Stinkfloyd

I think with a couple well placed plug welds as an insurance policy, I should be grand! 😁

I don't know if you have watched the project binky series on YouTube but they use Kielder power tools and love them! Seem to be decent kit.

Hmm.. now that is a very important bit of info! I wonder how to get round that? Maybe some strategically placed plug welds? The galvanised frames online seem to be galvanised after manufacture so they must be fully welded. So maybe worth a review with a blow torch to see what is welded and what is brazed prior to them going away..

Yeah it'll be on the list! I didn't know about the planting though but there is a boy near me that does blasting for decent cost so I will check first and pay him a visit if needs be.. thanks for the heads up!

They would likely distort but unlike bigger items should be able to be fettled back into shape with some light tapping... but they'll be used to galving smaller items hopefully and I'll mention distortion to them when I arrive

Exactly my thought process... or at least how I justified it to the Mrs 🤣

I have a Sailsbury axle with a brand new pan waiting to go on it 😁

Yeah that is a fair point. A cold galv was a real option for me but i will explain my thinking on this a bit. The company near me that does galvanising charges for galvanising by the ton. Given that land rover parts are generally fairly light weight, you should get a lot for your money for the ton. So my galvanising list would likely be as follows: Door frames Rear tub cappings Roof rack (re-glav and dome of the coating has sacrificed itself over its 20 odd years). Front bumper Rock sliders Bonnet frame With the potential to also galvanise: Axles casings The repaired bulkhead I also have a couple non land rover bits and pieces for galvanising. Now, I am very aware that some of that would be considered. unnecessary and some of it is overkill. But all that will still be less than a tonne in weight and I'm going to be getting bits and pieces done anyway. I know it probably seems illogical. But I have the money to do it now and plan on having the defender for many many years and what is in the bank today is no guarantee of what will be in the bank tomorrow. So I'm opting for the overkill option while I have the funds with the intention of never putting another door, bumper or rock slider on it again!

In the meantime I'm tempted to start the restoration with the doors, as all the doors require refurbishment. The rear doors were replaced with doors from a fire damaged defender. Thankfully the frames are straight but the skins are very warped, so both rear doors need new skins. Both front doors need welding on the lower frame so I will likely just purchase repair sections and weld them in. I will also be replacing these door skins due to dents and a bit of corrosion on the bottom of the plates. So since I'm taking the skins off 4 of the doors, I've decided I'll be as well doing the same with the rear door and sending all the door frames off for galvanising once any repairs have been carried out. Then new door skins all round. Not cheap I will get 5 "new" doors for the price of 1 door with a galvanised frame. Watch this space 😁

And for those who haven't lost interest in the thread already.. it now has 5 forward gears and 1 reverse. It made putting it back into the unit a lot easier last night! Although bitter sweet fitting a box knowing it will be taken out of there again without really turning a wheel. In other news, the chassis is rotten! Rear crossmember is rotten, outriggers rotten, gearbox crossmember rotten, chassis where gearbox crossmember is located rotten both sides.. Now, for someone with no other option, the chassis could be saved with a lot of time but only for the next patches to need done in a year or two. Thankfully my intention from the start was to fit a galvanised chassis! So, I have a few things to sell in the meantime (my motorbike, an old hilman imp project, disco 1 front and rear axle and some modular wheels for a series to name a few things) then chassis will be purchased. I have also decided to go down the galvanised bulkhead route. The bulkhead currently on it is fairly solid but does need some welding. So I will likely weld it up and sell it. But I'm going for a new galvanised bulkhead because, ultimately, this will be a vehicle I intend to be driving in 20 years time. So i would rather do all the work now rather than in 5-10 years. Especially since I'm getting it sprayed at the end of this!

So... gearbox is in, transfer box refitted but I can't say the job is "complete" as the exhaust bolts snapped and had nothing in my stash.. so a hanging exhaust and still on the ramp but it should be off the ramp tomorrow. 😁 Other than a breather hole having paint in the threads, it fitted up well and quality looks good.

Let's see if we can get it in and running in a day!

Got the box unwrapped and all looks great!

On a totally different topic to the current disagreement, I picked up some goodies! 3 liters of atf dex 3 and 3 liters of ep 80w90 (could not get ep90 for love nor money.. but t/box isn't under warranty anyway). Hoping to do the box tomorrow. Aiming to do it in a day.. watch this space...

Interesting when you consider the r380 is supposed to be stronger... I suppose maybe rallying is a very unique situation that most boxes don't see so another area becomes the week point in the modified box?