Series I Series 1 Full restoration (5 year plan) - Page 3





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  1. #41
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    Default Re: Series 1 Full restoration (5 year plan)

    Nice!!! Well done
    Wolverine : 93' Range Rover Classic 3.9L EFI

  2. #42
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    Default Re: Series 1 Full restoration (5 year plan)

    One job I will not do again. Rather pay someone to do this I think.
    After battling for ages to remove the shackle bushes from the chassis, I HAVE ONE NEW ONE IN PLACE.
    The other 3 will not go in.
    I stripped both my threaded jacking rods to force the Damm things in.
    The hole was drilled clean with a wire brush, the bushes had been in the freezer for a week.
    Dipped them in grease BUT NO they now remain half in
    So now I will shop for a ###### pusher puller thing to get them in.
    What a battle to remove and install.
    Should have shoved poly bushes in



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    Defender Kalahari
    Series 3 SWB
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    Series 1 Station Wagon 88''

  3. #43
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    Default Re: Series 1 Full restoration (5 year plan)

    Anyone know how to find and install the steering relay sleeve thing.
    This could be part of the chassis because when I pushed the 62 year old relay out the sleeve crumbled out.
    Might have to out engineer the problem and make a plan.



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    Left below is the part hidden within the Chassis.
    Above right is mine crushed to bits.
    I have a new steering relay so may as well get a new sleeve thing.

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    Defender Kalahari
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    Series 1 Station Wagon 88''

  4. #44
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    Default Re: Series 1 Full restoration (5 year plan)

    Diffs all stripped and clean ready to reassemble with brand new parts, all bearings and seals will be new

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    Another part to install is the proper rear bumper as below.
    Will need to cut the old rubbish off and weld this new one on.
    A jig of square tubing will be made to keep alignment and all dimensions correct as it is now for the "bak" fitment. (well I think that is how it should be done)
    Just trying to get my head clear for a few days and forget about Shackle Bushes till Monday when I will get the holy grail of pushers or pullers

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    Defender Kalahari
    Series 3 SWB
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    Series 1 Station Wagon 88''

  5. #45
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    Default Series 1 Full restoration (5 year plan)

    Tip #1 - cut your replacement bushes in half.......
    Tip #2 - make a jig that bolts on the existing tub mounts before you cut anything. You want to bolt to the front tub supports (back of the seat box)
    Tip# 3 - steering relay sleeve is just a piece of schedule water pipe. I’ll try remember to get sizes for you
    Last edited by GaryFrank; 2019/06/01 at 09:19 PM.

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  7. #46
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    Default Re: Series 1 Full restoration (5 year plan)



    DIY

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  9. #47
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    Default Re: Series 1 Full restoration (5 year plan)

    Quote Originally Posted by GaryFrank View Post


    DIY
    Great progress, mate!!
    Cheers,
    John

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  11. #48
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    Default Re: Series 1 Full restoration (5 year plan)

    ... are those shackle bushes hard steel ?
    ... or couldnt you put a hacksaw blade through
    and then fasten upside-down into hacksaw ...
    etc

    Last edited by BushNomad; 2019/06/02 at 07:46 AM.
    ... Land Rover Owners dont idle long ...

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  12. #49
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    Default Re: Series 1 Full restoration (5 year plan)

    I normally burn the rubber out to get the inner sleeve out and then cut the outer sleeve with a hacksaw

  13. #50
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    Default Re: Series 1 Full restoration (5 year plan)

    Quote Originally Posted by GaryFrank View Post
    I normally burn the rubber out to get the inner sleeve out and then cut the outer sleeve with a hacksaw
    Im sure the tactic works but ...
    ... must be smokey business ...
    ... Land Rover Owners dont idle long ...

    2002 Defender 130 DC HCPU. : Own the road...Any road
    ‘1981 R-Rvr Classic 2-Dr 3.5L V8... The Greatest Rover.
    ‘1975 Series3 88 PUP... Simply Classic...
    ‘2017 Metalian Mini ... A Home from Home

    * The Monarch of the Glen *http://www.4x4community.co.za/forum/...1&d=1507751251

  14. #51
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    Default Re: Series 1 Full restoration (5 year plan)

    I cut them out with a hacksaw then pressed them out. Eventually they shot out.
    Getting them back is a problem. To late to cut them now.

    Thanks Gary, I see the relay at the machined lower end is 66.3mm.
    The chassis roughly is 110 height and 70 for the sleeve, but I will wait for in the week please.
    Defender Kalahari
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  15. #52
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    Default Re: Series 1 Full restoration (5 year plan)

    Stinky smoke

  16. #53
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    Default Re: Series 1 Full restoration (5 year plan)

    Fantastic thread, thank you!
    Subscribed.
    Guillaume
    Fortuner Epic 4.0 V6 AT

  17. #54
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    Default Re: Series 1 Full restoration (5 year plan)

    WELL, that was easy, really easy.
    Shows you, walk away and try another day.
    No need for freezer and sukkel

    High tensile steel threaded rod M12. Special long nuts, Power bar and they are all planted into the chassis.
    Next job

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    Defender Kalahari
    Series 3 SWB
    Series 2 SWB (Near Future)
    Series 1 Station Wagon 88''

  18. #55
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    Default Re: Series 1 Full restoration (5 year plan)

    Great looking work!!

    I am planning on doing the rear chassis bushes on my S2A this weekend - do you have a photo of the M12 threaded rod setup (are you using washers etc as well as nuts)? Did you just buy this at a normal hardware store?

    Thanks a million!

  19. #56
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    Default Re: Series 1 Full restoration (5 year plan)

    nice progress Greg. those schackle bushes are not that old. fitted in 2012 when the springs replaced and maybe 3000km max use over 4 years.
    Luke aka Jedi

    1954 Landy Rover Series 1 86"- Rambling Rose
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  20. #57
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    Default Re: Series 1 Full revamp (5 year plan)

    I have been away so need to get back into this "hobby"

    I want to cut off the rear cross member and install the new one.

    How do you make a jig.
    1. Is the jig only to hold the rear sides in place to stop twisting and opening up.
    2. Is the jig only to line everything up as it is now.

    I bought some 32x19 steel to use as a jig but cant find info on how to build a jig.

    @ Gary Frank, the size diameter of the steering relay, have you found the size pipe yet ?
    PLEASE


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    Defender Kalahari
    Series 3 SWB
    Series 2 SWB (Near Future)
    Series 1 Station Wagon 88''

  21. #58
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    Default Re: Series 1 Full revamp (5 year plan)

    Quote Originally Posted by imgreg View Post
    I bought some 32x19 steel to use as a jig but cant find info on how to build a jig.
    There is no hard and fast "this is how you build a jig" info out there. For a one-off job, just wing it.
    All you need to do is make it so you can remove the old piece and fit the new one with accuracy.
    Cheers,
    John

    Rover P6
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  22. #59
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    Default Re: Series 1 Full restoration (5 year plan)

    My RCM jig bolts to the tub mounts (seatbox area) and rests on the tub supports. Will try remember to take a pick..... and measure that pipe

  23. #60
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    Default Re: Series 1 Full restoration (5 year plan)

    Quote Originally Posted by GaryFrank View Post
    ..... and measure that pipe
    It's a 6m length, Gary...
    Cheers,
    John

    Rover P6
    Land Rover Discovery II Td5 Manual
    Range Rover P38 HSE
    Moto Guzzi LeMans
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