Aaron's 90 rebuild (round 3)

aaronmorris said:

I've tried looking at the pictures of your new bulkhead on your thread and can't make it out 100% But if their is little holes near the vents on the bit that is raised you could fit the rivet on type as it should have for the age of bulkhead.
Let me know if it has as I may have a spare set you can have.

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Aaron, you're right. I've had a look and didn't think there were holes at first, but they are on the inside! That's good news cos I thought I was going to have to glue something in. I'm putting together another list of things I've realised I need for another online order. I'll price up the vent grilles. If they are daft money I'll buy yours off you you if you do find you have a spare set.

The welding looks great. You sound like me trying to get it spot on! My footwells are pretty wavy, I presume after being hot dipped. Mine have got bars tack welded on the back, I don't think that is standard and presumably to help keep them from buckling with the heat.

Al2O3 said:

Aaron, you're right. I've had a look and didn't think there were holes at first, but they are on the inside! That's good news cos I thought I was going to have to glue something in. I'm putting together another list of things I've realised I need for another online order. I'll price up the vent grilles. If they are daft money I'll buy yours off you you if you do find you have a spare set.

The welding looks great. You sound like me trying to get it spot on! My footwells are pretty wavy, I presume after being hot dipped. Mine have got bars tack welded on the back, I don't think that is standard and presumably to help keep them from buckling with the heat.

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Definitely got some mate, it's just a case of where, on the shed roof I think. Let me know if you're struggling or as you say silly money and I'll bung them in the post for you.

Got the other side done today, same as other side, both footwell and foot. Went slightly better than yesterday, but still taking a bloody long time and still top corners etc to do

Drilled hole through one of the panels and plug welded the two together (I think that's what they're called)



Tried to do it on the outside where possible, just keeps the inside looking tidy, and much easier to tidy the welds up on the outside too as more room.



Started grinding the welds down flush on one side then had enough, will hopefully try and do some more in the week.





Bit of a ballache to be honest, need a better welder too, one with proper adjustment instead of silly switches which aren't all that controlable.

Aaron, I've priced up the vent screens (Fly Screens - part number 395185)
They're not just silly money they are bonkers!!
Paddocks £85
LRDirect £90
and I think that is per side!
There's some on ebay in Cyprus for £65 +£21 postage and they are per side.
If I was you I would get them off the shed roof, clean them up and get them on ebay.
Very much appreciate the offer, mate. But, you are sitting on some cash there so get some good money for them.
I'm going to buy some mesh and fabricate some.

Al2O3 said:

Aaron, I've priced up the vent screens (Fly Screens - part number 395185)
They're not just silly money they are bonkers!!
Paddocks £85
LRDirect £90
and I think that is per side!
There's some on ebay in Cyprus for £65 +£21 postage and they are per side.
If I was you I would get them off the shed roof, clean them up and get them on ebay.
Very much appreciate the offer, mate. But, you are sitting on some cash there so get some good money for them.
I'm going to buy some mesh and fabricate some.

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Crikey. I didn't realize they was that silly. But it's very honest of you mate, had you said nothing I'd have happily just stuck them in the post for you.

So last weekend I had another day repairing the bulkhead, both the top corners and inside.
If I'm completely honest I'm not 100% happy with the fit of the panels. I have used yrm before and they fitted a darn sight better than this time around.
Still needs all finishing off, pin holes filing, grinding flush etc, forgot to take any pictures last week so grabbed a couple while I was in the garage last night.
All a little awkward trying to work around or remove previous owners bodges, but hopefully look ok when finished.





And then earlier this week a very nice man delivered me some new (to me) axles
These are the axles I will be using after a little work.
I thought the neighbours hadn't complained for a while, and as I was moving them up the drive with the engine crane she decided to come out saying 'Are you going to shut up, you keep disturbing my son... My house is shaking and I'm going to phone the police if you don't shut up'
Yeah, ok Makes me laugh how she can come out and complain, yet when we take her post for her when she's not in she can't even come round and collect it and sends her dad for it days later.



Anyway, I finished early yesterday as my boss was going to the races, so decided to have a break from the bulkhead and strip some axles instead.
I bought these some time ago, but they're pretty nasty, their was no pictures when advertised so took a gamble, but hey they was plenty cheap enough and I'll just keep a few spares.



Started stripping, hmm, wonder how long that's not had any oil in for.



One lovely top swivel bearing.



The other side wasn't much better



Started removing the swivel balls, 2 of the bolts rounded so just chopped them off with the grinder and usual trick of stillsons to get them out.



The other side was all going well until.... Not what I was expecting



And that was the front axle stripped. Axle casing wants a little welding after bashing it with a hammer and chisel to check a dodgy looking bit. Diff seems good though with minimal backlash, maybe the only thing.



Did the rear too, but obviously much less to go wrong/be ****ed their. Running out of room in the garage and got the other 2 to strip yet but will use the best of both plus new on re-assembly.

aaronmorris said:

Crikey. I didn't realize they was that silly. But it's very honest of you mate, had you said nothing I'd have happily just stuck them in the post for you.

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I priced up some stainless mesh with a similar sized hole. It was very cheap. I was just about to buy it when I got a message on LZ from greyhair to say he had found some on ebay for £35. I bought them to save the time constructing my own. I reckon greyhair did me a good favour there because I reckon that was a very good price. Given the new price for them, if yours are in reasonable condition, you should get a lot more than £35. Well worth looking after them I reckon!

Your bulkhead is looking great. It will be well worth the time you are spending on it. Remember a refurbished and galvanised bulkhead would be £850 + and you'll be doing a better job.

Tipping down with rain here today forecast all day too.

Strewth I hope the ones I bought up are better than those

Al2O3 said:

I priced up some stainless mesh with a similar sized hole. It was very cheap. I was just about to buy it when I got a message on LZ from greyhair to say he had found some on ebay for £35. I bought them to save the time constructing my own. I reckon greyhair did me a good favour there because I reckon that was a very good price. Given the new price for them, if yours are in reasonable condition, you should get a lot more than £35. Well worth looking after them I reckon!

Your bulkhead is looking great. It will be well worth the time you are spending on it. Remember a refurbished and galvanised bulkhead would be £850 + and you'll be doing a better job.

Tipping down with rain here today forecast all day too.

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Ah, glad you sorted some mate, I'll stick mine on one day when I'm skint, it's what I usually do.
And cheers it looks ok, but I'm not 100% happy with it. But yes the cost saving compared to buying one is a fair chunk.
I have another bulkhead in the back yard, I just wish I repaired that one instead as it's probably not as bad.
Is similar here too, been on and off all morning, brightened up now mind, so have me dinner and back out it is.

Marmaduke said:

Strewth I hope the ones I bought up are better than those

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Much better Hoping to have those stripped by the end of today, but doubt they'll need much.

Well I've had another few hours stripping axles again today, while I was wide eyed at 6am I didn't start until dinner, was raining and miserable so stayed inside
These are much better than the others.
First job, remove 5 bolts and pull half shafts out.



Undo brake pipe, or in my case cut it off and remove union using a 6 point socket as I will be making new ones. And remove 2 caliper bolts.



Flatten tab washer and remove nut.



Remove tab washer using suitable prising tool.



And pull hub off.



Bearings actually looked pretty good.



On one side at least. The other was stuck on the stub axle, but should come off with a little persuasion and can the asses condition fully.



Undo 6 bolts and remove stub axle, using soft hammer to break seal.



Remove brake shields and throw them in the bin.



Remove 10 nuts holding and pull from housing. This one took quite a bit of persuading to come un-stuck.



And again the diffs seems pretty good, but will have to change the flange to 4 bolt to suit defender.



And then moved onto the front axle.
Prize rubber cap off. Remove cir-clip and associated shims.



Again 5 bolts and pull the flange off. These seem very good with little-non movement on the splines.



As per rear axle remove caliper, locking washer and 2 nuts.



Remove hub.



And stub axle,



Pull cv's / half shafts out.
Looking much better than the other ones, and genuine hardy spicer too.



Remove swivel seal retainer and 2 bolts holding top pin and keep the shims safe.



Give the hub a sharp tug to dislodge the swivel seal and the whole housing will come off.



It's at this point I usually cut the old seal and retainer off with the grinder, it just saves it flapping about in your way while fighting to remove the crappy 12 point bolts holding the swivel on.
Which I sheered another one of doh! So I best get some decent drill bits ordered.


Again, 10 nuts, a sharp clout and the diff comes free.



So I've now got 5 axles in bits Guess I can pick and choose which parts to use or not and have plenty of spares.
Sorry if some of it is a little higgledy-piggledy but I seem to be missing a few pictures and forgot to take some.

Need to have a tidy too.

you trying to corner the market in axles ,Aaron,,lol nice to see you re out annoying the neighbour ,,,i would have started at 6 just to pee them off lol ,,,,watching thread with interest .

You'll certainly have plenty of bits to choose from. Looks like you had fun taking them apart. Just goes to show what a little water ingress can do over a period of time.

GATSO said:

you trying to corner the market in axles ,Aaron,,lol nice to see you re out annoying the neighbour ,,,i would have started at 6 just to pee them off lol ,,,,watching thread with interest .

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Haha, not quite Gatso, just bought ****'e first time around unseen.
And sod the neighbour, she only has to put up with it on a weekend now, unless I get in the groove anytime soon and start having a few hours on a night. Which maybe I should as I'm getting nowhere fast.
And cheers, should be a little more interesting once things get moving and going back together, things are slow going at the mo.

Brown said:

You'll certainly have plenty of bits to choose from. Looks like you had fun taking them apart. Just goes to show what a little water ingress can do over a period of time.

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Yep, wasn't too bad, just a little ****ed about snapping bolts.
Water ingress has a lot to answer for, but I'd say some of it was partly down to lack of or no maintenance over long periods. Luckily they was cheap enough not to worry about.

Yes, that sort of damage doesn't happen overnight. I just had a look at my bearings I fitted nearly a year ago and everything looks almost identical to how I put them together - the grease is still yellow and hasn't gone black yet. That's after about 12,000 miles. So getting that much rust and dirt in your hubs takes some dedication.

At up cocker, nah then I've got some nice galvanised bits here for ya. Iam thinking of doing Newark auto jumble next Sunday, will you be around at your home and I'll pop up after Newark and drop her bits off mate.

Well no such progress this weekend.
Finished smoothing the welds on the bulkhead, but no doubt I'll look at it again and decide theirs something I'm not happy with.
But glad it is done and out of the way now.
Other than that it's just been a big sort out, could hardly move in the garage, so sorted a set of front axle parts I'll use and a set for the rear, all the rest went to the shed, so now that looks like a **** hole
So basically I've done **** all all weekend, I don't know where the time goes. Although I've been showing/helping my brother prep his wheels for paint (which apparently I'm painting) no idea where yet mind as their no room in the garage or the shed Might have to wait a few weeks until some stuff is cleared.

Think I will order some paint this week, means I can start painting a few bits, hubs, calipers, swivel housings, diff casings etc, just the stuff that I'm not sending for galv really.
I had planned to go Peterborough lro show, but decided not to go in the end as the kind of stuff I'd be buying would be of no use at the mo and more for later in the build, money which is better spent elsewhere currently, like ordering a chassis, paying for shot blasting or galv, all of which I'd like well on their way in the next few months.
Did anyone go.. did I miss anything?

Forgot to update last Sunday, but got the inner wing brackets and bonnet pull bracket welded back on.

Another weekend gone, another weekend seemingly wasted. Nothing seems to be happening, cleaned up all the axle parts up that wont be going for galv, calipers, hubs, diffs etc..
So they're all ready for paint, which I've ordered and will hopefully be here next week Then I can get cracking with that and it might feel like I'm getting somewhere.
Some pics in varying stages of prep.





Someone even put one of the hub seals in back to front.



The front calipers seem pretty good, but the rears have one tight piston on each side, But I will be rebuilding with stainless pistons anyway so not a major issue, just need to split and make sure are good internally.





On a better note, the first batch of blasting came back

All looking nice and clean. Are these the bits that you're intending to galvanise?

You must need to buy wire brushes for your grinder and drill in bulk. There's a lot of work there.

Brown said:

All looking nice and clean. Are these the bits that you're intending to galvanise?

You must need to buy wire brushes for your grinder and drill in bulk. There's a lot of work there.

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Cheers Stuff in the last picture is all what I sent out for shot blasting and is 'hopefully' all going for galv at some point along with the bulkhead.
It's just the hubs, diffs etc I've cleaned with the grinder, think I'd be their all month if I was doing the other lot

That lot looks great and will look even better when it's shiny!
Have you considered plastic inner wheel arches? I didn't know you could get them until I was examining my mates 61 plate a few weeks ago. Much lighter, obviously, but probably quieter too. As well as not rusting! If I'd known before I forked out for my replacements I think I would have went for them.