1976 series 3 rebuild

samc88 · Jan 30, 2013

We decided to remove the sills so they wouldn't get damaged if we were tempted to lean on it

Top of the fuel tank

The data plate (just thought I'd include it really

)

The fuel tank removed, There was about an inch of muck that was compacted behind the tank.

Removed the prop shaft

Notice the water on the floor which came out of one of the rear shocks

New ones shall be bought I think

We also removed the handbrake to clean all the parts, here are a few pics of that (may be of use to someone I suppose)

samc88 · Jan 30, 2013

Grinding the rot back into a square which makes it easier to make an accurate template and apply to the metal The metal we're using to weld to the crossmember are new discovery sills which are roughly the same thickness of steel as the crossmember and as we don't have the disco anymore we might as well as put them into use for something

)

I also decide to fill in the hole where the old towing electrics went to (just to make the back end look a bit neater really) which are now next to the back door of the vehicle.

Welding in the square plate

Cleaning up the welds with the grinder

Metal trimmed to shape for the towing electrics hole and temporarily pushed in to sow the nice fit achieved

After painting black to see how it looked

Now on to the inside edge of the crossmember
There was a small-ish hole either side that required patching and the vertical angle strips needed a part chopping out and replacing

Then a plate was welded in at an angle which will hopefully remove some of the water traps in the crossmember

And finally the rear section of the chassis was painted in red-oxide

And that is all of you finally up to date (at last)

The axle has been red oxided and we'll fit it back to the chassis within the next couple of days

waldershelf · Jan 30, 2013

Enjoying the rebuild, keep the picture coming.

johnny curt 1 · Jan 30, 2013

nice bit of work on the ass end of that chassis fella

brings back some fond 12 month old memories that does

Imortalrelic · Jan 31, 2013

Following with interest. Looks good!

honolulujoe · Jan 31, 2013

dominicbeesley · Jan 31, 2013

Well done fella....makes me feel a bit rubbish. Had a go today but only managed to clean a 1" square of rust off my petrol tank with a grit blaster before I got bored!

D

samc88 · Feb 3, 2013

Thank you all for the nice comments

This weekend we removed the hand throttle from the fron tof the cab

components on the other side of the bulkhead for the hand throttle

The rear axle was also refitted and giving a coat of red-oxide

The new shocks were fitted

The handbrake linkage was removed to allow the gearbox to come out easily

The cable for the speedo drive was disconnected next, it is held on by three screws which need a flat bladed screwdriver to undo

The nuts around the bellhousing were the next things to be undone which was carried out with a 17mm socket
Gearbox mount

Undoing the mount using 14mm spanners/ sockets

Transmission brake drum

Clutch slave cylinder was the next thing to be removed

A pulley block was attached to a beam running along the garage cieling and was used to take the weight of the gearbox as we slid it off the bellhousing to reveal this:

The gearbox, we believe an oil seal may have gone on this due to the abundance of oily sludge in the bellhousing and around the gearbox (some over 10mm thick

)

If you have any questions on what we're doing please feel free to ask

samc88 · Feb 3, 2013

Good God, I seem to be making regular updates for once, I must be ill

Today me and my dad hoisted the engine (the mighty 2.5 n/a diesel) out of the front
We started by removing the front panel and radiator as one piece and then disconnecting various ancillary components such as the fuel filter, throttle cable, clutch pipes, various wires etc. The battery holder was also removed using a grinder (It needs re-welding anyway)

The engine mounts were next to come off (these had thankfully been copper greased before so came off pretty easily, much easier than the gearbox mountings in fact). The whole vehicle was then shoved down the garage until the engine was under the hoist and a pallet truck slid underneath the front of the chassis.

The engine was hoisted up and the rolling chassis rolled back, the engine was then lowered on the pallet truck without any hassle. The landrover was then pulled back up the garage using my Dad's Defender 110 after we moved our trailer out of the way first.

The final job of the day was to remove the front wheels and place the front on axle stands, this gives us much better space to get at and clean the chassis at the front.

Rattlegun · Feb 3, 2013

You're really piling into that now, does it need much sorting out?

samc88 · Feb 3, 2013

Rattlegun said:
You're really piling into that now, does it need much sorting out?

Not much

The chassis was caught just in time before the rot set in so theres only small holes in the chassis left to weld now as well as the compulsory rotten footwell to replace. The engine is going to be rebuilt with new piston rings, bearings, gaskets and seals. The loom will also be replaced as some of it was shocking (if you'll pardon the pun

). I suppose it didn't really need stripping down this far but as we've got the space and tools we might as well do it

monster1971 · Feb 6, 2013

well done ,you have been lucky with the chassis my 76 s3 chassis was way beyond repair and i had to fit a new galv one .keep it coming you are doing great ,check the inside of the fuel tank before refitting i didnt and ended up with all kinds of probs

samc88 · Feb 25, 2013

Right then, the chassis has been welded and given a coat of redoxide. The new footwells have come, a brake servo for the series 3 is on order (after a while of searching for one), front axle has been cleaned and painted in redoxide. A few other bits and pieces have been cleaned aswell. After the chassis the next job is the engine, that shouldn't take as long seeing as we'll be working in the workshop which has proper heating in there

Pics tomorrow as promised

Dr_evil · Feb 25, 2013

No

WANT PICS NOW :Cry:

samc88 · Feb 25, 2013

Dr_evil said:
No

WANT PICS NOW :Cry:

Good things come to those who wait

Besides, I cba going out into the cold and rain to get in the garage

Dr_evil · Feb 25, 2013

samc88 said:
Good things come to those who wait Besides, I cba going out into the cold and rain to get in the garage

Man up

some of us don't have garages

samc88 · Feb 25, 2013

Dr_evil said:
Man up some of us don't have garages

Lucky me

Some of us don't have the use of nice workshops either (I'm envious

). No, tomorrow shall be picture day to show my progress (or lack of

)

Dr_evil · Feb 25, 2013

samc88 said:
Lucky me Some of us don't have the use of nice workshops either (I'm envious ). No, tomorrow shall be picture day to show my progress (or lack of )

Its a lovely workshop

I want one like that if I win the lottery

Land Raver · Feb 26, 2013

Fast progress! Are you going to top coat the red oxide? I wasn't sure if it is water proof long term.

Dr_evil · Feb 26, 2013

Come on then wheres the pics!

1976 series 3 rebuild

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