S3 109 Safari project......

kevstar · Sep 19, 2022

GSF 109 said:
While I wait for the riv-nuts to be delivered, I moved to the other side of the bulkhead. The original wiper motor was missing, but I picked up a replacement when I bought the bulkhead. I stripped the wiper boxes and took the spindles out, cleaned off all the old grease which had gone hard and packed with new. This allowed them to turn much more freely. I fitted the whole assembly, using the old bulkhead as a guide, as I had forgotten where everything went! . Following on, I fitted the washer jets, tubing and clips. Buoyed up by this initial success, I fitted all the nutserts into the holes in the bulkhead ready for the dash assembly to go back in. That’s a job for next week
View attachment 274339 View attachment 274340 View attachment 274341

Its coming together nicely.

mick the builder · Sep 21, 2022

Looking great, and the best part of the rebuild.

LincolnSteve · Sep 22, 2022

That is really looking great. It will be back together in no time. Also you have just saved me a few quid. I was going to get some contact adhesive for my vent flap seals but I see you've used puraflex 40. That's great news because i've already got some of that. Does it do a good job?

GSF 109 · Sep 22, 2022

LincolnSteve said:
That is really looking great. It will be back together in no time. Also you have just saved me a few quid. I was going to get some contact adhesive for my vent flap seals but I see you've used puraflex 40. That's great news because i've already got some of that. Does it do a good job?

Thanks

Yes, I’ve had good results with it,as it’s an adhesive and a sealer, and as you say it’s much cheaper than contact adhesive. I used it on my bulkhead as a seam sealer too as it’s overpaintable.

GSF 109 · Sep 24, 2022

Back onto the bulkhead again today and I thought the best place to start was the steering column.I stripped the column back off the bulkhead so I could get to the offending hole.

I bought some riv nuts from Kay’s fasteners and the quality looks pretty good. Rather than buy a rivnut gun I just used some washers and an m8 bolt and nut. Seemed to work okay. Better that splashing out on a gun!

GSF 109 · Sep 24, 2022

After fitting the column back on, I decided to strip the lower dash off the bulkhead. It came off with a fight but I’m fairly disappointed with the condition. I think I will need to find a replacement, so if anyone has one, let me know!

GSF 109 · Sep 24, 2022

After that disappointment, I took the top dash off and had a look at that. As you can see the metal support was rotten in a couple of places, but luckily I had a spare, so I decided the best thing to do was to use that one with my original dash top.

GSF 109 · Sep 24, 2022

Stripped down the metal support and cleaned it using a wire brush on my grinder. After removing the rust, I treated it with Kurust, primed with zinc rich primer, then 3 coats of gloss black. Looks a bit more presentable now.

GSF 109 · Sep 24, 2022

While I had the wire brush and paint out, I stripped the brake pedal box down, cleaned it back and painted the same as the dash support. I’ll reassemble next time. I did the same with the dash vent plates and heater box. Getting there now.

GSF 109 · Sep 24, 2022

I ordered some wiper spindle seals last week, so they finished off the wiper boxes job nicely. I also transferred more nutserts and wiring loom clips from the old bulkhead to the new. Every little bit helps!

GSF 109 · Sep 25, 2022

I purchased a set of pre-cut neoprene seals off eBay and I’m really impressed with them. Very accurate and neat.

I thought I would put the brake pedal box together after cleaning up and checking the servo. Looks so much better with a coat of paint and a new brake cylinder.

GSF 109 · Sep 25, 2022

After doing the pedal box I gave the heater box two coats of primer and two of topcoat. I can’t seem to be able to purchase the original type bulkhead seal, so I bough 5mm neoprene sheet, so we will see how that works out.

After the dash support panel dried, I stripped the original dash top to swap everything over, but it became quite obvious that the support panel is slightly different between the early and later dash tops. There is a different direction on the fold, so they are not interchangeable, unfortunately

. So one option is to repair the original support panel and use the original dash, or use the later dash and refurbished support panel.

Knappster · Sep 25, 2022

Looking good!

GSF 109 · Sep 25, 2022

Knappster said:
Looking good!

Cheers, feeling like I’m starting to get somewhere now

codfather79 · Sep 26, 2022

Looks really good.
You feel you are actually getting somewhere once things are being bolted back on!

GSF 109 · Sep 26, 2022

codfather79 said:
Looks really good.
You feel you are actually getting somewhere once things are being bolted back on!

Thanks, yes it also helps clear up the workshop a bit

GSF 109 · Oct 2, 2022

Thought I would move on with the heater box and get it painted and fitted. After two coats of satin black it definitely looks much better. I ordered some self adhesive 5mm neoprene sheet to make the bulkhead seal from. Thankfully it fitted perfectly but it’s a bugger to cut with a knife

. After drilling the bracket holes, painting the holes I fitted the assembly. Should have enough neoprene to make the seal for the lower dash.

GSF 109 · Oct 2, 2022

Talking about lower dashes, I managed to pick up a far better one from a friend of mine. It’s not perfect but beggars can’t be choosers! At least the metalwork is really sound, there are some additional holes that have been put into the front, but I guess that’s to be expected . Gave it a brush and wipe down to assess its condition. Going to give it a thorough clean, derust and paint next time.

GSF 109 · Oct 2, 2022

While the dash sits and waits for attention, I stripped the clutch pedal assembly down, derusted it with a wire brush in a grinder. Once all the rust was gone I gave it a good coating of Kurust, then two coats of gloss black. Can’t wait to get the pedal box put back together and that’s another job done!

steve24v · Oct 2, 2022

Some nice work going into this. As for seals, I've used old inner tubes before (too tight to buy anything

), wheelbarrow ones are a good size for most things

S3 109 Safari project......

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