4x4Direct's 88" Series II rebuild - Page 3





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  1. #41
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    Default Re: 4x4Direct's 88" Series II rebuild

    Our project was halted for some months now, mostly due to lack of space and because I first wanted to finish my Pontiac.

    Since my last post we took the Diffs to Cape Transmissions in Cape Town and the Gearbox to Friendly Motors in Cape Town. In both cases the the instructions to replace all seals and bearings with new ones.

    We decided not to get new srping packs as these still looked fine. They were only taken appart, cleaned and painted and received new bushes and shackles. Also the bushes in the chassis was replaced.

    So last week the project started again. I cleaned and painted the diffs and took a lot of brackets and pieces for sandblasting.

    Today we put the srping on the diffs, the chassis on the diffs and the gearbox inside the chassis.

    Thought it would be quick, but to get those old bushes out of the chassis and pressing in the new ones took us an hour or three.















    Attached Images Attached Images  
    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


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  3. #42
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    Default Re: 4x4Direct's 88" Series II rebuild

    Looking good so far....still a long expensive road ahead. My costs are at R120k so far.....

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  5. #43
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    Default Re: 4x4Direct's 88" Series II rebuild

    Last week we assembled the engine of our project Landy. Cleaned it, repainted it and this week fitted the engine. We still have to fit all the small things like alternator, petrolpump , etc, but I just wanted to fit the engine so long to clear up some working space.

    Some of the parts like the pulleys, fan and breather were sand blasted and powder coated.

    The engine was already 4 oversize and I did not want to go larger, so I had it re-sleeved and went back to Standard. Big ends and mains are 1 oversize.

    New oil pump, new waterpump, etc fitted. Roverland in Cape Town is very helpful and affordable with these Landy spares.




    Last edited by pietpetoors; 2017/10/05 at 03:39 PM. Reason: spelling
    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


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  7. #44
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    Default Re: 4x4Direct's 88" Series II rebuild

    Looking good...

    I find it way easier to get the brake pipes in before the engine & box.....

  8. #45
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    Default Re: 4x4Direct's 88" Series II rebuild

    Mmm, now that is a time to tell me. Thanks for the warning. It will be easy to lift the engine and gearbox as a unit since nothing else is connected yet.
    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  9. #46
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    Default Re: 4x4Direct's 88" Series II rebuild

    ;d;d;d

  10. #47
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    Default Re: 4x4Direct's 88" Series II rebuild

    Life happened and eventually after almost 3 years I am working on the Landy again.

    As per previous post we bought a 2A as donor vehicle.

    The donor vehicle's bulkhead was in very good condition so I decided to use it instead of the original.

    I had it sandblasted and I then painted it with Plascon Epiwash Strontium primer. I did 4 layers to make sure it is properly covered. Then added 2 layers of 2k primer to smooth it out.

    When I want to fit it today I saw the holes do not line up.
    Are these bulkheads supposed to be interchangeable?

    Something else I also found interesting is the different gauges, the orginal in our Landy is the black one and the yellow one is the donor vehicle.
    Donors has amp gauge where orginal had temp gauge.

    Can somebody please help, what should I do with the bulkhead which does not line up?











    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  11. #48
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    Default Re: 4x4Direct's 88" Series II rebuild

    I asked the same question to Series 1 club in UK.
    They say. JUST GET IT TO FIT.

    So a bit of jacking and pulling and mine fits.
    I see yours is already painted so be careful of cracking paint.
    They say they never 100% the same.

    Gary will know, he knows everything
    Defender Kalahari
    Series 3 SWB
    Series 2 SWB (Near Future)
    Series 1 Station Wagon 88''

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  13. #49
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    Default Re: 4x4Direct's 88" Series II rebuild

    SWAMBO dropped a bomb-shell on me and said she'd like a S1.

    She's been upset ever since she had to sell her Austin Healey Sprite.

    Originality isn't needed. In fact, I'd like to see if the 86 or 88 body would fit on a 90 chassis

    So if anybody has access to body panels I'm keen for a project.
    2012 Jeep Sahara Unlimited 3.6 V6
    Percivamus

  14. #50
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    Default Re: 4x4Direct's 88" Series II rebuild

    Thank you imgreg, got it to fit.

    I only painted primer for now. Want to make sure things fit before I paint the green.

    I am going for the dark green colour.
    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  15. #51
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    Default 4x4Direct's 88" Series II rebuild

    Thatís normal tolerance on a Landy firewall.
    Shove a tire iron in from the bottom, sit on your arse with your feet on the chassis and pull ..... push the bolt in with your knee. ( or, if youíre old like me.... cut a piece of wood 10mm longer than the gap between the chassis and the firewall leg and put a hammer to good use )

    The ammeter was fitted to the Series 2ís - the S2A & S3 had the temperature gauge....
    Last edited by GaryFrank; 2020/05/04 at 11:01 PM.

  16. #52
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    Default Re: 4x4Direct's 88" Series II rebuild

    I always fit a temperature & oil pressure gauge (mechanical preferably) on a new engine...... just a temporary mount to monitor the engine for the first 1000 Kayís....

  17. #53
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    Default Re: 4x4Direct's 88" Series II rebuild

    Hi, Interested to know where galvanising of chassis was done? Looks great.
    Did the galvaniser require any additional cleaning?

    I am getting a 90 chassis galvanised (when lockdown allows!), but it has lots of (ex UK) wax and paint inside that may form trapped ash and cause problems.
    Current plan is to acid/ caustic dip first to remove all paint, wax and corrosion.
    1964 SII 88"
    1983 LR90 V8
    2011 Def90 Puma

  18. #54
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    Default Re: 4x4Direct's 88" Series II rebuild

    Blikkie I cannot remember where I had it galvanized, it is some 2 or so years ago. It was at a place in Stikland.

    Bulkhead fitted, will take picture tomorrow.
    Spent the day cleaning all the small bits from the bulkhead to sand blast and paint. Items like pedals, linkage, etc.

    Underneath the indicator stalk switch is this wheel, does anybody know what this is for?

    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  19. #55
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    Default Re: 4x4Direct's 88" Series II rebuild

    Quote Originally Posted by pietpetoors View Post
    Blikkie I cannot remember where I had it galvanized, it is some 2 or so years ago. It was at a place in Stikland.

    Bulkhead fitted, will take picture tomorrow.
    Spent the day cleaning all the small bits from the bulkhead to sand blast and paint. Items like pedals, linkage, etc.

    Underneath the indicator stalk switch is this wheel, does anybody know what this is for?

    The wheel is the return to off position mechanism. Indicate say to the right and when you turn the steering wheel back to straight the wheel turns and cancels the indicator. The rubber is generally perished on those.
    Edwin
    Defender '99 TD5 Pick Up
    Rock sliders, Spare wheel carrier, Roof Rack, Aluminium canopy, Tentco RTT, Tentco Awning, 280Ah Dual batteries, 3 x Sliding Drawers, Water tank, Hot Shower, Kitchen

  20. #56
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    Default Re: 4x4Direct's 88" Series II rebuild

    Oh, ok, thank you, that is cool.
    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  21. #57
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    Default Re: 4x4Direct's 88" Series II rebuild

    Quote Originally Posted by pietpetoors View Post
    Good question
    Die suur word geneutraliseer soos dit sy werk doen, kan nie daar bly nie

  22. #58
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    Default Re: 4x4Direct's 88" Series II rebuild

    This week spent time to strip the other bulkhead and then sandblasted and cleaned a zillion of parts. Mostly bulkhead related parts.
    Also started with the repainting of them parts.
    Start all of them with Episwash primer. Normal parts will get 2K black. Parts which will be more visible might get 2K primer as well to be able to smooth them better and then 2K green.





    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


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  24. #59
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    Default Re: 4x4Direct's 88" Series II rebuild

    I am busy assembling the steering box.
    When I took it appart there were no sealant between the gaskets and shims and between shims and shims.
    Is that correct? Must it go back like that?
    Won't oil leak through the shims?

    What is the best way to do it?


    1999 Hilux Raider 4x4 2700i, 'n groene met swart tyres
    19 Voertsheck Jeep CJ5 Built on 1984 Nissan Safari mechanics
    2011 Touareg 4.2 V8 Diesel.
    Series IIA Landy being Rebuilt (for the past 4 years)
    1963 Willys Traveller


  25. #60
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    Default Re: 4x4Direct's 88" Series II rebuild

    Good Question.
    I have decided to rather use CV joint grease.
    Seems ok. But is not mobile yet and long term, i don't know.
    Now lets wait for someone to say that you cant do that
    Maybe we get some good input.
    Defender Kalahari
    Series 3 SWB
    Series 2 SWB (Near Future)
    Series 1 Station Wagon 88''

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