Defender 110, a Bedford cf and a utility truck walk into a bar...

[L19MUD]

1 hour ago, miketomcat said:

I've always cleaned up blocks with wet and dry on a piece of perspex. I've been known to do heads too, both Ali and steel but I always check with a straight edge after. Never had issues that haven't been attributed to something else.

Mike

Same - I tend to use a fine grade wet and dry with WD40 or similar. I can't think of a block that I have not done this on before putting a head back

[Badger110]

I found some remnants of the vacuum pump in the oil pan, right underneath the drain plug so were never drained by an oil change, small 3-4mm chunks of plastic which had melted within it and entered the oil ways.

 

Looking around the block I can’t see any more bits but knowing they’re in the oil, I’ve decided to strip it down completely and get it down to the engine shop to be thoroughly cleaned and a light hone to the block and head.

We’re off to Scotland in 3 weeks time and I’ve a contract to complete in the next 2 weeks so it’s looking like some late nights to be had 😁

 

 

[Wytze]

take oil and a filter.  It will be run in when you get there😋

[Nonimouse]

On 8/15/2021 at 10:28 AM, Badger110 said:

When I had the head skimmed I had a chat with the engineer about the block face and his advice was to use hardwood wider than the block, 1200 grit and take your time, which I did.

 

HG was Elring and yes, bolts in correct order, in fact this rebuild was the most ' by the book ' I've ever done using the LR manual.  

 

The spigot is a strange one as it looks to be elongated top to bottom and the input shaft to the gearbox has some movement, not a lot but some.  I also fitted the gearbox and engine together out of the truck so was as careful as I could've been, but that doesn't rule out a mistake happening

Gearbox's are beyond my scope if I'm honest and I'll probably drop it out and get it over to a specialist in the coming weeks for some advice on the input shaft movement.

 

 

 

Did you actually buy the HG from Elring or from a supplier - theres a lot of Elring copies floating about

[Wytze]

On 8/17/2021 at 11:15 AM, Badger110 said:

I found some remnants of the vacuum pump in the oil pan, right underneath the drain plug so were never drained by an oil change, small 3-4mm chunks of plastic which had melted within it and entered the oil ways.

 

Looking around the block I can’t see any more bits but knowing they’re in the oil, I’ve decided to strip it down completely and get it down to the engine shop to be thoroughly cleaned and a light hone to the block and head.

We’re off to Scotland in 3 weeks time and I’ve a contract to complete in the next 2 weeks so it’s looking like some late nights to be had 😁

 

 

Ten day's in...  is your engine back yet?  

[Badger110]

23 hours ago, Wytze said:

Ten day's in...  is your engine back yet?  

Nope!

 

All the parts have arrived, however life gets in the way with moving the house back around and work being rather busy.

 

As soon as I make a concerted effort to start, I'll be posting pics n stuff

[Badger110]

Spurred on by @Wytze 's enthusiasm to see some progress I sat down on my stool in the workshop and began the rebuild.

 

First off the bits had all arrived from Turner's

 

as well as a new spigot bush.

 

Main bearings went in without a hitch and were torqued up with the help of Nikki hanging off the end of the bar on the last setting or in layman's terms ' FT ' 

 

The con rod's turned out to be a trial as for some reason I'd mixed up the end caps.  I swear by all that's mighty I put everything in order when I took it apart but for some reason, they ended up not in order.  

This caused me some grief as the crank was binding when I first torqued up the caps.  

After lots of head scratching and checking the bearings, piston orientation, weather and how much I'd had to drink, It twigged that the fracture line wasn't looking right.  

You may think I had swapped number 1 for 4 but oh no, I'd gone and done it good n proper by swapping 1 for 3 and 4 for 2....how that is even possible??

Anyway, they all got sorted and with liberal use of the sticky stuff, the crank and con rods were torqued up 

The wellies in the background are for oil leaks incase you're wondering

 

Secondary ladder was fitted as well as oil pump, chain and pick up and shiny new spigot bush

 

After this the rear crankshaft seal went on

 

then the sump and flywheel.

 

Forgetting I'd added a fair bit of weight to it, I flipped it over straining my left testicle and broke wind all at the same time 

 

 

a couple thou was honed off the face but wasn't necessary on the block, but it was a piece of mind thing for me.

 

I now need a DTI to get the TDC and check piston protrusion so I've ordered one off amazon to arrive on Tuesday.

 

 

 

 

 

 

[Wytze]

3 hours ago, Badger110 said:

Spurred on by @Wytze 's enthusiasm to see some progress I sat down on my stool in the workshop and began the rebuild.

 

First off the bits had all arrived from Turner's

 

as well as a new spigot bush.

 

Main bearings went in without a hitch and were torqued up with the help of Nikki hanging off the end of the bar on the last setting or in layman's terms ' FT ' 

 

The con rod's turned out to be a trial as for some reason I'd mixed up the end caps.  I swear by all that's mighty I put everything in order when I took it apart but for some reason, they ended up not in order.  

This caused me some grief as the crank was binding when I first torqued up the caps.  

After lots of head scratching and checking the bearings, piston orientation, weather and how much I'd had to drink, It twigged that the fracture line wasn't looking right.  

You may think I had swapped number 1 for 4 but oh no, I'd gone and done it good n proper by swapping 1 for 3 and 4 for 2....how that is even possible??

Anyway, they all got sorted and with liberal use of the sticky stuff, the crank and con rods were torqued up 

The wellies in the background are for oil leaks incase you're wondering

 

Secondary ladder was fitted as well as oil pump, chain and pick up and shiny new spigot bush

 

After this the rear crankshaft seal went on

 

then the sump and flywheel.

 

Forgetting I'd added a fair bit of weight to it, I flipped it over straining my left testicle and broke wind all at the same time 

 

 

a couple thou was honed off the face but wasn't necessary on the block, but it was a piece of mind thing for me.

 

I now need a DTI to get the TDC and check piston protrusion so I've ordered one off amazon to arrive on Tuesday.

 

 

 

 

 

 

Very nice,  working hard and breaking wind go together like drinking and getting pi##ed😁

[Badger110]

Quick update;

 

Engine has now done 250miles with no issues and running nice n sweet.

Gearbox was returned, fitted, then the entire truck sent back to sort out the leak in the box...apparently it was a bad seal on the rear of the box, whatever it may have been, it has been sorted now.

 

So now i'm at the point of finally finishing the rear area which has gone through 3 complete changes since i first ripped out the rear seats.

 

I've also placed the trailer in the workshop as i want to work on that over the winter months

 

We shall see where the thread tales us from here.

 

P.S. yes they are wheel rims on it, i could only get it in there with these fitted 

 

[Wytze]

On 11/11/2021 at 11:23 PM, Badger110 said:

Quick update;

 

Engine has now done 250miles with no issues and running nice n sweet.

Gearbox was returned, fitted, then the entire truck sent back to sort out the leak in the box...apparently it was a bad seal on the rear of the box, whatever it may have been, it has been sorted now.

 

So now i'm at the point of finally finishing the rear area which has gone through 3 complete changes since i first ripped out the rear seats.

 

I've also placed the trailer in the workshop as i want to work on that over the winter months

 

We shall see where the thread tales us from here.

 

P.S. yes they are wheel rims on it, i could only get it in there with these fitted 

 

You are going to paint that camo green as well?   Are you happy with the trailer?  

[Badger110]

Trailer is good although not used it in anger for more than a week at a time.  Some areas need some work, the doors don't seal shut so the rain gets in which isn't a massive issue, but one that could be solved or at least reduced.  We keep everything in water tight bags or box's anyway, but the battery and fridge need some protection so i'll come up with something.

The kitchen area also needs some work to make it more suitable to use and do away with the wasted space in there.

Internal lights and some other mods to think about...fortunately the previous guy who made it had done all the work on the underside with the brakes, axles and frame so i just need to potter about in the top part

[Wytze]

In my head i want to build something like that to.  With a big rear door, like on a horsebox.  So i can take the bike on a trip to.  No time for that yet🙂

[Nonimouse]

On 11/15/2021 at 8:30 AM, Wytze said:

In my head i want to build something like that to.  With a big rear door, like on a horsebox.  So i can take the bike on a trip to.  No time for that yet🙂

I'm thinking along similar lines. But no bike. However I will go light weight and to avoid IVA unpleasantness, I'll use an existing box trailer and work up from there

[miketomcat]

1 hour ago, Nonimouse said:

I'm thinking along similar lines. But no bike. However I will go light weight and to avoid IVA unpleasantness, I'll use an existing box trailer and work up from there

I also have a plan to use a Tesco's delivery box on and existing trailer chassis (possibly horse box chassis). Mine would sleep 4 and have a toilet inside, kitchen area and storage accessed from outside. Awning with wood burner on the side. Just need time and money now..... DOH. 

Mike

[Nonimouse]

1 hour ago, miketomcat said:

I also have a plan to use a Tesco's delivery box on and existing trailer chassis (possibly horse box chassis). Mine would sleep 4 and have a toilet inside, kitchen area and storage accessed from outside. Awning with wood burner on the side. Just need time and money now..... DOH. 

Mike

Mike, speak to James about insulated boxes - he may have a source (like those ones in the yard)

[miketomcat]

2 hours ago, Nonimouse said:

Mike, speak to James about insulated boxes - he may have a source (like those ones in the yard)

I need to get my finger out and finish his engine cover first.....

Mike

[Nonimouse]

19 minutes ago, miketomcat said:

I need to get my finger out and finish his engine cover first.....

Mike

Probably best

[Badger110]

I went to get some steel for the trailer and came out with one of these

https://www.jasic.co.uk/arc-140-inverter-welder

 

£148+VAT which i thought was rather good as it saves wheeling the Mig around and i always liked the versatility of a stick welder, especially one this small as i can chuck it in the back of the truck for small work jobs.

 

I've got it on the 32 amp commando plug as that was what the mig was using, not tried it on a standard 13amp.

 

Learning curve here we come...

[Wytze]

17 hours ago, Badger110 said:

I went to get some steel for the trailer and came out with one of these

https://www.jasic.co.uk/arc-140-inverter-welder

 

£148+VAT which i thought was rather good as it saves wheeling the Mig around and i always liked the versatility of a stick welder, especially one this small as i can chuck it in the back of the truck for small work jobs.

 

I've got it on the 32 amp commando plug as that was what the mig was using, not tried it on a standard 13amp.

 

Learning curve here we come...

Good choice.  I got a Jasic .  210 amp's. 

Never had any problem with it.  

[landroversforever]

I've got one of their big TIG sets and its a lovely machine  

[Ed Poore]

On 11/30/2021 at 9:09 PM, Badger110 said:

Learning curve here we come...

I was lucky enough to have a friend who used to be a high-pressure gas pipeline welder amongst other things hold my hand for 20 minutes using my stick welder. Such a transformation. The thing I couldn't get over was how slowly the stick travels in comparison to consuming the stick.

Funnily enough shortly after the liner in my MIG went so used it as an opportunity to upgrade to a Euro torch, it still hasn't been finished as I've not found the need... Doesn't help that most of what I'm welding these days is 20mm odd thick steel plates.

[Wytze]

How is your welding coming along?  

[Badger110]

It isn't 

 

I've taken on too many things and welding isn't involved in this, however i did do a small bit of horizontal welding on some railings and let's just say i've got a long way to go yet! 

 

On the trailer side of things, i've fitted both water tanks and now decided to remove them and have just one large tank.

 

I'm all for saving money using what i have but at times it's better to make it simple for myself and for the future, so one tank, one pump and it's done.

 

I've fitted the hot water system and it works very well on the trial period...there is some fettling to do with water flow and i'm testing different pipe diameters and distance's to get the most from the heater and water supply without unnecessarily wasting water but i am very impressed with it.

It's quick to heat up the water with a 900mm pipe from the unit to the standard basin tap using approximately 500ml of water from cold to nice and warm for a shower/washing up (30C registering on the unit )

 

 

I've found some composite aluminium sheets on faceache which will replace most of the timber sheet material in the build other than the phenolic plywood for structural parts too, hopefully i can pick them up over the weekend from Taunton.

 

I've also found some aluminium sheets ( 1.5mm thick ) to make up some drawers for a works van which may also find it's way to be used in the trailer....🤔

 

I would post some pictures but i'm in blinkered mode and the workshop looks like organised chaos without any organisation involved  so i'll wait until i clean it up abit

 

 

[Wytze]

Good to hear you're still at it.   

My first welding was'nt  that great ,  started on a car to restore back then. 6 weeks in, i started redoing what i started with.  Just start on some left over sheet. Get the feel for it.  It will come sooner then you think.  

[Badger110]

There are some benefits to being ill with covid and stuck at home for 3 weeks, it gave me the opportunity to redo the rear of the truck.

 

I've spent some time in the past coming up with ideas and thinking of how/what scenarios i would need them in and in the end, none of them really worked in real life. 

 

I built the last idea of the truck on the basis we'd be in it...in the end we spent 90% of the time when parked up, sat outside it and rarely used the interior that much.  When i used the truck on a course for a week, it did work really well, but the sink and cooker were a waste of space if i'm honest as when you want to cook outside, you had to move it all around.

 

So the rebuild of the interior remit was as follows;

 

To be able to sleep 2 people and a basset hound.

 

Storage for all our gear, clothes, food for extended periods

 

Comfortable and warm if we need to sleep in it. 

 

Cooking would be done with our hiking gear ( Primus cookers ) and water would be from a container only.

 

Lighting and power where needed. 

 

 

 

So first up was to dismantle the rear of the truck and examine what i had to play with, take some measurements and pop down to a local place to use their CNC machine.

 

I cheated a little here using the CNC machine as normally i'd do all that work myself ( being a wood butcher ), however it's sometimes easier on the mind and time, to give it to someone who has the ability to do it quicker and it's less stressful

 

Armed with some drawings, i came up with some ideas of how it was going to look and asked them to cut out the facia's of the storage units with the doors and hinge recess's done for me.

 

Picked these up the following day and began the build on the near side first.  

 

The floor was the original celotex (30mm ) and the walls were already lined with 10mm acoustic 

 

I began by mocking up the idea i had, which was quite a loose idea, but one i knew i could change as i went along.

 

My first thought as i did this was the compressor wasn't in the right place anymore, so i removed it.  I was also going to move the webasto as well, but in the end left it in the same position 

 

This is a top down view of the near side showing the webasto and compressor before i moved the later

 

 

Some of you will notice that the Webasto has been replaced by a chinese version, this is because one turned up brand new for 70quid, and as the webasto is due a service, i fitted this one.  Everything is pretty much the same except the controller, which if i'm honest, is better than the webasto as it has a manual pump override for priming the system!

 

 

The nearside was finalised with storage to the rear, 3 top storage areas which also work as a work space when the roof is up and storage underneath the work space for cooking etc

 

No laughing at my picture. I like it. 

 

Next up is the seating for the rear area