FORUM CLASSIFIEDS DIFFLOCK.com Links & Networks
Forum Homepage
Log in
Profile
Search
Private Messages
Forum Members
Register
Classified Ads
Search Ads
Place New Ad
My ads
Place your classified
ads here for FREE
NB: Adverts placed in the general
forum areas will be deleted
Difflock Homepage
Online Shop
Contact Us
FAQ
Calendar
Garage
Facebook
Twitter
Youtube
Advertise With Us - Reach your target market by advertising on the Difflock.com forum.
Click here or call 0845 125 9407


Rebuilding Defender 90 CSW
Goto page Previous  1, 2, 3
 
 
Post new topic   Reply to topic    Difflock Forum Index -> Land Rover
View previous topic :: View next topic  
Author Message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue Jul 05, 2016 9:35 pm    Post subject: Reply with quote

Well, it's just about there now.
I've been spending every minute I can on it and there have been plenty of ups and downs since my last post, but here are a few key stages.
Bought a new full exhaust system, Britpart, but hey ho.

I bought YRM all in one outer sills. They're 3mm thick and very solid. I had a bit of an issue getting them to fit.

This was on the drivers side and I wasn't happy with the drivers door fit either.
Decided to remove a spacing washer from the bulkhead set up.

The door was a much better fit - the curve in the door lined up with the curve in the tub much better!
The sill was a much better fit too.

Fitted the window seals and door to sill seals.





Was going to rub down and repaint the wipers, but decided it was false economy given the price of new ones. Bought some galv rear mud flap brackets and an aftermarket central locking system!

Hadn't had the rear wiper fitted for the last six years Shocked But fitted it to this new door.

I decided to paint the faded front grille silver, so did the light surrounds as well. Got Zambezi silver made up at Halfords.

Was pleased with the look when they went on.

Bought a galvanised bumper and some silver 3D 'Defender' letters for the bonnet and 'Tdi' letters for the bottom of the wings. So, apart from some inner trim, door cards etc, it's just about there.
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue Jul 05, 2016 9:43 pm    Post subject: Reply with quote

Couldn't add any more pictures to the last post for some reason. Here it is almost done.




Pushed the boat out (special permission from the management) and bought some side steps.



Next job is to clean the tow bar assembly and rear step so I can get them galvanised and I need to fit improvised front door switches so the internal light works and the doors trigger the alarm. Rear door card to refurbish and fit.
Back to top
View user's profile Send private message
RichardD
Marshall


Joined: 13 Mar 2003
Odometer: 22856
Location: State of Confusion



PostPosted: Wed Jul 06, 2016 8:18 am    Post subject: Reply with quote

Stable, you can only add 10 photos per post.

That is a work of art, not a rebuild but a full on restoration building the car the way it should have left the factory.

Without doubt it one of the best and most sympathetic restos I've seen in a long time and is a credit to the time effort and expenditure. At first I thought you should have painted the chassis black both for aesthetics and to hide it from prying thieving eyes but by painting the grill silver it just brings it all together.

Keep the pics coming

__________________________________
Poking the Grim Reaper with a stick then running away. The devil made me do it but God said it was okay with him.
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Wed Jul 06, 2016 11:02 pm    Post subject: Reply with quote

Cheers, RichardD. Very kind words and greatly appreciated. I'm very pleased with it. It looks great stood on the drive and feels great to drive. Got a new set of BFG's on yesterday and they have transformed the drive and road manners even more. First impressions are these KO2's are much better than the old compound.

I've obviously never posted more than 10 pictures at a a time before! Couldn't work out what I was doing wrong. Smile

A few more things to do, so will probably add a few more pics.

Thanks again.
Back to top
View user's profile Send private message
kev.h
Gate Opener


Joined: 15 May 2011
Odometer: 45
Location: lancashire



PostPosted: Sat Aug 13, 2016 11:34 am    Post subject: Reply with quote

VERY nice rebuild, a job blinkin well done
Back to top
View user's profile Send private message Skype Name
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue May 30, 2017 1:56 pm    Post subject: Reply with quote

Unfortunately, I need to do a bit of an update.
My shiny new Landy ran well up until mid February. Then started to have very slight starting issue. It would start, but was a bit rough for 20 to 30 seconds. After a week or two I started finding oil around the block and dripping on to the drive. Sad Did the usual checking breathers etc Because it must have been getting blown about it was impossible to trace where it was coming from. The Mrs uses the Landy as her daily drive to work and I got a call from her broken down on the side of the A1. 'It was making a horrendous noise' she said. Was a clanking or engine revving really high I replied Shocked 'Engine was screaming' was the reply Shocked Shocked Shocked Because of the noise and panic she's not sure how she stopped it, but it only ran away for about 10 seconds. It got recovered home.

The turbo had a small amount of play on it, but border line to be catastrophic, so I decided to take the head off to have a look inside. Discovered No4 injector was goosed which would explain the rough starting.

The injector had caused it to run lean in that cylinder, which makes it hot and the piston crown had started to melt. Sad

The bowl in the crown is bigger diameter than it should be and the centre cone is just about melted away.
I could have got a second hand lump to put in, but you don't really know what you are getting and having spent all the time and money on the body rebuild I thought I might as well rebuild the engine so I know I've got something decent under the bonnet.
Lifted it out and began the strip down.

I had to buy and engine stand, but they are not very expensive. Stripped , labelled and photographed everything.

Got another surprise when I slid the pistons out. ALL of the rings in piston No1 were exactly in half Shocked

No idea how that would have happened.
It explains why it was pushing oil out as it must have been pressurising the crank case. Sad
It was all very dirty.

Got it stripped and found an engine machine shop in Newcastle and took the block and head down.
Had to get it bored out to 40 thou above standard and had 6 though skimmed off the head. By the way, the head gasket had not gone, but I thought a skim was worth it while I was on.
After machining they give it a hot wash so it looked decent when it came back. I then spent a few hours polishing it with wire wheels and brake cleaner.
Came up nice.

Painted it red.
I ordered red engine block enamel off Amazon. When it arrived it had Ferrari red on the tin. Very Happy Shocked

Used Kolben Schmidt pistons as they are reputed to be good. gapped the rings just in case and they were all spot on.


Replaced the main crank bearings and thrust washer.

On assembly I lubed everything with Lucas engine lube so at first start up it wouldn't be dry. You can see it in the picture above.
getting the end seal in to position for the front of the crank is a pain of a job. Took ages to work them in. There is a tool to help, but I didn't have it.
I might have reached the picture limit.


Last edited by stable on Tue May 30, 2017 7:41 pm; edited 1 time in total
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue May 30, 2017 3:22 pm    Post subject: Reply with quote

I had!
The crank shaft main bearing end seal was a pain to get in. There is a special tool to help, but I didn't have it. This is it just before final torque down.


Replaced the oil rotor

Packed it full of vaseline so it wasn't pushing fresh air at start up.
Got all the pistons and big end bearing in.

I changed the main camshaft end bearing as it was showing wear. The others are much harder to get out, seemed ok so I left them. The end one gets the most wear as it has the cam belt pulling on it. This is the original showing the wear. That's actually a raised seaction from where the oil channel is on the camshaft.

This is the big journal on the end of the camshaft showing the oilway that the bearing shell had worn in to, if that makes sense.

Popped the cam in and then checked the piston upstand.

This allows you to check what thickness head gasket to use. i'd also checked the valve clearance to the surface of the cylinder head.
Started getting some ancillary bits on.



Cleaned the sump and painted it with rustoleum.
Back to top
View user's profile Send private message
** GED **
Mud Obsessed


Joined: 18 Jun 2014
Odometer: 2039
Location: Scouser



PostPosted: Tue May 30, 2017 3:40 pm    Post subject: Reply with quote

i hate landrovers.

but the care and time you have put into that is amazing.

well done and i hope it rewards you.

Cool

__________________________________
the other co-founder of the DCJC

Member of TEAM CHAOS
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue May 30, 2017 3:46 pm    Post subject: Reply with quote

Put the timing gear casing on and fitted a new water pump and the power steering pump.

Put the head on to the initial torque setting so I could lift the engine in.

Fitted a new rear crank oils seal. One of the fancy ones with a dust seal included.

Put the casing on and fitted a new clutch.

Got the engine in that night just as it was getting dark!

The inlet manifold and intercooler were a tad oily Rolling Eyes So they got a good clean.


Torqued the head down fully.

and set the timing with a new belt.

I'm under orders to take some stuff to the tip, so I'll finish off the write up tonight.
Back to top
View user's profile Send private message
Nightbar
Difflock Royalty


Joined: 30 Sep 2003
Odometer: 20799
Location: In a state of anticipation...


1999 Land Rover Defender

PostPosted: Tue May 30, 2017 5:08 pm    Post subject: Reply with quote

Looking good!
__________________________________
The ex-Difflock Ambassador to Naples, Sir Nightbar DCJC DFS and 2 bars.

Plant a tree for the Difflock 3
Back to top
View user's profile Send private message MSN Messenger Skype NameeBay Name
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue May 30, 2017 7:17 pm    Post subject: Reply with quote

Nightbar wrote:
Looking good!

Cheers Nightbar. Tip run and evening meal done. So, more update.
Fitted the new (refurbed) injectors and the rocker assembly.

And set the tappets. Checked them twice. Smile
Fitted starter motor, alternator airbox and air pipe.


Fitted new spill pipe connectors and used red pipe Embarassed

Put the last seal in, the crank pulley seal in the outer case.

Installed the outer casing and fitted the crank pulley.

The final 90 degree turn was a canny struggle even with a three foot breaker bar.

Fitted all of the other pulleys and a new belt.

Fitted the new (reconned) turbo and the EGR blank and new pipe.

Then the very clean inlet manifold and radiator and connected up all the associated pipework and put the oil in.
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Tue May 30, 2017 7:33 pm    Post subject: Reply with quote

Put the antifreeze in and did the final top up with water through the thermostat housing.

Turned her over with the stop solenoid disconnected and with the return pipe from the turbo in a milk carton to ensure the turbo was getting fed. It said to do this on the turbo installation instructions! Can't see how it wouldn't be getting oil though Question
This is the oil coming out.


I was at the stage of giving her a try and I'd began to get a bad head with the stress I think. Shocked
This is the first start attempt.

Link

Took a while for the fuel to get through even though I'd primed the new fuel filter a bit.
It sounds a hell of a lot quieter and feels a hell of a lot smoother than it did before. Very Happy Very Happy
Took it out for a spin.

Link


It took me about 10 weeks to do. Big learning curve!
Took it out for a big run yesterday and it felt great.
It'll be interesting to see how it holds up over the next few months. Shocked
Back to top
View user's profile Send private message
jojo
Mud Obsessed


Joined: 11 Aug 2007
Odometer: 5422




PostPosted: Wed May 31, 2017 9:41 am    Post subject: Reply with quote

Nice job well done. Enjoy - you deserve it.

J

PS and some super pics.
Back to top
View user's profile Send private message
stable
Articulating


Joined: 19 May 2005
Odometer: 828
Location: Northumberland



PostPosted: Wed May 31, 2017 8:18 pm    Post subject: Reply with quote

jojo wrote:
Nice job well done. Enjoy - you deserve it.

J

PS and some super pics.


New bits or painted bits always look good in pictures Very Happy
Back to top
View user's profile Send private message
jojo
Mud Obsessed


Joined: 11 Aug 2007
Odometer: 5422




PostPosted: Thu Jun 01, 2017 9:22 am    Post subject: Reply with quote

stable wrote:
jojo wrote:
Nice job well done. Enjoy - you deserve it.

J

PS and some super pics.


New bits or painted bits always look good in pictures Very Happy


Yep, look much better than mud, crud and grease and in this project the series of pics shows that a lot of care has been put into making a good job of it.

J
Back to top
View user's profile Send private message
Display posts from previous:   
Post new topic   Reply to topic    Difflock Forum Index -> Land Rover All times are GMT - 12 Hours
Goto page Previous  1, 2, 3
Page 3 of 3

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot post calendar events in this forum
Specialist Tools

Oil Safe

Facebook

Evo Oils

Service Kits

Join our mailing list for upcoming events, special offers, discount coupons and expert advice on the latest 4x4 products!

* indicates required





    
Powered by phpBB © phpBB Group