bellowhead
111 Terra Series Viatorem
- Posts
- 302
- Location
- Nr pontefract West Yorkshire
well done fella
My 109" Series 3 :)
- Thread starter robbh
- Start date
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robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
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- Edge of the New Forest. Wiltshire
Thanks
Also have a small update for you all
In one piece at last
and the pile of rubbish that was swept up from underneath Still need to do a few jobs to make it drivable but are small ones in the grand scheme of things
Brakes and clutch still need to be bled, floors and tunnel still need to be fitted and also the exhaust.
Exhaust has been taken into my work tonight so i could use the oxy/acetylene set to heat them up and bend them to fit round the gearbox crossmember.
Hopefully should get that list of jobs done tomorrow and then i can finally take it for a spin
:crazy_driver:
robbh
Crazier than a box of frogs on acid
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Ah
thank you for pointing that out Didn't realise it would make a difference And thanks for the link.
Should keep me busy for a while
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
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- Edge of the New Forest. Wiltshire
Small update
Still not drivable yet as i can't get the engine to rev also still haven't got the exhaust to fit either
Anyway today's job was fitting a discovery fuel pump into my tank as I don't think the inline fuel pump is delivering enough fuel to the engine.
Here's the disco setup before i pulled it apart for the pump itself.
The setup i currently have in the tank. Basically just a long tube with a gauze on the end.
And this is what i now have to go inside the tank.
After that connected the 2 wire that came off the pump, drilled a hole and fed a wire through and sealed it up
Will fit it tomorrow once the sealant is dry and hope the engine gets enough fuel when it's fitted
Still not drivable yet as i can't get the engine to rev
also still haven't got the exhaust to fit either Anyway today's job was fitting a discovery fuel pump into my tank as I don't think the inline fuel pump is delivering enough fuel to the engine.
Here's the disco setup before i pulled it apart for the pump itself.
The setup i currently have in the tank. Basically just a long tube with a gauze on the end.
And this is what i now have to go inside the tank.
After that connected the 2 wire that came off the pump, drilled a hole and fed a wire through and sealed it up
Will fit it tomorrow once the sealant is dry and hope the engine gets enough fuel when it's fitted
robbh
Crazier than a box of frogs on acid
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It would but I do have a return feed , you should just be able to make out another pipe going into the tank on picture 2.
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
- Location
- Edge of the New Forest. Wiltshire
Update time
Been a little while since I've done anything as i needed a break from it as the engine is stressing me out big time
Still having issues with getting the V8 running properly (posted about this in the V8 section).
Can get it to tick over but not rev. Anyway i won't bore you with the details and just say that I've removed the flapper system and am now in the process of fitting the hotwire system off of a 3.9.
So here's how the engine sits at the moment.
And this is what will be fitted upon gaskets arriving
Whilst waiting for the engine gaskets, i have pulled my finger out and got the disco front axle finished. All welding done and now painted.
Just need to order all new seals, gaskets, bearings etc then i can stick em back together and sling em under the 109
Couple of pictures.
Axle fully painted and drying.
Stub axles also had a lick of paint where needed
Been a little while since I've done anything as i needed a break from it as the engine is stressing me out big time
Still having issues with getting the V8 running properly (posted about this in the V8 section).
Can get it to tick over but not rev. Anyway i won't bore you with the details and just say that I've removed the flapper system and am now in the process of fitting the hotwire system off of a 3.9.
So here's how the engine sits at the moment.
And this is what will be fitted upon gaskets arriving
Whilst waiting for the engine gaskets, i have pulled my finger out and got the disco front axle finished. All welding done and now painted.
Just need to order all new seals, gaskets, bearings etc then i can stick em back together and sling em under the 109
Couple of pictures.
Axle fully painted and drying.
Stub axles also had a lick of paint where needed
Last edited:
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
- Location
- Edge of the New Forest. Wiltshire
Differential in bits
It got covered in grinding dust when it was sat next to the bench so thought I'd strip it down and give it a good clean shame i can't afford a locker to go in
It got covered in grinding dust when it was sat next to the bench so thought I'd strip it down and give it a good clean
shame i can't afford a locker to go in
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
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- Edge of the New Forest. Wiltshire
Update for the disco axles
Got the diff back together and set all tolerances etc. Tis easy enough if you got the rave manual
Yesterday I also had a box of goodies turn up from island 4x4. Basically all new seals, gaskets and bearings.
Luckily i had already rebuilt a disco axle earlier in the year that never was used so stole all the nice new parts from that (bar gaskets which i ordered some new ones). The discs are new and unused but have gained a bit of surface rust in storage Also fitted was a 4 bolt flange conversion kit. Just need to lob the halfshafts in and it's complete
So here's the rear axle in one piece at last ready to fit to the series
My attention then turnt to the front axle. This is how far I've got
Only one swivel ball with new bearing races fitted
Tomorrow's plan strip another front axle i have and hope i have a decent swivel ball as the other one i have for this axle is pitted and generally fubar. Which is bad especially considering with these axles the hubs and cvs will be run in ep90 NOT one shot ****e!!!
Then hopefully i can fit the rest of the bits and get it in one piece ready to fit..... Oh and strip, clean, check another diff
Got the diff back together and set all tolerances etc. Tis easy enough if you got the rave manual
Yesterday I also had a box of goodies turn up from island 4x4. Basically all new seals, gaskets and bearings.
Luckily i had already rebuilt a disco axle earlier in the year that never was used so stole all the nice new parts from that (bar gaskets which i ordered some new ones
). The discs are new and unused but have gained a bit of surface rust in storage Also fitted was a 4 bolt flange conversion kit. Just need to lob the halfshafts in and it's complete So here's the rear axle in one piece at last ready to fit to the series
My attention then turnt to the front axle. This is how far I've got
Only one swivel ball with new bearing races fitted
Tomorrow's plan strip another front axle i have and hope i have a decent swivel ball as the other one i have for this axle is pitted and generally fubar. Which is bad especially considering with these axles the hubs and cvs will be run in ep90 NOT one shot ****e!!!
Then hopefully i can fit the rest of the bits and get it in one piece ready to fit..... Oh and strip, clean, check another diff
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
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- Edge of the New Forest. Wiltshire
Just noticed what I've done wrong in the second picture of my last post I hasn't put the swivel seals on :doh:
Ah well at least it wasn't fully rebuilt before i noticed
robbh
Crazier than a box of frogs on acid
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- Edge of the New Forest. Wiltshire
Hi all.
Another update. Although didn't quite get as much done as hoped. Spent most of the day stripping down the axle and then meticulously cleaning parts.
So here's the axle i wanted to strip. As i wanted the non pitted swivel off of it.
Stripped down and the mess i made doing it
All the parts in order that they came off ready to be cleaned.
Only other thing i managed to get done after all that (as i wanted to watch the rugby) was fit the other swivel ball this time remembering the swivel seal and retaining plate
[
Tomorrow will finish off cleaning a few bits, then can get on and finish modifying the swivel knuckles.
Will take pics of the knuckles tomorrow and explain a bit more about it
Then can get the rest of it together
Another update. Although didn't quite get as much done as hoped. Spent most of the day stripping down the axle and then meticulously cleaning parts.
So here's the axle i wanted to strip. As i wanted the non pitted swivel off of it.
Stripped down and the mess i made doing it
All the parts in order that they came off ready to be cleaned.
Only other thing i managed to get done after all that (as i wanted to watch the rugby) was fit the other swivel ball this time remembering the swivel seal and retaining plate
[
Tomorrow will finish off cleaning a few bits, then can get on and finish modifying the swivel knuckles.
Will take pics of the knuckles tomorrow and explain a bit more about it
Then can get the rest of it together
robbh
Crazier than a box of frogs on acid
- Posts
- 1,755
- Location
- Edge of the New Forest. Wiltshire
Right then.
Series axle has been stripped of it's steering arms.
So here's the plan to get over the problem of steering when fitting a disco axle to a series.
Get your swivel knuckles and cut off the original steering arms.
Get hold of a pair of series steering arms and basically bolt then to the disco swivel knuckles. (stole mine off my series)
If only it were that simple.
To start on the disco swivel knuckles there are only 2 bolt holes. Easy enough just drill 2 more holes i here you say. But no, again not that simple.
You need to keep the lower swivel pin that's originally fitted then plonk the series arm on top. (sfter cutting off the original pin for the series swivel!)
This in itself causes a problem as there is nothing below the other 2 holes on the steering arm.
So a solution. And a few pics to give you an idea.
The disco swivel knuckle with series arm and original lower pin in place.
The series arm and lower swivel pin.
The swivel knuckle bolt holes. Before modifications.
Now the plan from this point is to machine off about 7mm from the outside face of the lower swivel pin.
Thus dropping down the series arm and making the original bolts fit properly.
Will then make up a packing plate for the other side, bolt it all together then drill 2 more holes. Then unbolt it and tap the swivel knuckle to take the appropriate bolt. High tensile m10 bolts to be exact.
Hopefully once the machining and drilling/tapping is done should be a matter of bolting the rest of the axle back together again.
Machining will be done tomorrow so will take some pictures
Series axle has been stripped of it's steering arms.
So here's the plan to get over the problem of steering when fitting a disco axle to a series.
Get your swivel knuckles and cut off the original steering arms.
Get hold of a pair of series steering arms and basically bolt then to the disco swivel knuckles. (stole mine off my series)
If only it were that simple.
To start on the disco swivel knuckles there are only 2 bolt holes. Easy enough just drill 2 more holes i here you say. But no, again not that simple.
You need to keep the lower swivel pin that's originally fitted then plonk the series arm on top. (sfter cutting off the original pin for the series swivel!)
This in itself causes a problem as there is nothing below the other 2 holes on the steering arm.
So a solution. And a few pics to give you an idea.
The disco swivel knuckle with series arm and original lower pin in place.
The series arm and lower swivel pin.
The swivel knuckle bolt holes. Before modifications.
Now the plan from this point is to machine off about 7mm from the outside face of the lower swivel pin.
Thus dropping down the series arm and making the original bolts fit properly.
Will then make up a packing plate for the other side, bolt it all together then drill 2 more holes. Then unbolt it and tap the swivel knuckle to take the appropriate bolt. High tensile m10 bolts to be exact.
Hopefully once the machining and drilling/tapping is done should be a matter of bolting the rest of the axle back together again.
Machining will be done tomorrow so will take some pictures
robbh
Crazier than a box of frogs on acid
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Occasional road use if i get bored of driving the eurobox and fancy the V8 roar on the way to work but mainly an off road toy.
Why do you ask?
CarlosVanDango
Active Member
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- 197
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- Rotherham
very interesting
