaaay too big for the truck but all I have right now and can't see that changing before MOT. They do not rub (anymore) but I now have the turning circle of an oil tanker (probably the same oil tanker I need to fuel the thing). They are also very heavy to pull around on the steering.

Got the mrs to rub down and etch prime the tub while I followed up with the schutz gun and blatted it with liquid tub liner.

(http://farm8.staticflickr.com/7053/6782635806_78180d4f9b_m.jpg)

Removed the seat belts and mounts.

Stopped the indicators flashing 90 to the dozen.

Carb still needs doing and there an occasional miss fire.

Need to add some retainer straps to the seat backs.

Not sure what else...

(http://farm8.staticflickr.com/7181/6928757811_25c848a0c4.jpg)
Title: Re: It lives !
Post by: NiteMare on February 26, 2012, 03:12:56
that's looking very nice, a set of proper landrover wheels on there would finish it nicely (maybe 6.5" 130 rims)

what's the liquid tub liner, a rubber coating ??
Title: Re: It lives !
Post by: Saffy on February 26, 2012, 07:50:49
that's looking very nice, a set of proper landrover wheels on there would finish it nicely (maybe 6.5" 130 rims)

what's the liquid tub liner, a rubber coating ??

I'd be happy with 205's or 7.50's. I do have a set of series1 rims with 6.00's but the tyres are non-certified things which when they were imported and then had the sidewalls etched with "max speed 12mph" lol.

The stuff in the tub is just a hard setting stone chip coat which is over paint-able. I have a 110 tub here which has had a treatment of that stuff in white by whom ever built it and it is really tough and hard wearing.
 http://www.amazon.co.uk/U-Pol-Gravitex-Stone-Protector-Overpaintable/dp/B004QDMZ4G/ref=sr_1_1?ie=UTF8&qid=1330242248&sr=8-1

Title: Re: It lives !
Post by: lambert on February 26, 2012, 08:30:13
You have mail.
Title: Re: It lives !
Post by: Saffy on February 28, 2012, 18:56:25
MOT booked for Thursday afternoon  :shocked:
Lost to do tomorrow, including collecting a trailer that my neighbour has kindly lent me to transport the truck to the MOT station.
Title: Re: It lives !
Post by: Hightower on February 28, 2012, 20:24:14
The stuff in the tub is just a hard setting stone chip coat which is over paint-able. I have a 110 tub here which has had a treatment of that stuff in white by whom ever built it and it is really tough and hard wearing.
 http://www.amazon.co.uk/U-Pol-Gravitex-Stone-Protector-Overpaintable/dp/B004QDMZ4G/ref=sr_1_1?ie=UTF8&qid=1330242248&sr=8-1

Saffy, how many litres of the Gravitex did it take to do the tub.  It looks just the thing I need to do mine with ;-)

Thanks
Title: Re: It lives !
Post by: Saffy on February 29, 2012, 06:14:13
The stuff in the tub is just a hard setting stone chip coat which is over paint-able. I have a 110 tub here which has had a treatment of that stuff in white by whom ever built it and it is really tough and hard wearing.
 http://www.amazon.co.uk/U-Pol-Gravitex-Stone-Protector-Overpaintable/dp/B004QDMZ4G/ref=sr_1_1?ie=UTF8&qid=1330242248&sr=8-1

Saffy, how many litres of the Gravitex did it take to do the tub.  It looks just the thing I need to do mine with ;-)

Thanks

I bought four in total . 2 covered it quite well but a 3rd and maybe 4th will finish with a leveling orange peel coat nice. It flows out of the schultz gun really nice too.
Title: Re: It lives !
Post by: Saffy on February 29, 2012, 15:37:24
(http://farm8.staticflickr.com/7200/6795123328_a93aa6c50a.jpg)

Omg - fitted 205/70 tyres... they sooooooooo small.  Hah but at least it can turn now and no chance of rubbing up against metal work! Had to gently urge one of the brake hose to not touch against the wheel - no idea what was in my mind when I fitted +2 inch braided hoses back in the day - pain in the butt for locating nicely.

Made some leather strap seat back retainers - seat no longer fall over when hitting brakes.

High beam and the left hand indicator decided they didn't want work any more. Urged them back to work with a bit of poking around the column switch with my swiss army knife.

Checked all the oil levels, all okay except the gearbox which needed over 2 litres! Guess that's near dry.

Really needs a wash and de-mossing but other than the unknown I think it's ready for MOT.

Picking up trailer in a bit, will have to load truck on tonight.





 
Title: Re: It lives !
Post by: lambert on February 29, 2012, 16:18:40
(in best lou and andy voice)  "a want that one!"
Title: Re: It lives !
Post by: Saffy on February 29, 2012, 18:49:39
(http://farm8.staticflickr.com/7179/6795568232_ca6bd490cb.jpg)
Title: Re: It lives !
Post by: Saffy on March 01, 2012, 19:08:54
The landy train is off...

(http://farm8.staticflickr.com/7066/6798298316_f2530e55cf.jpg)

They should have a rule that if you can't see the Severn Bridge then you don't have to pay!
(http://farm8.staticflickr.com/7199/6798299226_dd9cbe4263.jpg)
The toll women didn't laugh either.

(http://farm8.staticflickr.com/7058/6798300156_cc040679af.jpg)
Despite half blinding the MOT guy when it dripped oil in his eye - the truck PASSED with no advisories.
Title: Re: It lives !
Post by: lambert on March 01, 2012, 20:06:38
Yay go you!
Title: Re: It lives !
Post by: Welshbreed on March 01, 2012, 22:06:03
congrats man. Cant wait to see the next few mods... now its legal and all! :evil:
Title: Re: It lives !
Post by: Saffy on March 02, 2012, 06:54:59
Not sure about mods but next move is to swap out the gearbox for a recon late SIII model that I have in the shed.  I think will really need to take the head off check for a burnt valve once and for all. The holes are already in the tub for a roll hoop...
Title: Re: It lives !
Post by: Saffy on March 03, 2012, 18:00:35
New set of NGK plugs and a new set of leads yesterday and it running nicer. Topping out about 50mph.... used to do 70mph. Will do the valve clearances and ignition timing and see how things go. Do think it might have suffered some valve seat regression as I remember the gaps closing up suddenly between services.
As it is, it does run fairly briskly and so took it out for a wee trip onto the Plains - forgot how harsh it is over bumps  :shocked:

Had a smile on my face anyway.
Title: Re: It lives !
Post by: NiteMare on March 03, 2012, 23:27:19
jack the chassis up so the axles hang from the springs and slather plenty of EP90 in between the leaves then get back out laning with a bit of weight in the tub to get the springs working and clearing out the rust, once working properly they ain't as bad as you might think they are

i spent about a month oiling and cleaning the springs on my first landrover, they were just as good as the cheap paras i replaced them with, so all i got was a chassis lift with the paras  :laugh:
Title: Re: It lives !
Post by: Saffy on March 04, 2012, 10:02:54
jack the chassis up so the axles hang from the springs and slather plenty of EP90 in between the leaves then get back out laning with a bit of weight in the tub to get the springs working and clearing out the rust, once working properly they ain't as bad as you might think they are

i spent about a month oiling and cleaning the springs on my first landrover, they were just as good as the cheap paras i replaced them with, so all i got was a chassis lift with the paras  :laugh:

ah cheers but I should have mentioned by now it's on parabolic springs. It's normal ride is not harsh but going over speed humps or pot holes at anything other than super dead slow will make the front end bottom out onto the bump stops.
This is where it gets funky..... 
There is only about 2 inch travel on the front end due to the bumpstop pads being lowered. They are lowered in an attempt to prevent the Engine's crank pulley HITTING THE AXLE in extreme conditions. Seems to vary but in my case 86inch S1 + SIII 2.25 engine + SIII LWB axles = awkward engine bay geometry. During a few greenlane trips I heard/felt odd noise and noticed marking on the top of the axle and in the crank pulley - with the extended bumpstops it never happened again but resulted in this bang harshness when dropping into a hole. 
As it's been a few years since playing with truck, maybe it time to have a look to see if there is an alternative solution.
Title: Re: It lives !
Post by: Welshbreed on March 04, 2012, 21:22:56
if your going to do the engine, might as well take it to bits, check the bearing caps or wear and piston heads for build up of coke etc. replace spark plugs, ignition & Valve timing. check the sleeves for scores...  be a fun day doing all that :cheesy: made myself a bit jealous there...
Title: Re: It lives !
Post by: Saffy on March 05, 2012, 20:14:46
picked this roll cage/hoop tonight...... dunno if to fit or not.... whatcha all think?

(http://farm8.staticflickr.com/7194/6810668978_4552c17cba_z.jpg)
Title: Re: It lives !
Post by: NiteMare on March 08, 2012, 12:04:07
rollcage.. are you intending to turn it upside down ??

it sounds like your front springs are knackered if you're hitting the axle case, i run para's on my 88" but i also have a disco 200tdi fitted

when i originally fitted it i struck the front axle with the crank pulley which necessitated i put the pulley on the lathe to remove the rear Vee and take a couple of mm off the front lip (cast iron pulley)

i also got 4 thick shock top washers and fitted 1 below and 1 above both the engine mount rubbers giving me approx' 1/4" engine lift, i haven't hit the axle since

i did consider bumpstop extensions but i wanted to retain articulation and compression, i've been lucky and not had a problem

i do offroad and greenlane in this motor and i'm not shy of giving it welly when i need to

measure your bumpstop to axle space, i'll try to remember to check what the standard space is supposed to be
Title: Re: It lives !
Post by: Saffy on March 08, 2012, 18:38:25
rollcage.. are you intending to turn it upside down ??

it sounds like your front springs are knackered if you're hitting the axle case, i run para's on my 88" but i also have a disco 200tdi fitted

when i originally fitted it i struck the front axle with the crank pulley which necessitated i put the pulley on the lathe to remove the rear Vee and take a couple of mm off the front lip (cast iron pulley)

i also got 4 thick shock top washers and fitted 1 below and 1 above both the engine mount rubbers giving me approx' 1/4" engine lift, i haven't hit the axle since

i did consider bumpstop extensions but i wanted to retain articulation and compression, i've been lucky and not had a problem

i do offroad and greenlane in this motor and i'm not shy of giving it welly when i need to

measure your bumpstop to axle space, i'll try to remember to check what the standard space is supposed to be

Roll hoop more of a method to get the seat belts back in as I can mount the upper seat belt point on the hoop verticals- Haven't made up mind yet as I am loath to put more holes in the poor truck and I would need to make up the chassis mounts too.

Paras not knackered as they are new and it did same on the standard springs which where also new, and also the same with the old MOD light weight springs I had on it when I got it - but they where floppy things. I think the reason the 88 inch came about is because the 2.25 didn't bode well in the 86" bay. The pulley trim is not a bad shout as it's a 'civvy spec' MOD engine fitted with twin belt V pulley fitted and so it could easily lose the front unused groove and gain some clearance.

Raising the engine in it's mounts has issues of itself. Another quirk is that as it stands I can not fit a standard elbow to the zenith carb as there is not enough clearance between the top of the carb and the bonnet. I have had a 'bubble' in the bonnet in the past to allow fitting but since put the bonnet back to standard and made a custom 'pancake' elbow to fit instead. Raising the engine would cause problems.

I just have to take it slow dropping into holes or get a compacted spine.


Title: Re: It lives !
Post by: Saffy on April 07, 2012, 19:49:21
Decided against roll cage.

Gearbox and tranny have been leaking oil big time from rear and front oil seals. It's a series II box without syncromesh on 1st and 2nd but that never bothered me........ but seeing it's peeing out oil and I have had an MOD reconditioned SIII box (less than 20k on it) sitting in the shed since i've owned the truck.... It's time for a change....

(http://farm8.staticflickr.com/7058/7054290585_1e50d0a609_z.jpg)

(http://farm8.staticflickr.com/7097/7054292957_c9a5cb68b0_z.jpg)

Not to much of a pig to get out and even easier sliding replacement back in. The mounts that where on it are totally different so they needed swapping over. Drives nice.

I sold a recon 200tdi genuine defender engine and all parts needs for a conversion to a neighbour couple year ago and kicked myself for it. Anyway he has only just got around to fitting it to the 90 he has has in storage. So I bought the 19J TD (i know, I know) that was in the 90 and plan to fit it into the series very soon. Modifying the offside chassis engine mount worries me a bit but I am committed to do the job now. Should be a nice match for car and gearbox.
Title: Re: It lives !
Post by: Saffy on April 09, 2012, 14:49:15
and... today.... out comes the engine...

(http://farm8.staticflickr.com/7068/7060652735_c5543ea1cd_z.jpg)

Took four hours in the wind and rain.

Next weekend engine insertion exercises are planned.
Title: Re: It lives !
Post by: lambert on April 09, 2012, 20:23:45
There are worse ways if spending a wet bank holiday Monday than taking engines out of land rovers.
Title: Re: It lives !
Post by: NiteMare on April 21, 2012, 00:57:07
the 19j should have an easier life in this  being as it's something like 1/2 a ton lighter, maybe an intercooler to help keep intake temperatures down ??  thus helping on temperatures in general

an overdrive or 3.54 diffs to help keep the revs down or even a high ratio transfer box, all possibilities to help protect the engine

anyway regardless of my ideas/thoughts i hope you're enjoying it  :grin:
Title: Re: It lives !
Post by: Saffy on April 21, 2012, 20:24:45
the 19j should have an easier life in this  being as it's something like 1/2 a ton lighter, maybe an intercooler to help keep intake temperatures down ??  thus helping on temperatures in general

an overdrive or 3.54 diffs to help keep the revs down or even a high ratio transfer box, all possibilities to help protect the engine

anyway regardless of my ideas/thoughts i hope you're enjoying it  :grin:

Thinking of intercooler as I have a couple of standard tdi's ones here but that'll be a future project.
I have only got as far as modifying the o/s engine mount on chassis, fitting a new clutch plate and bolting the lump in place.... oh and making a throttle linkage.

Had looksee at seeing if I could get the TD's standard radiator in but there's no chance on the height. A defender tdi one will fit in the 86 inch but I have not one spare. So have fitted the 2.25 thermostat housing on the TD and will use the Series Rad with Series top house. Haven't figured the bottom hose yet will have to make one up. Do not know what impact having a non-pressurised coolant system will be.

Main issue at moment is that ditching the TD radiator means no oil cooler, some people block it off it seems but being a 19J it might be wise to fit a separate one. There are quite cheap 13 row MG ones on ebay which are a nice size - do not know if the fittings are right though?

Need to plumb in the fuel and electrics yet. Might do those tomorrow and worry about cooling and oil next week   :undecided:

oh and the exhaust needs thinking about... forgot that  :grin:
Title: Re: It lives !
Post by: Saffy on April 22, 2012, 15:08:34
I've plugged up the oil cooler ports on the engine for the moment using brass radiator plugs from BnQ. Any thoughts on doing that?

Fuel plumbing is going to be easy.

Have made up a bottom hose to rad, so that's ready to go.

Found the old kenlow fan that was fitted to the truck many moons ago.

haven't really done much - stupid rain showers every 5 minutes annoyed the hell out of me.

Another job that needs doing is that battery needs relocating into the passenger seat box. Will need to bolt the seatbox back in first though  :cheesy:
Title: Re: It lives !
Post by: NiteMare on April 22, 2012, 22:04:44
i've no idea really about the 19j except they've a poor reputation so can't offer any suggestions about blanking off the oil cooler ports, i've no idea if it works in the same way as the Tdi with the thermostat in the oil union/housing

i sympathise with you about the showers, i've loads of work i want/got to do and i'm sick of being soaked even with my canvas up   :sad:
Title: Re: It lives !
Post by: Saffy on April 22, 2012, 22:08:57
i've no idea really about the 19j except they've a poor reputation so can't offer any suggestions about blanking off the oil cooler ports, i've no idea if it works in the same way as the Tdi with the thermostat in the oil union/housing

i sympathise with you about the showers, i've loads of work i want/got to do and i'm sick of being soaked even with my canvas up   :sad:

...if it did work in the same way as the tdi (i think it does have some sort of valve thing going on to control flow through oil cooler) then what impact would blanking off be? not going to effect oil flow through engine  or something? I planned on running it like that until I sort something out with oil cooler. I was hoping it be okay as I not going to be belting around above 55mph - no towing no loads cept my lard butt.
Title: Re: It lives !
Post by: Saffy on April 22, 2012, 22:40:47
i've no idea really about the 19j except they've a poor reputation so can't offer any suggestions about blanking off the oil cooler ports, i've no idea if it works in the same way as the Tdi with the thermostat in the oil union/housing

i sympathise with you about the showers, i've loads of work i want/got to do and i'm sick of being soaked even with my canvas up   :sad:

...if it did work in the same way as the tdi (i think it does have some sort of valve thing going on to control flow through oil cooler) then what impact would blanking off be? not going to effect oil flow through engine  or something? I planned on running it like that until I sort something out with oil cooler. I was hoping it be okay as I not going to be belting around above 55mph - no towing no loads cept my lard butt.

well duh ...... I am a dumb ass ( well nearly) did some more research and I will need to remove the oil thermostat from inside the filter housing else if when oil is hot enough the thermostat will open and try to route the oil through the no existent oil cooler, cut the oil supply all together and engine melts :D
Title: Re: It lives !
Post by: Saffy on April 24, 2012, 19:00:22
......and now........ have ordered an after market oil cooler and a couple of 1/2inch bsp female/female adaptors..... change my mind like a women, but the thought of ditching the oil cooler on a 19J irks me.

Title: Re: It lives !
Post by: NiteMare on April 27, 2012, 20:07:19
looks like you're sorted, good to hear of progress  :grin:
Title: Re: It lives !
Post by: Saffy on April 28, 2012, 14:15:04
Have the oil cooler, looks sweet but haven't plumbed yet as other things need doing first.

Drained the petrol out of the tank (filled 20litre jerry !).  Fitted a fuel return to the tank. Fitted the TD fuel filter housing to the bulk head and plumbed all the fuel lines in. All in the rain of course. Getting a tad tired of the weather now as a two day job is taking for ever. Have booked a week off next month so it better be fair sailing.

Next on the list is fitting the seatbox back in. Fitting battery into the seatbox and route the charging cabling, wire up starter motor, do the chassis/engine block earth straps.
Title: Re: It lives !
Post by: Saffy on May 05, 2012, 22:48:29
Battery now mounted into the seat box. New cables made up from battery to starter motor solenoid and earth strap to chassis. Made a start on some of the loom mods. The starter turns over with key so that's sorted.

Have refitted the original series solenoid to the the bulkhead and have routed the glow plug cabling through it.

such slow progress  :rolleyes:
Title: Re: It lives !
Post by: Welshbreed on May 06, 2012, 18:36:26
such slow progress  :rolleyes:

As is life my friend, as is life
Title: Re: It lives !
Post by: Saffy on May 06, 2012, 21:13:51
End is in sight - kinda.

to do...

bolt up wings to front panel.
install Front panel loom.
Wire up some sort of leccy fan control.
Fit the oil cooler (no idea how I'm going to connect it up yet)
Fit exhaust reducer (temp solution)
figure out what I am going to do in regards to the temp/oil sensors
figure out what I am going to do with air intake/ air filter.
block off the heater pipes (no heater in my truck)
add coolant - engine oil - fuel and fire it up and write a list of snags :D
Title: It lives !
Post by: Hightower on May 06, 2012, 22:19:02
Good on you Saffy.

I know exactly how you feel.  Still to do on mine:
Bolt on wings, fit mud guards underneath
Fit doors
Glaze door tops
Wire up lights front and rear
Rejig seat mounts

Looking for some good weather to finish....
Title: Re: It lives !
Post by: lambert on May 07, 2012, 07:44:26
So near to done, well done both of you.
Title: Re: It lives !
Post by: Saffy on May 09, 2012, 17:17:35
End is in sight - kinda.

to do...

bolt up wings to front panel.
install Front panel loom.
Wire up some sort of leccy fan control.
Fit the oil cooler (no idea how I'm going to connect it up yet)
Fit exhaust reducer (temp solution)
figure out what I am going to do in regards to the temp/oil sensors
figure out what I am going to do with air intake/ air filter.
block off the heater pipes (no heater in my truck)
add coolant - engine oil - fuel and fire it up and write a list of snags :D

sod the rain - hauled out the angle grinder and MIG and made the exhaust.  I used an online company to make be a custom sized reducer - 60mm to 47mm........ OMG they need to invest in a tape measure - even totally clamped down there is a 3mm gap... useless. So I welded it - job done.

Oil pressure switch was simple as extending and  pushing on the existing series spade. 
The coolant temp sensor needed swapping - how surprised was I that the thread was the same between the engines... not complaining about that!
My truck has a oil temp gauge - the 19j hasn't got as standard. Wondering if there is a plugged port that I can use as it would be nice to have that sensor working.

Still haven't done the front loom, oil cooler or leccy fan or air intake BUT I couldn't wait so put in the coolant - fuel and engine oil and fired the beast up  :grin: Once primed it ran - whoop. 
Title: Re: It lives !
Post by: lambert on May 10, 2012, 06:07:07
Keep at it, don't let the rain put you off too much.
Title: Re: It lives !
Post by: Saffy on May 12, 2012, 18:47:35
woohoo it's done and been for a test drive on sailsbury plain. Drives lovely, totally different with both the engine and SIII gearbox (was a sII non synchro before). Very chuffed with the 19J turbo diesel - more than enough power there and very responsive too.  Wish I never sold off my overdrive though :rolleyes:

Couple of snags on the list but minor stuff.
Title: Re: It lives !
Post by: lambert on May 13, 2012, 06:44:07
Well done. Let's have some pics of the finished install then.
Title: Re: It lives !
Post by: Saffy on May 13, 2012, 07:39:38
(http://farm9.staticflickr.com/8017/7186479904_6cf8e2ba08.jpg)

Not much to see really. Uses a modified rover air box with a K&N cone filter mounted inside.

Exhaust uses the top 10 inch or so of the 2.5TD's down pipe to mate to the manifold, goes into a reducer on the vertical and then on to the series exhaust. The reduction didn't have any noticeable effect on performance so will be in no rush to replace the rest of system with bigger bore.

Oil cooler is mounted vertical behind the rad on the off side, held in place with brackets welded to the radiator side. Uses the 2.5TD oil cooler pipes bent and wriggled to fit. Will be replacing these with nice new routed pipes at some point.

Battery lives under passenger seat.

Original starter solenoid is now used as a relay for the glow plugs.

Old (large) Kenlow fan fitted in the front of the rad. If truck is left to idle a long time with a few rev's thrown in then the temp goes up to 3/4 of gauge and the oil is flowing through the oil cooler but I bottle it and turn on the fan which bring the temp down to halfway and maintains it. On the road I didn't need the fan until pulling up and idling after a hill climb where temp had to be controlled with fan. I want to modify the front pulley and the old series MOD mechanical fan and fit that somehow. I dislike leccy fans on 4x4 unless that is no choice.

Title: Re: It lives !
Post by: Saffy on May 13, 2012, 12:45:35
Put it work today with the Dump Run and also collected some gravel.
(http://farm9.staticflickr.com/8153/7187733436_1e7965c5ea_z.jpg)

On the way back from Wicks store the engine cut out and truck rolled to a stop.  :shocked:  checked the vitals and everything looked fine - oil/water/fuel/ stop solonoid click click, no obvious leaks or high temps. Then I remembered the last thing I did last night when parking up was to turn off the inline fuel tap  :embarrassed:  Had driven close to 2 miles with the fuel turned off !
Title: Re: It lives !
Post by: lambert on May 14, 2012, 08:02:18
Looks good, what's the insurance like on that with all the mods.
Title: Re: It lives !
Post by: Saffy on May 14, 2012, 18:40:58
Looks good, what's the insurance like on that with all the mods.

(http://emotibot.net/pix/5303.jpg)

A massive 25 quid increase for change of engine details. So can't remember... erm something like 130 fully comp in total.  Got to do the DVLA logbook change next.
Title: Re: It lives !
Post by: lambert on May 14, 2012, 21:03:46
No I'm genuinely interested as the last engine I replaced cost an extra grand to cover though it was to make a vr6 polo which may explain that.
Title: Re: It lives !
Post by: Saffy on May 17, 2012, 19:53:41
Didn't like the pipes I used for the oil cooler. i just jury rigged the old defenders pipes and eased some bends into to and routed them all over till them mated to the oil cooler. Was a do for now but I suspected they restricted the flow and could brake due to work hardening of the metal pipe.

Sooooooooo didn't want to pay someone to make up hoses (and get it wrong) and didn't want to risk cutting and jublee clipping hoses on to normal fittings (some people say it's okay). Then I found fit for purpose products at Merlin Motorsport....

http://www.merlinmotorsport.co.uk/OIL-SYSTEMS-Oil-Hose-Unions-Aeroquip-Fir-Tree-Oil-Unions/c162_213_3430/index.html?page=2

Aeroquip FIRTREE unions for use with the proper push fit AEROQUIP hose .  Major effort to put together but the result is great stuff. So if anyone need to make up some custom oil cooler hoses then this Aeroquip is one way to go. The Hose itself is rated at 300psi and these push fit joints are good for 150psi.
Title: Re: It lives !
Post by: Saffy on May 17, 2012, 20:03:04
Other issues of the day .......

The engine is old but isn't chuffin like a train - but it does chuck oil out the rocker cover breather on prolonged high revs . Final destination of the breather is my air filter box intake. So oiled up air filter (common for 19J!) and oil that drips out of the aircleaner intake when parked up.  I have made a baffled oil catcher tank to sit inline between the rocker and air intake - just need to mount it and test it. Hopefully it will help.

Steering box is leaking! Deep joy.



Title: Re: It lives !
Post by: Saffy on June 09, 2012, 19:02:01
Still waiting for my V5 back from the DVLA.... taking their time will have to give a call next week.

I want the docs back so that I can send them straight back to the DVLA and get the registration number transferred to the Defender.   :kiss:
Title: Re: It lives !
Post by: lambert on June 09, 2012, 23:16:59
That would be the joy of cherished number plates. They have always benefited from a visit to the local office when I have moved mine. Vosa ~ pita.
Title: Re: It lives !
Post by: Saffy on September 02, 2012, 18:15:03
Plates all swapped.

The Series new plate is

556
YUM

I like it. 

Bought an overdrive and fitted it this weekend. Takes the edge off the high revs in 4th.  Bought some 7.50 tyres on LWB rims which will look more suitable for the truck.

Title: Re: It lives !
Post by: Welshbreed on March 14, 2013, 22:11:18
Anything new here then?
Title: Re: It lives !
Post by: Saffy on May 06, 2013, 11:57:58
(https://lh5.googleusercontent.com/-WZSfxSvXTv4/UEjQGRoKGjI/AAAAAAAAJt8/L0oqrvEEo1U/w756-h567/photo.JPG)
Truck been taken out occasional, mostly for dump runs as it easier to get crap in and out of and less hassle parking up in the recycle centre.
MOT negated this time around as it no longer needed.
Interior panels coated in liquid tub liner.
Door mirrors replaced again (going to need a supply of these and treat them as consumables!)
Canvas has held up well with no bad shrinkage.
Truck spent whole winter season with no door tops on and suffered no ill.
Engine likes at least 20 seconds of glow plug and it will then start on first turn when cold.

Updated to do list:
Took the thread plate off wing tops so there a colour mix match and lots of flakey paint -- whole truck front end and doors could do with a splash of green paint.
Still only have one windscreen motor and wiper, be nice to have two though not legally needed.
Would like to fit a better steering wheel then the button that's on it at moment. I have a pinch bolt type boss to fit too.
Handbrake / overdrive linkages some how hit hard against seat box when hand brake is fully up - lots of vibration at idle - need to sort that
Needs a better radiator fitted, the series one does not seem to make the grade with the TD engine. a de-framed 200tdi rad would do the trick.
Defender intake grill in wing that covers a hole need to be patched.
Need a spare wheel. Need a 86 inch series 1 bonnet with spare wheel mount plate fitted or just the plate to fit to existing bonnet.
Want replace the crappy retro fitted fuse box with a better arrangement.
Title: Re: It lives !
Post by: lambert on May 06, 2013, 16:15:31
Looking good.
Title: Re: It lives !
Post by: brixworth-alan on May 08, 2013, 21:22:16
What tyres are you running saffy? I need to consider new boots on mine as mine were sat with not enough air, in a load of nails in a field through 15 winters.... Im thinking they might not stand much road use...
Title: Re: It lives !
Post by: Saffy on May 09, 2013, 19:14:29
What tyres are you running saffy? I need to consider new boots on mine as mine were sat with not enough air, in a load of nails in a field through 15 winters.... Im thinking they might not stand much road use...
crossply widow makers, lose it early (esp in wet) but highly recoverable before the point of no return as long as your expecting the sideways slide.

these pretty much have all the same pattern:

Goodyear Hi Miler Xtra Grip 7.50
Deestone Extra Grip
Security ML814
Flamingo TM718
Kenda X-Grip

updated photo of truck, that last one been around a bit. Mirrors moved to doors top hinges. These are spare set of door top that are not glazed, I keep these on all the time now - no need for windows!

(https://lh4.googleusercontent.com/-0ibwh27b9T4/UYvnwsEAMUI/AAAAAAAAKP4/qzSXtkvND9Y/w722-h567-no/s1_may2013.jpg)
Title: Re: It lives !
Post by: LandRoger on May 09, 2013, 20:54:33
She 553 YUM looks swell M8 , I have a Defender wiper motor with drive and the mounting stems for the wipers if you want it as a freebee its in very good nick .what is it about leckie fans you don't like?its one of my first mods to any Landy  they don't take any power away from underpowered engines and a small bonus in the mpg so im led to believe, if you want w/motor etc can meet on the Plain sometime .
Title: Re: It lives !
Post by: Saffy on May 09, 2013, 22:32:29
She 553 YUM looks swell M8 , I have a Defender wiper motor with drive and the mounting stems for the wipers if you want it as a freebee its in very good nick .what is it about leckie fans you don't like?its one of my first mods to any Landy  they don't take any power away from underpowered engines and a small bonus in the mpg so im led to believe, if you want w/motor etc can meet on the Plain sometime .

Thanks for the offer Roger...buuuuuut the truck used to have SERIES3 wiper set up (same as defender pretty much) which was all retro fitted nicely and all very sensible, so I removed it and fitted the early series individual motors that are supposed to be on it (well just one of them so far!) because they are more funky and age related (not a major factor on this truck I know but heh ho). The one that is fitted works really well and pulls the wiper blade back and forth with quite a bit of torque.  .....Oh I remember now.... there was a sensible reason for my madness, I could not flip the windscreen down with the later wiper type arrangement.

Electric fans - mostly reliability. Retro fitted, there are lots out there with sub-quality wiring and switching. They tend not to get used for long periods - so have plenty of time to clog up with crap from the natural driving a 4x4 encounters (mud and water) so there's a greater chance they are not going to turn on when switch is flicked or termo-switch trips (motor over heats, or draws high start up current and blows fuse). With engines like landrover TDI's in the mix - I'd rather not increase any risk of over heating one. Mechanical ones just work properly with great reliability and even the hydrostatic ones fail safe- my preference is standard mechanical.
This series 1 will likely keep a leccy fan as modifying to fit the MOD metal fan will be a bit problematic. I first need to replace the series rad with a 200 TDI one (the TD rad that came with engine is way too big to fit to physically fit into series and 300tdi rads are plumbed wrong side) Though, when it was hot day last weekend the temp went up to 3/4 and was held at bay by the fan even driving it hard up the hills onto the ridgeway so there's not really a major cooling problem with the truck.
Title: Re: It lives !
Post by: LandRoger on May 11, 2013, 18:44:19
My 90 with Disco 200tdi had NO fan fitted I drove it like that for months until fitting a leccy one from an Astra!with a manual switch that I prefer+ warning light . :wink:
Title: Re: It lives !
Post by: Saffy on May 11, 2013, 19:29:56
Aye, but not something i'd promote.
Title: Re: It lives !
Post by: Saffy on June 10, 2013, 19:43:35
Drove S1 to work on a hot day last week and return journey the temp gauge was sat just in red after about a mile driving - leccy fan was on but not helping. Pulled over and engine wasn't over heating as far as I could make out.  Drove the other 19 miles home expecting engine to puke any moment but seems it was just the temp sender that puked on me.

Decided to buy a series III sender to match the sIII temp gauge. Was expecting to have to modify or make an adaptor for the thread difference but turned out to be correct fit for the 19J 2.5TD also. It's a 560794 part number and my 19J has the sender fitted in the top of head towards the rear of the engine above the exhaust manifold (some have the sensor up front near or on the thermostat housing).

Temperature reads more sensible now on the gauge. Not sure I need worry about fitting a TDI rad anymore ---- more testing needed.
Title: Re: It lives !
Post by: lambert on June 11, 2013, 06:45:13
That's a happy coincidence then. Hope it saves it from boiling without telling you.
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