Tonks4x4 Defender 6x6 Expedition Camper

Tonks4x4 · Aug 14, 2013

A little update. The V8 4.2 has now been fully stripped and has been sent off to the engine centre for machining.

I have already collected the crank which is now 10thou undersized and polished ready to go.

But I have not been able to find any engineering shops to perform the machining on extending the keyway.

So I have taken it upon myself to set to with the dremel and some grinding stones, it took me an hour or two but have managed to sort it.

Here is a picture of the keyway in position and the old one to see the size difference

This is one of the grinding stones used which just happens to be 1mm thinner than the slot required

And a mock up of the crank timing gear, front cover and crank pulley to make sure everything is as it should be

All the parts can now be meticulously cleaned and painted where required in preparation of having the block back.
And then I can get on to building it back up.

Also I have purchased a pair of leather captains seats with double armrests which I intend to fit...

Wizzywill · Aug 14, 2013

Loving this good work

Tonks4x4 · Aug 16, 2013

Had a little time to do a few bits.
Got a call from the engine centre to say the block is ready and the new cam bearings have been fitted.
So first of all etch prime the block, a few coats of silver paint, a little bit of detailing for some contrast and then lacquered.

Once this was dry, it was flipped upside down and I have fitted the crank and new bearings etc.

Also the front wings of the original body have been painted in what appears to be house paint or something as equally as horrid.

So they have been broken down into sections and have been working with the dolly to get them as flat as possible so there is as little filler as possible.

I hope to get the pistons cleaned cleaned, re ringed and installed tomorrow if I can get some time to myself...

timtheenchanteruk · Aug 16, 2013

jealous much

Tonks4x4 · Aug 17, 2013

Grabbed an hour or so today. So set to cleaning pistons.

At least you can read them now.

Then out with the old rings and clean the rig gap with rig gap cleaning tool

Then pistons can be fitted with the new big end bearings.

Tonks4x4 · Aug 17, 2013

Then on with all the new timing gear

Hope to get the front cover painted on Monday after inspecting the oil pump. Then I am waiting on the heads coming back from the engine centre.

Landyjd · Aug 17, 2013

This looks great. I'm enjoying seeing the engine being built up, really interesting.

samc88 · Aug 17, 2013

Looking really good

Whats the timing gear made from? Doesn't look like metal (maybe its just me

)

Tonks4x4 · Aug 18, 2013

samc88 said:
Looking really good Whats the timing gear made from? Doesn't look like metal (maybe its just me )

Your right it's a standard aluminium one with Nylon ring gear.

Full steel ones are available from the likes of real steel etc but as this engine is not for competition nor am I increasing the rev limit. The standard one should suffice.

DaveM-sport · Aug 18, 2013

The steel one would be slightly noisier too if imagine and assume the quieter the engine other than a nice exhaust note is was you want on something that'll be crossing continents

Tonks4x4 · Aug 19, 2013

Well took a while to clean everything before painting but most stuff is etched ready for final flatting and coating tomorrow

The only other item that was cleaned and fitted was the oil strainer...

chrisyleigh · Aug 20, 2013

Epiiiiiccccccccccc! I soooo want one wonder what the resale value would be on this can imagine it being thousandddssss!

Tonks4x4 · Aug 22, 2013

Not a deal to report managed to get front cover painted.... Gone for a dove grey which am hoping it will tie in with the camper theme once built.

Also the heads have been finished so picked them up from the engine centre this morning

So the heads have also now been painted and fitted.

ifloochies · Aug 22, 2013

Tonks4x4 said:
Not a deal to report managed to get front cover painted.... Gone for a dove grey which am hoping it will tie in with the camper theme once built.

Also the heads have been finished so picked them up from the engine centre this morning

So the heads have also now been painted and fitted.

Is that a britpart box I see sitting at the base of the photo??
Dear Lord, say it isn't so:screaming_bug_eye_f... None of those in this awesome build.

Tonks4x4 · Aug 22, 2013

ifloochies said:
Is that a britpart box I see sitting at the base of the photo??
Dear Lord, say it isn't so:screaming_bug_eye_f... None of those in this awesome build.

Lol, yes it's a water pump. And one of the very few things that is a blue box item, most stuff is Genuine or OEM.

200tdi ayre · Aug 22, 2013

Tonks4x4 said:
Lol, yes it's a water pump. And one of the very few things that is a blue box item, most stuff is Genuine or OEM.

Don't expect it to last much longer than out of the box

Tonks4x4 · Aug 22, 2013

The hydraulic lifters have been soaking in oil all night so they have gone in.

The inlet manifold has been painted along with some of the ancillary parts, so they have now been fitted.

Steering pump, pulleys and thermostat housing all painted

I have ordered some more paint for doing the fuel rail, rockers and plenum chamber so will get that done next week as I'm off to Eastnor all weekend

But placed the rocker covers and plenum on to stop any foreign objects falling in etc

craigyb · Aug 28, 2013

That engines looking

JonnyP · Aug 28, 2013

Lovin this fred :0)

Tonks4x4 · Aug 29, 2013

Been slack with taking photos.
Offered up the manual flywheel to check everything was as it should be.

Then I gave it a very light skim in the lathe to clean the surface. It was then bolted up with a good quality clutch and heavy duty bearing.

Re visited the bulkhead fitting and had to re hit the drawing board!

I must have been half asleep last time I offered it into position as I mounted it on the front of the out riggers instead of the rear like some kind of idiot.

The stick clearance issues are now more apparent and along the lines of what I was expecting.....

So I have removed the selector mechanism from the top of the LT85 gearbox and have started drawing up a new custom selector plate with an extension housing that I can make one up with the milling machine from a large block of Aluminium.

Meanwhile most of the engine parts are now painted and re fitted.

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