Sting Ray's '89 90 - Complete Restoration

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On Friday I set about removing the bushes from the arms that connect the chassis to the fulcrum. Having tried drilling in the past and gotten fed up of snapping drill bits, I set fire to them with my blowtorch (MAP gas). This worked exceptionally well – just a few minutes of heat and the inner collars popped right out; the outer sleeve still had to be hacksawed/chiselled out though, which was rather laborious. I’ll drop them round to the powdercoaters in the next few days, along with a few other odds and sods.

On Saturday I got on with prepping the rear axle for painting, so put a sanding disc on the grinder to remove the waxoyl and old paint. After making a bit of a mess inside, I moved outside and got the majority of it done, save for the areas that are inaccessible; I’ll see if I can borrow a friend’s aluminium oxide blaster. I’ll take a photo later this week of the fully sanded axle, but here's one after a minute or so:

https://postimg.org/image/2cs0b4xpfv/][/url]

I’m expecting a large order form Paddocks in the next couple of days, including the rear caliper brackets that will be used as a template for the ‘diesel jim style’ adaptors that are needed to carry out the disc brake conversion. The etch primer ought to rock up as well, which I may well just brush on, although the top coat will be sprayed – still haven’t decided whether to use bog standard black paint, Jotun 87 or Raptor yet…
 
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So it’s been far too long since I last updated this thread, but it’s good to report that progress has been made.

For starters, I now have my very own lock up that the 90, my motorbike, tools, and the 110 stuff can live in whilst I crack on with this nut and bolt rebuild. I’ve also got a small compressor and HVLP gun for the paintwork (non-bodywork stuff).

The chassis has finally been ordered although I am waiting on a delivery date.

The rear axle is nearing completion, having tapped a larger hole (1/4”) for the new breather elbow, painted the casing, added a diff guard and replaced all the hub bearings. I’m just waiting on the caliper bracket adaptors, which are required as I’m converting the drums to discs via the Diesel Jim method (Google it).

The front axle has just had a new diff pan welded in as the original was dented to buggery. It was also shot blasted at etch primed, so I will probably be painting it this weekend. The front hubs have also had new bearings fitted; I was surprised how easily the outer races came out and went in – just a few minutes at most. Once the axle is painted I can crack on a sort out the swivels etc and fit the diff.

I’ve managed to get my mitts on a very tidy 110 CSW tub – a couple of small rapirs will be needed, but very little else – it also came with a pair of B posts, so now I have two sets :D

In addition, I’ve picked up a 300tdi and R380. The engine has been almost entirely stripped, and my boot is full of parts for soda blasting and powdercoating. Speaking of which, I collected the powdercoated parts for the rest of the vehicle before Christmas, and they look blooming lovely :)

The Transfer Box is almost back together following painting – I’ve just got to the get the right shoes and springs.

One of the things I am most pleased with, is the bolts, plain nuts, washers, and some odds and sods, all of which have been re-zinced. Quite frankly, it’s porn :D

I’ll get some photos up shortly.
 
So today I finished painting the front axle, and then I set about reinstalled the studs - what a PITA that was! It took approximately 1.5 hours to get all 10 in - in hindsight I'd have refitted them before the new diff pan went in - there really wasn't much room to knock them in at all.

Another order was made with Paddocks this evening, which should mean I now have all the bits and pieces to finish both axles.

I need to decide on suspension soon. I know Nene rate the OME setup, but I'm wondering if it's really that much better than the likes of Terrafirma, which is more reasonably priced. I know the finish on OME is naff, but TF isn't great either. Either way, I'll need HD due to the amount of extra weight I'll be carrying, and would like a touch more clearance than stock too.

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Here's some of the parts that I had zinc plated:

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Two of the new calipers:

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Trying to get a few things organised!

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I'm not sure why it hasn't been attached in the post, but the other image that you can click on at the bottom of the is the rear axle, which is waiting to be fully assembled.
 

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Not much progress to report today, although the new swivels housings were assembled and fitted (see attached file).

I'll need to borrow/purchase a spring balance and dial gauge to set the swivel preloaded and end float fairly soon too.

The diff will go in once I've hoovered/cleaned inside the axle casing again, and some more 3/8" UNF nyloc nuts turn up.
 

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I've managed to borrow a spring balance gauge so will sort the preload out tomorrow, as well as fitting the diff (new nuts have arrived), half shafts and hubs.

The really good news is that the rear brake caliper bracket adaptors have FINALLY been fabricated - hurrah! I will now be able to finish the rear axle this weekend too, save for making and fitting the rigid brake line.

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This afternoon was productive - apart from torquing the hub nuts, fitting the pads and drive members, the front axle is pretty much complete - oh, and the axle grease needs to go in! See the attached photo.

I'll finish that tomorrow and set about finishing the rear axle as well.
 

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Only just noticed this thread :oops: - what a stunning build :) Tis on my bucket list to do one for me at some point - but don't hold your breath :(

Watched :)
 
Thanks - it's been an aspiration of mine for some time too!

The front axle(see attached photo) is pretty much there now - shame I've had to fit the original ****ty wheels for now.

I can't really progress the rear axle any further til I've got the disc bolts, which I forgot to order :-( This leaves me at a loose end for a few days...I should probably use the time to buy a few things including the suspension, and make the chassis loom.
 

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Both the axles are now complete :)

Despite the caliper mounting bracket adaptors (Salisbury drums to discs conversion) being fabricated to the correct dimensions, I had to grind off some of the caliper mounting bracket in order to clear the inside of the discs, thereby allowing the hub assembly to sit flush on the stub axles and rotate freely. End float will be checked at a later date, and after ~ 100 miles or so of driving, whenever that will be!

Still waiting for the chassis so my hands are tied 'til then, although I really must get on and make the chassis loom, which will need to consider expansion for electrical gadgetry :D
 
This has been blasted, rinsed in the dishwasher, had the post-wash oxidation removed with a scourer, lacquered with EHT lacquer, then baked at 160 degrees for 30 minutes :D

The other engine ally parts will have the same treatment to prevent tarnishing and cleaning of inevitable leaks. I'll stick some more photos up when I'm done :)

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