Series 1 Trialler rebuild

Ok so i've had a series 1 80 inch trialler for some time its been a trialler for most likley decades but I'm trying to get it back better and stronger for next years trials comps. This tread is mainly to kick my own ass into getting on with it!

Its currently fitted with a 3.9 V8 on carbs but as yet I've not seen it run Nor do we know what Cam has been fitted as apparently its been messed with so it may run like a bag of nails. pics and rebuild pics to follow:

How it was when it was last log booked,





How it was when I recieved it:

Rear axle is to be swapped for a salisbury unit. Cheap strength. I plan on having a go at team recovery and so on so I want the drivetrain to be as strong as possible without costing a fortune.

Salisbury axle on stands:


Notice the axle mounts have already been moved inboard for SWB mounts. they have been done well but I will be cleaning then up.

Rear axle has been wirebrushed down and painted:

Filler and Drain bungs will be swapped for newer 1/2 inch female square instead of the male ones currently fitted.

Removed the half shafts back plates and hubs to be cleaned up:


Cleaned backplate vs dirty old backplate:


















Getting the brake drums off was a PITA,

brake adjusters did nothing so it took some effort to get the brake drums off.

Todays progress:
Wire brush and paint second backplate and hub Ready to install.

nice , how much did you pay for it? what gearbox is fitted ?
good luck with your project

What axle are are u running in the front in the middle off building one my self

Would love to see piccys of others motors!!

Front Axle: I want to run an early 90/110 axle due to the bigger stronger 23 spline CV's but with RR swivels stronger swivel pins. I do have a 4 pin P38 diff center I have fitted to the older std rover casing with some machining. I picked up a front and rear ashcroft 4.75:1 CWP's quite cheaply as new. The front CWP is installed on the P38 carrier. The problem I have is the diff internals are 15.5mm in an 18mm carrier so I'm on the look out for a gearset and cross pin for a P38 that are 18mm variant.


What I want to run: Ideally I want to run ashcroft front shafts and CV's but they are pricey. I have found some cheaper CV's in the states awaitin an email to confirm they are still available so they may well go on. I picked up some Kam Front shafts but they are the weaker 32 spline variants and not alot stronger than LR but better so they will do for now but will not fit early 90/110 CV's but will fit Disco stuff.

I may well throw on a series axle to get it going but team recovery and it goes pop I'll be most upset!

So the answer is I'm not sure yet.

If a cheap disco/RRC 10 spline Domed stub stafts should turn up then I could do it in stages. I.e fit the Disco casing much modifying of mounts. Run the P38 centre and Kam front shafts. see how weak the front domed stubs are and if need be drill and tap them to weaken them to make a fused point and run them until I can afford the decent CV's.

If I drill and tap the stub shafts I can put a long bolt in and slide hammer out the broken bit if at a comp and be running in a few mins. All this work is to stop me having to pull a diff or front shaft just to save as much time as poss. I'm quite a careful driver and been lucky so far on my heavy 90 running 37 inch tyres no CV's or shafts have broken in anger one front shaft which was unlucky I think its life duty was exceeded and (one other but it was a britpart £30 special salisbury shaft running through a detroit and was a silly clutch snatching climb out a river bed). but on the whole I'm quite sympathetic so I think I am the weakest link in my build/comp sp far!

piston-return-spring said:

nice , how much did you pay for it? what gearbox is fitted ?
good luck with your project

Click to expand...

I paid £600 but it had some other goodies on it I took off and sold so not too bad it has the standard 4 speed gearbox and 3.9 V8 on Carbs will see how badly it runs!