Series 3 109 Six Pot Rebuild Thread

[BikerB]

Just realised I started my rebuild thread in the wrong section.
New chassis due on Monday after a long wait to start building up from the bottom up my 6 pot 109.
As soon as the weather starts getting better it will start work, the plan is to rebuild everything mechanically but leave it looking much like it currently does externally apart from straightening everything, not even sure If I''ll paint it.
The starting point

 

[Knappster]

Great project! Keep the pics coming!

 

[BikerB]

Chassis arrived late last night so my excuses are starting to run out....
Surprised to find Polybushes in the chassis, I had though they would be metalastic. Had to email them though as they have made a mistake, the steering damper is supposed to be welded on and it isn't. Order paperwork is correct so mistake made somewhere at Richards

 

[BikerB]

Will be shortly looking for some of the parts to start this project, as soon as the weather warms up. I have a hankering for a winch but not interested in an electric one, I fancy a period Capstan winch. There look as if they are available but in Germany and very pricey. Is there somewhere I would be able to pick up up cheap, even if it need a rebuilt and refurbished?
Although I want it to work it really is just a period fashion statement, don't expect it to be used in anger, or it it is then I am in trouble

 

[BikerB]

Got out today and removed the bumper, steering cover, steering damper, both front shocks and started on the rear shocks.
Chassis is quite rotten, the dumb irons are toast and at one point jacking up the front the jack went up and heard lots of crunching noises, withdrew and jacked further along the chassis.
This does make me feel a lot better about replacing the chassis

 

[Marmaduke]

Got out today and removed the bumper, steering cover, steering damper, both front shocks and started on the rear shocks.
Chassis is quite rotten, the dumb irons are toast and at one point jacking up the front the jack went up and heard lots of crunching noises, withdrew and jacked further along the chassis.
This does make me feel a lot better about replacing the chassis

Ot hasn't fell in half yet so it can't be that bad

 

[BikerB]

Ordered two half rear tubs and some other parts today to allow me to repair and fix the original bashed tub, haven't been able to source a decent tub anywhere locally and transport costs are making it easier to rebuild the original tub than try and get a good new one.
Still working out whether to cut down the rear bulkhead to the level of the wheel boxes and looking for a wheel well part to mount the spare wheel above the wheel in the rear.
Can't do much other than strip down some parts until the weather gets better, maybe do a few bits and bobs like send of the rad to get rebuild etc, just starting to gather the bits needed till there is more daylight and higher temperatures!

 

[BikerB]

Well my Craddocks order fell through, got surcharges of over 80 quid for delivery on the side panels on the online order, had a call today to say it was going to £300 for delivery so cancelled the order.
With my probably going to have to go south to acquire a safari roof at some point its going to be cheaper to pick these up personally with other stuff once the lockdown comes to an end and closer to when I will need them. May as well save up and pick up all the large and fragile items like fuel tanks and glass at the same time in the summer

 

[BikerB]

Well the fun is slowly starting, parts of the original chassis are toast but this was expected, starting stripping the tunnel and floors to allow the gearbox to come out along with the two props and then the engine.
Bulkhead footwell on the nearside pretty stuffed but the pillar looks OK, driver side not bad. Comparing the chassis there is an outrigger just behind the bulkhead outrigger on the OS of the chassis that isn't on the original, what on earth is it for? One door frame fell off when I opened the door

Not much holding on the dumb irons at the front

 

[wireman]

Well the fun is slowly starting, parts of the original chassis are toast but this was expected, starting stripping the tunnel and floors to allow the gearbox to come out along with the two props and then the engine.
Bulkhead footwell on the nearside pretty stuffed but the pillar looks OK, driver side not bad. Comparing the chassis there is an outrigger just behind the bulkhead outrigger on the OS of the chassis that isn't on the original, what on earth is it for? One door frame fell off when I opened the doorView attachment 231608 View attachment 231609 View attachment 231610 View attachment 231611
Not much holding on the dumb irons at the front

Possibly and auxiliary under seat fuel tank.

 

[Kaitlan]

Nice project! Good luck!

 

[BikerB]

Well seatbox now out after playing hunt the bolts to get them all disconnected. They were obviously all seized and different sizes, got about 3/4 of them out whole, about 1/8 snapped when removing and the rest had to be ground out. The worst ones were the ones down at the seat belt mounts, they were a complete pig to get out.
So, the seatbox is now out and the next step when I get time is to remove both props, the handbrake and then the gearbox.

 

[Britcyclerider]

Good to see a six cylinder S3 being saved. Looks like you have got your hands full though, but I'm sure it will be well worth it.
Did Richard's respond positively to their apparent mistakes?
Good luck!

 

[BikerB]

They just said twice that the welded on option was not available and then stopped replying. Having checked my paperwork the order, the confirmation of the order, the invoice and even the delivery note all say welded on steering mount.
Its not critical but just a bit annoying bearing in mind all the warnings about checking the order and ensuring any errors are notified to them before the actual build!

 

[BikerB]

Got both doors off and starting to work on the sills and front wings, playing hunt and remove all the bolts. Starting to look sorry for itself now.
Progress slow as the weather still isn't good enough and there is still limited daylight.
Hopefully in the next month or two I'll get the garage tent up at the side of the hose and get the new chassis inside and painted.

 

[BikerB]

Now that I am getting on, props disconnected, sills off and nearly got both wings off, just a few odd seized bolts that are difficult to get to, I can now see the size of the engine more clearly. That is going to be a bit of a beast to get out and on the work bench

 

[BikerB]

Got both wings off today and cut off the radiator panel. The beast is looking somewhat worse for wear now.
Now I have good access I will start taking off subassemblies, then lift out the turny bits.
Only spending a few hours every weekend at the moment, its not quite warm enough and light enough in the evenings to do much midweek, but its getting there.

 

[wireman]

6 pot on eBay
https://www.ebay.co.uk/itm/series-3...5QwAAOSwDOBgZxAv&LH_Auction=1&redirect=mobile

 

[auld duffer]

Where abouts are you based ? I know some of the companies think Perth is the highlands . Im just down the road across the Angus divide . If you want to get large parts delivered to my address you could have an easy drive around to collect , better that a trip all the way south .. Im based near to Glamis Castle .. Im not sure if the fella I get a few bits from would be able to help with a safari roof , I could ask, again its closer to you than travelling south, he is based near St Cyrus ( Montrose ish )

Chassis looks the business. great start ,, Its a frustrating process stripping the old stuff from the chassis requiring the full range of tools in the tool box lol .. I was lucky that the old military underseal saved most of the threads and all but a handfull of bolts sheared . digging the heads out of the underseal was another matter lol..

If you find an old X trail in a scrappy near you, grab all the main door seals from the body, (leave the secondary ones that are attached to the doors ) they fit the landy really well ..

 

[BikerB]

I'll probably take a trip down south to pick up some of the larger items when the lockdown finishes with the trailer, maybe with the wife and make a weekend of it. Got the brake servo and heater off last weekend but not in any hurry as yet. Got some work to do at the side of the house and then I can put up the garage tent I have and put it in there to start in earnest.
I am in Inverness, tried the local independent Landrover place in Inverness and they were too busy to speak to me about parts supplies, twice. There is a place in Tain, will try them next but I'll keep your offer in mind.
If I can get the weather and time this weekend I am hoping to lift out the gearbox and engine as they are essentially disconnected. The good thing is because I am scrapping the chassis I can just plasma cut off the various brackets rather than worry about getting into some of the bolts. I think the handbrake bracket will get this treatment tomorrow rather than try to get into the seized bolt
I also want to get the weight off the front chassis, there is really not a lot holding the front spring hanger onto the chassis, keep thinking I'll go out one morning and it will have simply snapped off!