Land Rover Rustorashun and other shit

[LynehamHerc]

Bloody hell, not posted since March!

the yootoob channel is still going well https://www.youtube.com/c/ChurchHouseClassicsLimited

and I have been busier than ever. Anyway trying to pick up my posts from where I left off,

If you spent less time reading on the bog that'd help.

[richardthestag]

part 2 -

LSE wheel came back, air suspension is very lethargic and noisy too. oh and it started to snow

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Looking for a decent battery for the Series 3 200TDI proved to be a challenge. 55amp/hr is no where near enough to get it started without glowplugs. Battery is installed under the passenger seat (defender style) alas the box is not big enough for a half decent battery

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The early 1971 Range Rover came in from a mate for me to do all the stripdown and prep (7 fucking days of prep) which included fitting new wings, bonnet and tailgate. Steve "The Body" walked around it with his paintgun

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I reassembled it and sent it back to it's owner. Visited him a month later to cut and polish. Looks fucking gorgeous. This is Bahama Gold or as Mrs thestag calls it "baby shit". I quite like it.

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EAS air suspension block came out of the LSE, pump is fucked so was replaced. This helped but it is still noisy - no I suspect the exhaust poppet / diaphragm

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Series 3 88" 200tdi is now mobile - at last - brakes are shite because of the twin leading show setup. I got there but not before Project Bob - the ex-bobtailed 1971 Range Rover popped back for some fettling. Great to see it back, drives and looks amazing

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Parts Range Rover chassis and s3 station wagon body arrived on site. Rolling chassis has no ID and is destined to sit on top of the container until..

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#2 son managed to fill his 2002 Mk4 9n Polo with water while pressure washing it. 4" of water in drivers side, drowned the airbag sensor and created chaos. Yes thanks for that David

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Next project has made it's way into the workshop 9 months late, anyway my brief is to sort the mechanicals, start the rebuilt engine and get the brakes working

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Despite having a rebuilt LT95 4 speed gearbox it dumped most of its oil over the last 8 months. transmission cover comes off to aid engine removal and investigate why it is dripping out of the bellhousing

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More to come

[richardthestag]

Part 3

Engine came out ok

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Fucking shitloads of space in these engine bays

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the most stupid thing I have found yet! Previous trained and professional mechanic did this and must have though "yeah that'll do pig"

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Oil was leaking from the gearbox oil pump cover - below and the left of the thrust bearing here. 7 bolts - 6 were finger tight

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Gearbox cover is shit, needs quite a lot of steel letting into it. Not my job though

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cleaned and fixed the leaking pump gasket. The bellhousing had been hacked about for a previous Perkins Prima engine install. I had a good bellhousing so sold that to my customer.

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Probably the same mechanic who installed the clutch cover, fitted this spigot bush - yes good work I would say

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Clutch, spigot bush, gearbox pump and bellhousing fixed and the engine can go back in again.

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My new pick-up project arrives.

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Owned by a proper Carnie family from Yorkshire. Used to tow the Ghost Train to various fairs and carnivals in the 1990s, I have a wedge of info but would love to see it with the fucking huge trailer hanging off the back of it. My plans are to make it look standard from the waist down but keep it as a pick up. It is a 1975 car in very solid condition considering etc. Engine is 200tdi from a disco, gearbox is LT95 4 speed with overdrive. Love it

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[Eddie Honda]

Looking for a decent battery for the Series 3 200TDI proved to be a challenge. 55amp/hr is no where near enough to get it started without glowplugs. Battery is installed under the passenger seat (defender style) alas the box is not big enough for a half decent battery

How big is the "box" LxWxD??

[richardthestag]

Part 4

Series 3 88" 200tdi is a 1982 vehicle and had lap belts across the front row of seats. Not good for a thorough MoT test. This frame came from Exmoor Trim and allows the 3 point seat belt to do it's thing without shattering shoulder blades etc

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Battery box in this pic came from a series 3 specialist who makes the deep box for a bigger battery. The 100amp/h battery has no issues at all starting the old girl up

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This is another customer Range Rover, a really early Vogue SE - needs quite a bit of work around front inner wings and body frame. Oh and the bastard will not start either. Will fix that though

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inner wings are held in with spot welds, easy enough to remove, you need to be brave though

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As expected, bulkhead, footwell and sill all need work, here an mot patch fell off the car when I cut trough 4 tack welds.

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Similar shite MOT standard welded repair over rot at the back end of the same sill

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More of that later, onto Ghost Train again, 200 TDi disco install, no wastegate actuator, must have been nicked

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Also the exhaust downpipe runs a fingers width from the clutch hydraulic flexi. I swapped out master and slave and now it goes and stops.. fuck yeah

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More tomorrow, need Gin

[richardthestag]

part 5 coming right up

Vogue SE outside, this view of the front footwell is not uncommon. Rot has accelerated under the MoT bodges

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I started to cut out the localised areas of rot with a view to splicing new steel in where needed. However there was so much,

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Especially on the top edge of the sill which makes up 1/3 of the floor. Damp underlay had just about finished it off, so after a quick discussion with the customer a new sill was ordered.

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New front inner wings trial fitted. On this age of car the whole body frame is painted satin black which makes life a little easier

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Bit of a bulkhead overload at the moment, the bulkhead on the 75 RR inside the workshop is a shocker. this job was supposed to be done by the next company. However there is no point in me routing brake lines across the bulkhead and front inner wings if it is all to come apart. So the customer asked me to do this bit. Gaaaaah

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Passenger side "looks" in better shape but there is some shit welding and look at the wonky angle of that inner wing support

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This is after removing 3 layers of patches, all but the outermost one were well past it

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[richardthestag]

part 6

The only way forwards has to be to replace the entire side section of the bulkhead. Luckily this panels are widely available

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Removed axle from the Vogue SE as it needs new brakes and polybushing. just easier to do it this way.

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Ground back all the suspect crap on the 75 RR drivers side A-post. this is what I found. You can never underestimate the side impact protection of filler. Nice job that.

Someone had fitted a lower a-post repair panel and rather than weld it in on all 4 sides that did one and filled the rest.

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I cleaned it back, inserted 16 gauge steel on the inside of the a-post and lap welded it into place, after a skim of filler this will be strong and look good.

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With that done, I use the a-post bolt holes to align the new bulkhead side panel and weld it to the top half of the bulkhead

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and weld the a-post closing panel into place rather than wedging it in

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Went down to devon on a drinkathon weekend with my dad and brother. Also bought back another pile of crap from dad's barn. He is moaning about all my crap all over the place

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This is the scrap RR chassis without an ID, I lifted the engine and box off, the rolling chassis is now strapped down on top of one of the containers

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[richardthestag]

last part, I will try to be more regular with these updates

Passenger side of the 75RR bulkhead was so shit that I just cut the lot out and rebuilt it back up as the factory would have had it. Bastard thing

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The series 3 200tdi is finished and is now back with it's owner

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and as if I don't have enough to do, my wife harangued me into painting #2 sons mk4 polo. The original clear coat had failed so all needed to come off. #2 son says I'll get that done in a day He managed the rear 1/4 and the bonnet in 2 days. He had some panel damage to the rear quarter that I needed to fix

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Before prime

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and topcoat, not worried about a match as the whole car is going to get done. All he has to do is get rid of the clearcoat and I'll paint it for him as and when

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[Hooli]

Good to know ya still alive n busy.

[The Reverend Bluejeans]

I spotted this at a local do yesterday - a 1991/2 3 door in basic spec. I never knew there was such a thing but it's imported from Spain and converted to RHD.