Defender-Sam
New Member
umm well in my head its simple, plumb engine in, fit front callipers, change rear adjuster, bleed brakes and clutch, fit panels, paint, fit seats and matting. done!
but i know its gonna be a lot more in reality.
Looking good bud. Have been thinking of making a wheel carrier myself as I have all the tubing already here. How have you done the hinged sections - have you put any bushes or anything inside the tubes??
thanks dude, i thought about some sort of bushes so brought some nylon bar with the idea to make some bushes but its slightly too large and not having any way to turn it down. in the end i just went for welding a disk (like a washer) with a 12mm hole in maybe not the best idea but if it collapses ill cut then out and liberate some sort of bush to fit.
Adam1979
New Member
thanks dude, i thought about some sort of bushes so brought some nylon bar with the idea to make some bushes but its slightly too large and not having any way to turn it down. in the end i just went for welding a disk (like a washer) with a 12mm hole in maybe not the best idea but if it collapses ill cut then out and liberate some sort of bush to fit.
Cheers. Never thought abut the nylon bush idea. Should be able to get one of our engineers to sort that out for me in work. Maybe weld in some washers aswell just to stop the nylon wearing away.
Cheers. Never thought abut the nylon bush idea. Should be able to get one of our engineers to sort that out for me in work. Maybe weld in some washers aswell just to stop the nylon wearing away.
90maniac
Active Member
It always is more than you think lmao, in the same boat atm
Defender-Sam
New Member
right then had a ball ache of a day today, started off well with a delivery from paddocks containing some of the parts I've been waiting on back door, seals, callipers etc.
went to screw fix to pick up some cutting discs and a new hole saw.
chucked on the scruffs and headed to the garage. thats when it went down hill, offered up the door and too my disappointment it don't fit, turns out the opening in the tub is about 15mm over size meaning that the door won't seal and has a fair size gap. After an amount of head scratching i decided to cut it in half (the door not the the landy) and make a split tailgate like the series had so after banging on the sides and the roof it was clear that the gap needed some attention
cut in half stripped off the skin welded two sections of 8mm rod in and made a new steel skin,
some finishing work still required and bending the top over level with the height of the rear cappings,
got to get hold of some hinges, handle and rams for the top section then apply a similar method to make that wider not quite as bad so hopefully will reuse the skin.
whilst the paint was drying i had a crack at my hilift mount idea and seems to work well so far just need to make a bracket for the top so i can take it off whilst the spare wheel is still on,
now i know people will probably tell me that i should sort it out properly but to be honest i don't know whats gone wrong. the only thing i can think of is that the new floor panel i have fitted is slightly too wide and has opened up the tub. its had a new floor, floor supports, rear panels, top cappings and side end cappings. and its defiantly not coming apart again I'm still recovering from doing over 300 rivets by hand. and i think the split tailgate will be more useful.
thanks Sam :confused2:
went to screw fix to pick up some cutting discs and a new hole saw.
chucked on the scruffs and headed to the garage. thats when it went down hill, offered up the door and too my disappointment it don't fit, turns out the opening in the tub is about 15mm over size meaning that the door won't seal and has a fair size gap. After an amount of head scratching i decided to cut it in half (the door not the the landy) and make a split tailgate like the series had so after banging on the sides and the roof it was clear that the gap needed some attention
cut in half stripped off the skin welded two sections of 8mm rod in and made a new steel skin,
some finishing work still required and bending the top over level with the height of the rear cappings,
got to get hold of some hinges, handle and rams for the top section then apply a similar method to make that wider not quite as bad so hopefully will reuse the skin.
whilst the paint was drying i had a crack at my hilift mount idea and seems to work well so far just need to make a bracket for the top so i can take it off whilst the spare wheel is still on,
now i know people will probably tell me that i should sort it out properly but to be honest i don't know whats gone wrong. the only thing i can think of is that the new floor panel i have fitted is slightly too wide and has opened up the tub. its had a new floor, floor supports, rear panels, top cappings and side end cappings. and its defiantly not coming apart again I'm still recovering from doing over 300 rivets by hand. and i think the split tailgate will be more useful.
thanks Sam :confused2:
Defender-Sam
New Member
Had a short day in there today spent three hours cleaning up amazing how much dust and crap from making the wheel carrier, once tidy i removed the wheel carrier and got a little more done on the rear door welded in some bar to support the top and then bent it over just needs welding up and painting.
if anyone reading this has a lift up tailgate i could really do with some pictures of the hinges at the top ? i think I'm going to struggle to mount them because of my vents?
thanks Sam
if anyone reading this has a lift up tailgate i could really do with some pictures of the hinges at the top ? i think I'm going to struggle to mount them because of my vents?
thanks Sam
Defender-Sam
New Member
thanks for the pic, my plan is to mount it using that sort of thing. its a pic of where the hinge mounts on the inside of the roof I'm after. i know there are brackets but they seem to no longer available so i would need to fabricate some, also i have roof mounted vents so wondering if its possible to mount them around them.
thanks Sam
Defender-Sam
New Member
thanks dude, yeah its more the hinge than the ram bracket i need but i can already tell from that pic that a conventional lift up hinge bracket wouldn't work. i think i will need to remove the vents can anyone comment on whether this will be a problem (blanking off these vents)?
its the vents above the door in question.
Sam
Defender-Sam
New Member
looking into it further might be cheaper and easier to do a "Trewey"
http://www.landyzone.co.uk/lz/f7/defender-hardtop-2-piece-rear-door-46244.html
seems a good way to do it if I'm struggling for parts.
http://www.landyzone.co.uk/lz/f7/defender-hardtop-2-piece-rear-door-46244.html
seems a good way to do it if I'm struggling for parts.
90maniac
Active Member
think you should do it that way looks good i think
Defender-Sam
New Member
had a free couple of hours when i got in from work so attempted to get the door top mounted,
cut away two sections of the roof and used the bottom door hinges, in an attempt to make it fit in and not look out of place,
opens well
just got to acquire another set of hinges and fit the sides and roof properly before trimming the bottom of the door top.
all being well i will have a go at getting the brakes finished tomorrow, got an adjuster on the ns rear drum to change and the front callipers to fit along with the brake pipes on the front axle.
cheers Sam :tea:
cut away two sections of the roof and used the bottom door hinges, in an attempt to make it fit in and not look out of place,
opens well
just got to acquire another set of hinges and fit the sides and roof properly before trimming the bottom of the door top.
all being well i will have a go at getting the brakes finished tomorrow, got an adjuster on the ns rear drum to change and the front callipers to fit along with the brake pipes on the front axle.
cheers Sam :tea:
Defender-Sam
New Member
as i promised i had a crack at the brakes today, started with replacing the rear adjuster as the spindle was just turning inside the cam,
snapped the old cam in half and then knocked the spindle through with a punch,
new assembly (bearmach)
finished and put back together.
then moved to the front and fitted both the callipers along with the copper pipes going from the calliper to flex but kinked one and split it so need to get another one made up.
getting down the job list slowly... and the parts box is emptying.
cheers Sam
snapped the old cam in half and then knocked the spindle through with a punch,
new assembly (bearmach)
finished and put back together.
then moved to the front and fitted both the callipers along with the copper pipes going from the calliper to flex but kinked one and split it so need to get another one made up.
getting down the job list slowly... and the parts box is emptying.
cheers Sam
Defender-Sam
New Member
Thanks, yes i added it up (something i said i would never do) and got a BIG shock
but as the saying goes "in for a penny in for a pound" to late to back out now only way forward is to get it finished.
