Pajero Gen 2 restoration - Page 4





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  1. #61
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    Default Re: Pajero Gen 2 restoration

    I had an hour this afternoon spare, so I sanded down the resin to get rid of all the high and uneven spots.

    Looking good so far.

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    Tomorrow I will add bodyfiller to the surface.

    I am still working on the final layout of instruments and lamps which will dictate how I will do the face. Currently I am leaning towards making a polycarb faceplate that will fit into the "frame" and rest on the resin face.

  2. #62
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    Default Re: Pajero Gen 2 restoration

    Finished cleaning up the resin surfaces today. I think this layout will work best with the available space and faceplate functions.

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    The hooter switch is just a placeholder. The switch to activate the VSR and lock in the second battery system will be located there.

  3. #63
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    Default Re: Pajero Gen 2 restoration

    I had some time between all my projects to work on the gauge pod. I put it on the back burner a bit as I had to think how to make the gauges fit.

    I made some section hand sketches to get my thoughts in order and a plan of action finalised.

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    So based on the previous layout, I marked out what will go where.

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    Drilled out the corners of the polycarb section.

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    and cut out the section for later reuse as a moulding surface when I will bend the polycarb section.

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    Double checking everything to make sure I am on track.

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    It was at this stage that I realised my intended plan is good, but the way to achieve it will require that the front panel be removed as a separate section. So out came the front panel.

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    Today I decided to lay down some fibreglass to start the new plinth for the front panel to rest on and get the front panel to thickness.

    Making some backing for the edges and getting the curvature in place.

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    First layers down and looking good.

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  5. #64
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    Default Re: Pajero Gen 2 restoration

    Wow, due to this restoration project I was gifted an air jack! It did pass a sniffer dog inspection so it should be good.

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  6. #65
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    Default Re: Pajero Gen 2 restoration

    I had a free hour and spent it cutting out and smoothing down the new gauge pod faceplate.

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    I am also starting work on the backdoor fold down shelf. Two external faces I made a while back with a new layer of fibreglass added over the weekend.

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    Now I need to sandwich these together with some bonding resin paste to get the faces running parallel.

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    Last edited by mygoggie; 2020/06/10 at 08:34 PM.

  7. #66
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    Default Re: Pajero Gen 2 restoration

    You are an inspiration.
    Jakes Louw
    2012 Jeep Sahara Unlimited 3.6 V6
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  9. #67
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    Default Re: Pajero Gen 2 restoration

    very cool. Well done.
    Walter aka "Meerkat"
    slightly modded 02' 105 series 1FZ-FE
    https://www.facebook.com/kepanamibia/


    My heart will always beat to an African drum...

  10. #68
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by AboutAfrica View Post
    very cool. Well done.
    Dankie @AboutAfrica :-)

  11. #69
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    Thumbs up Re: Pajero Gen 2 restoration

    I have had various requests to get my backside in line and start doing all these projects of mine on video as well.

    So please give the poll at the top of this page ^^^ (yes, up there!) a vote so that I can motivate myself!

  12. #70
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    Default Re: Pajero Gen 2 restoration

    The past two days were spent working on the various projects. I managed to complete the fibreglass work on the gauge pod and the backdoor fold down shelf.

    The shelf's two sheets bonded together with bonding resin.

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    The gauge pod's faceplate I wanted to build up so that I can create a lip to hold the polycarb window in place and also create a thick strip at the bottom into which I can mount all the LED lights.

    The white mat is where the polycarb window will come. I wanted to cut it out before creating the lip, but on rethinking, I decided it will be better to resin it all in, add some more layers and router the area to what I want.

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    To seal the back of the area, I stretched some duck tape over the area.

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    All layering done and built up to what should be enough depth to do all the cut outs and holes I require.

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    The one corner of the gauge pod's bottom lip was too thin for my liking so I need to create a new corner. I cut out the incorrect bit and installed a block to form the back of the corner so that I can add new layers on top.

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    The gauge pod itself received another layer of cloth that will form the backing lip for the faceplate.

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    And I left it to set. Alas with the cold weather, that simply did not happen and this morning all the resin was still running. I moved the parts into the sun and by this afternoon everything was more or less cured.

    Next step is cutting, sanding and then smoothing with quality body filler.
    Last edited by mygoggie; 2020/06/14 at 06:25 PM.

  13. #71
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    Default Re: Pajero Gen 2 restoration

    Bad news ... somewhere in the front drive train a vibration has started ... the last thing I do need right now is such a problem.

    Tomorrow I will start hunting for the cause. I really hope it is a simple issue.

  14. #72
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by mygoggie View Post
    Bad news ... somewhere in the front drive train a vibration has started ... the last thing I do need right now is such a problem.

    Tomorrow I will start hunting for the cause. I really hope it is a simple issue.
    Fingers crossed for you, that its a simple (not costly) fix
    1999 Pajero 3500 v6 LWB (Poncho) - Overland/camping project (Build log)

    2006 Ford Ranger XLT Double Cab - Daily

  15. #73
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    Default Re: Pajero Gen 2 restoration

    A quick post. Did the front side of the gauge pod cover this morning as I had some extra resin left over from the water purification project.

    Click image for larger version. 

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  16. #74
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by mygoggie View Post
    Bad news ... somewhere in the front drive train a vibration has started ... the last thing I do need right now is such a problem.

    Tomorrow I will start hunting for the cause. I really hope it is a simple issue.
    I have spent the last two days trying to find the issue. It sounds like a bearing on its way out.

    And then @MariusFourie sent me this link - https://www.4x4community.co.za/forum...-disintegrated

    I climbed back under the Paj and that bearing feels rough. Why oh why did I not replace it? OK, finances, yes, $$$.

    Now onto finding a replacement off the shelf.
    Last edited by mygoggie; 2020/06/17 at 03:43 PM.

  17. #75
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    Default Re: Pajero Gen 2 restoration

    I have contacted my local SKF bearing supplier and asked for a quotation and stock availability on the 6007 sealed bearing.

  18. #76
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    Default Re: Pajero Gen 2 restoration

    Collected the bearing this morning. It is an SKF 6007-2RS1 for future reference.

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    Tomorrow I will start stripping the RH drive and get the bearing replaced.
    Last edited by mygoggie; 2020/06/19 at 11:07 PM.

  19. #77
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    Default Re: Pajero Gen 2 restoration

    The saga continue ...

    I replace the bearing which was not a big job after all. I will make a video of this and put it on my YouTube! channel.

    The vibration got worse ...

    This morning I took the Paj to the propshaft place who replaced the original union couplings on the rear and front shafts. The rearshaft's unions were shot after only about 2000km. So they replaced these again and rebalanced the front propshaft.

    The bad vibration is now gone, but I can clearly feel a bearing or two is not too happy now. So something got damaged ... sigh and another sigh ...

  20. #78
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    Default Re: Pajero Gen 2 restoration

    Please give some advice
    The top bump stops are still hitting after I cut a section off. I'm I correctly assuming the torsion bars are set to high. The front must lower?

    Thank
    Pajero Gen2 1996 2.8TDi LWB

  21. #79
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by hogbeast View Post
    Please give some advice
    The top bump stops are still hitting after I cut a section off. I'm I correctly assuming the torsion bars are set to high. The front must lower?

    Thank
    Yep, you will need to lower it. Maybe turn the socket on the arm one tooth on the torsion bar. It is easy to do with everything assembled. Just slack the torsion bars off, undo the two socket bolts, move the socket onto the torsion bar until it is free of the splines and rotate one tooth. Move forward again and fasten the two bolts and put the bars under torsion again.

  22. #80
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by hogbeast View Post
    Please give some advice
    The top bump stops are still hitting after I cut a section off. I'm I correctly assuming the torsion bars are set to high. The front must lower?

    Thank
    you can always look at the infamous ball-joint flip. Otherwise if you have cut the bump stops you have to turn down the torsion bars a bit.
    Walter aka "Meerkat"
    slightly modded 02' 105 series 1FZ-FE
    https://www.facebook.com/kepanamibia/


    My heart will always beat to an African drum...

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