Series 3 109 Six Pot Rebuild Thread

[BikerB]

The kit arrived today so decided to start assembling it back together, since I had most of it pretty clean and checked I didn't expect any issues, should be pretty much assembly only now.
The kit was a bit long in arriving from GLF classics but that was unusually the GPO, for some reason they were a lot slower than normal this week.
Any, had a replacement mainshaft already and the kit seems fairly comprehensive with the additional Clutch Sleeve I ordered with it plus everything was labelled up

Got the layshaft in and checked prior to inserting the output gear.

The mainshaft is already assembled into the output shaft ready to insert but I'll rebuild the synchro unit first before putting them both in and sticking in the layshaft tomorrow night. I actually hope to finish it tomorrow as most of the work is now done.
Clutch sleeve is already in and torqued so I will hopefully be able to stick it in the gearbox tomorrow finished unless I run into an issue.

 

[BikerB]

In preparing for the rest of it I replaced the springs ball and detents in the synchro in the house, what a palaver as it took about 6 goes with the bits pinging everywhere! Finally got it so its ready cleaned and checked for tomorrow.
Assembled the main bearing and seal ready for the output gear and that's it for tonight.

 

[BikerB]

Well thats it back together and on the gearbox, just the adjustment of the synchro unit once I connect the operating rod and then the detents to be fitted. One more thing done.

Layshaft and synchro unit in.

Nearly there!

Onto the rest of the gearbox..

Empty rebuild box

 

[BikerB]

I have cleaned and painted the last ancillary parts, fitted and adjusted everything and its now completely ready to drop in, even got fluids in it.
Now need to get the chassis in the workshop so I can drop it in and start on the engine and wiring in the warm and dry.

 

[BikerB]

Bit of a hiatus just now, bought another motorbike and with the gearbox blocking the bench I have simply run out of room to work, currently building a half sized garage to take some of the bikes and get the Landrover into the workshop so I can continue with the rebuild.

The roof is now on and insulated and the sides are clad but still need insulated and lined, Its nearly there now so I will be able to move on with various projects, including the Landy

 

[BikerB]

Well I finished the new bike garage a couple of weeks ago and took down the garage tent to get at the Landy today. Its now safely in the workshop although I have had to throw the Midget out to make room. I have a major sort out planned for tomorrow then I can move on with the Landy, now its under cover and away from the damp I can start cleaning it up and start fitting more parts to it.

 

[BikerB]

Chassis now in the workshop on mobile stands and gearbox finally dropped in , now that it is indoors I can start attaching lots more as the chassis is far more stable inside on the concrete floor and I have light and power.
There will be a bit of a slowdown as I am just about to head to the TT but when I come back it should go a LOT quicker than it has been

 

[BikerB]

No progress for a while, just been sitting in the workshop gathering dust due to various jobs going on around it, maybe get some time during the winter now its inside and accessible although until this week the workshop was packed out with lots of second house stuff awaiting going to there..
Unfortunately this other house got in the way along with me currently building a new cupboard and installing a new central heating system in the current one.
I don't retire for a few years, if its not finished by them maybe I will have the time then.

 

[Wagon Loon]

Looking lovely

 

[BikerB]

Just finished putting in an new unvented cylinder tonight and half replumbing the house to suit it so I can hook up the new oil boiler to it. Tomorrow before I do this I need to go to the other abode and take out the water tank, fit an electric shower and remove the immersion tank and fit an unvented hot water heater for the rest of the hot water. Then start rebuilding the kitchen.
The 109 project is somewhere down this list which is longer than the above, and the damn grass and hedge need cut before the end of the summer.
I am hoping I can finish off all the work and spend some time over the winter on the project, at least its now inside nice and snug instead of in a tent!

 

[Wagon Loon]

Yep, everything seems to get in the way of what we really want to be doing, so I give at least one day a week to move the Landy's along. Having a new'ish 300 TDI pick-up on stands for some chassis re repairs, and a new wiring harness doesn't help either, nor does having my daughter's polo dropped on me without much warning for a service and MOT, just a front springs to fit and it's all good. It's mostly inside my gazebo, so folk must think the Circus is in town lol.
Good luck keeping the ball rolling on your project in between everything else

 

[rubix101]

Looking great! As a 6 pot owner who originally intended to rebuild mine with my sis who rebuilt her Series2 on a galvy chassis, this is how I imagined it turning out. Alas it was not meant to be & is presently sitting rather neglected in my yard. Your pics & descriptions would have proven really helpful & I am sure are an inspiration to others undertaking similar rebuild projects. Keep up the good work!

 

[BikerB]

Unfortunately life getting in the way, currently going from this, having removed an old range

to nearly finished

Couldn't get anyone to do it so had to do it myself! It, and other enabling works around building the rooms etc are keeping me away from more interesting stuff like the 109 and the bikes.
Apart from the nuisance of having to do it rather than pay someone to do it I suppose the whole job is in a lot better, accesible and maintainable than your average plumberer would have done.

 

[rubix101]

Unfortunately life getting in the way, currently going from this, having removed an old range
View attachment 300904
to nearly finished
View attachment 300907
Couldn't get anyone to do it so had to do it myself! It, and other enabling works around building the rooms etc are keeping me away from more interesting stuff like the 109 and the bikes.
Apart from the nuisance of having to do it rather than pay someone to do it I suppose the whole job is in a lot better, accesible and maintainable than your average plumberer would have done.

There is a certain satisfaction in doing it yourself & making any future maintenance easier for yourself -future proofing! Pity you are so far away - I have a safari roof sitting around - far south west Cornwall. 6 pots rule - apart from V8's of course!

 

[1988smithy]

Pity you are so far away - I have a safari roof sitting around - far south west Cornwall.

LZ Relay..?

 

[Wagon Loon]

She's not a 6 pot, but I do love the safari roof on Gigi, still driven daily

 

[rubix101]

View attachment 300921
She's not a 6 pot, but I do love the safari roof on Gigi, still driven daily

In the unlikely event we get a hot summer, safari roofs really do come into their own. Nice galvy body capping's on Gigi!

 

[Wagon Loon]

Thanks, they're the original with age related marks. Some had been painted with aluminium colour, still got a length to clean.
If they're getting close to rusting I take a little clear coat to preserve them as they are, followed by a light rub to dull any shine.

 

[BikerB]

There is a certain satisfaction in doing it yourself & making any future maintenance easier for yourself -future proofing! Pity you are so far away - I have a safari roof sitting around - far south west Cornwall. 6 pots rule - apart from V8's of course!

A safari roof is still one of the larger parts I need to source, mainly so I can leave the dog in the Landy if need be, plus they look cool. Haven't managed to find one close enough to collect though!

 

[rubix101]

Thanks, they're the original with age related marks. Some had been painted with aluminium colour, still got a length to clean.
If they're getting close to rusting I take a little clear coat to preserve them as they are, followed by a light rub to dull any shine.

There is something about the old galvanizing process that is so superior to todays - thicker/double dipped, or just that the quality of steel was better back then? Preserving originality is always a good thing. My dads old series 2 bonnet has been polished so many times the alloy is starting to shine through the paint. I LOVE it!