steve b

On the wheels , I use a lever bar between the BJ securing bolt head and the axle mounting face to try and lift it up. Can you mount a video camera underneath to view the rear axle nose from the side and and rock it forward in gear then back in reverse? If the nose is going up/down then it will be the A frame joint or bushes or the trailing arm bushes Steve

hockey stick to axle bush(es) ? A clunk is not a noise the R380 makes? Output splines on the R380? Steve

Not that different to the Tdi I'd suspect. That is very light indeed , you need some soft ply tyres to suit now. Shame ATV/Mule tyres don't come in your size Good result Steve

That's a very tidy job you've done Tom, panels look good quality too. Steve

A plastic bag over the reservoir neck and replace the cap reduces drain out Steve

Yes - any free dirt/rust will damage gears and bearings . As FF says mag drain plugs are very worthwhile to collect any free metallic flakes but starting with clean internal surfaces is a must. If it's off the vehicle and stripped bare you could take it to a local HGV yard - most have steam cleaners Steve

Removing the diff and everything including the stub axles will show it's true state. A good pressure/steam wash would sort it or a 5" stove flue brush and plenty of brake cleaner by hand, finished off with a rag ball on a string to wipe any residue out followed by lots of oil checks and changes as needed. Replace all seals and check the seal lands for scoring while you're in there. Also clean the diff gear set then clean it again Steve

I would agree with this. Unbolt the MC from the servo can and inspect the piston end and bore for fluid. No pipes need to be disconnected to do this and with a small G clamp the piston can be pushed in to see more bore. Drum or disc on the back? Steve

The H-L function and the Difflock(transfer box difflock) are separate even though on the same lever. In low DL to high no DL the shift can be one movement (allowing for road speed and de-clutching) and vice versa, keep an eye on the DL light on the dash to confirm unlock or lock Welcome to the forum , and Defender living Steve

Thanks Ralph, I thought the MOD records would be more detailed. The main info on this 109 is it has been resting for 26 years so it will need some tlc even though it has been in the dry mostly by the initial look around. Steve

Ouch... Did you try Agri-hire for the seals first? Steve

Having a template to prove theory is always worth the work , and oh boy, did it work Steve

Thanks - the reg no. and the con. no show nothing on Merlin database, maybe it was on classified duties... Steve

Yep, been there too. So awestruck I completely forgot to take pics. Loved the Southland , so different to the rest of NZ.

....just a bit of wiring and it will be done then You have made that faster than an on-line order and delivery from a supplier.... Steve

From Britcar's site Steve

It would appear you intuitively chose a good mix of donor material, reminds me of Burt Munro casting pistons for his Indian in that film. It looks great Stephen Steve

Did you use that wheel as material for this cast? As others have said , it's a very clean cast with no porosity or inclusions. Steve

I like it , looks like a set car off Bladerunner. Nice job Mike Steve

Cool , look forward to the build. .........I have an '86 V8 90 on one of my many back burners waiting to be finished Steve

Modern stuff eh, just won't manage the unexpected use... It looks great btw, I'm sure there will be other ally casting projects along the way now- 3D printers? ppfff Steve

This may be the greatest re-purposing of domestic tools ever, certainly way more adventurous than a dishwasher running diesel to clean stuff Steve

Does it still have the valve in the rear circuit? - down on the OSF chassis near the footwell. Steve

Drum or disc on the back? Clamping the flexi's should give a solid pedal with correct free play at the top, then release one clamp and check pedal , re-clamp and release another and repeat Steve

I'm pretty sure if you have rebuilt it then all will be well, it certainly engages ok from your description. They are fairly simple in function Steve