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  1. #81
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Today was a good day.

    Ben worked on the 130 while I pampered Blink Tank.

    I swallowed hard this morning and got a large FEW tap and die set. Bloody expensive. But we need it.

    Ben have spend this entire day to fit all the wheel bearings and tap out all the holes with lock-tite bolts. It is plain stupid to put just another blop of the stuff in a dirty hole. Next time it will break off.

    He is doing a great job.

    The suspension and axle rebuild was an extremely time consuming job and I have not even got to the gearbox and motor.

    Next week, I will leave that to my son and Ben.

    I need to spend some time at work too.

    We have learned a huge lot from Land Rover enthusiasts on youtube.

    I guess when this car is done, she will be quite tight.
    “The price of stability is unpreparedness.”

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  3. #82
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Biltong

    Your investment in time and money on this project is so appreciated.

    The fact that you are taking the trouble to update us - in real time almost - is also appreciated. There's an army of us out here following the thread with interest and enthusiasm. I've just spent the weekend in SA, if I had had two days extra, I would have been on my way to Bloem. (I'm really good at cleaning parts... ) Maybe next time, if this is still going on.

    You will be ending up with three amazing vehicles at the end of this, and knowledge and expertise that couldn't be acquired any other way. I salute you and your team of friends and relatives.

    Steve
    Ex - 109 SIIA R6 pickup, rebuilt from a kraal find, still thrashing around in the Zim Lowveld.
    1972 88 Safari SW petrol - Mellie
    1995 Disco I 300TDi - Daisy
    Ex - 2003 Face Lift Disco II Td5 auto - d'Arcy. Now living by the sea in KZN.
    2003 Defender 110 Td5 - Bruce
    Ex - 2005 D3 V8. Still in the family in Washington State USA.
    Ex - 2007 Freelander Td4 HSE. Still in the family in Bury St Edmunds, UK


    Life is a journey. Have you determined your final destination?

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  5. #83
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Sigh.

    I was time for me to return to work yesterday and I had to leave Cobus and Ben to continue.

    I had no option but to have the gearbox assembled by a Landy specialist, as I just cannot get to that at the moment. What a pity.

    I really hope that we can progress enough this week to install the entire drive train this weekend, and then this car will at least be running.


    Then it is time for the next one. I am in the process to rebuilt a Td5 motor in the mean time, and need to urgently order some spares.

    I also need to get the auto box sent away for a check.

    I dearly hope my Lexus Van has less problems on the drive train - although I think the gearboxes are both toast. I did order another transfer case.
    “The price of stability is unpreparedness.”

  6. #84
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    And now, just an official word of thanks to all the many oaks who helps to get the van on the road.

    I worked with multiple suppliers and hands, and most of them pulled some heavy weight to get parts sourced.

    My laborers are not fast, but they do the job the way I want: When they walk away, every little thing is perfect - nothing of the typical there is never time to do the job right, but always time to do it over.
    Last edited by biltong; 2021/04/20 at 06:28 PM.
    “The price of stability is unpreparedness.”

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  8. #85
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    By now, the spares on the heap seems like we can build two complete cars from it.

    There were countless of challenges on this first fan because we don't know it up to the last bolt and nut.

    That said, my assemblers made again some progress today, although some it was a time consuming fault that had to be rectified.

    Then disaster struck!

    Cobus had to remove a c-type retainer clip on the side shaft that holds the CV in place, and as he took it off with the pliers, it pinged and launched into outer space.

    F! Those clips are made from unobtanium. You get them with a brand new CV only and to buy a new CV for a clip, is harsh.

    The other part from unobtanium, we somehow got one of.

    So, I had to make a plan. In desperation, I went to a bolts and nuts shop that I know have a few boxes full of random springs. On my way I phoned my oaks on site to measure it with the vernier.

    As I went though the boxes, I got a coil in the waste bin and thought this looks close to the vernier measurement, so I put it on the steel ruler to confirm.

    It seems good enough.

    I held my breath.

    At the shop, the thickness of the wire looked close enough, and I took out the dremel to cut a coil.

    When I fitted it on the shaft, the clip was just a bit too open for my liking, but I guessed the wire diameter was OK. I gently worked it in with the screw driver and the CV clicked home with less than half a balhaar of play.

    Sometimes one needs to improvise a little
    “The price of stability is unpreparedness.”

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  10. #86
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    That's Land Rover passion for you, a heap of attention to detail and a touch of improvisation.

  11. #87
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Almost back on the wheels.

    All the bearings were packed and tensioned. All bolts Locktited.

    Diff cover cameback on.

    Side shafts are in place.

    The axles are now super tight. If you move the diff pinion a fraction the side shafts moves as much.

    I also got the gearbox back, and they did a superb job with the assembly. It feels fantastic.

    Hopefully this weekend we will have the entire drive train back.


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    Last edited by biltong; 2021/04/23 at 04:45 PM.
    “The price of stability is unpreparedness.”

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  13. #88
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Today was a hard day in the shop.

    We managed to put most of the ancillaries back on the motor, get the wheels back on the motor and Cobus started to cut new carpets.

    I bought a very tough carpet with some thick undervelt which was glued together. It looks quite nice.

    The we wanted to put the gearbox back, but there was yet another surprise...

    I was aware the wiring loom of the Lexus one was 'n gemors, but this one had electrical problems too, so yesterday we thought lets just trim all that first while the looms are more accessible.

    Anyway, this is a second round already cutting out stuff we wee was not standard and as we went along we learned that they have done plenty of botched up jobs in the loom.

    The left front headlight was "repaired" one day by bridging it over from the right one. As we went back we found a plug under the dash that was burned out, probably because they powered a set of spotlights initially without using a relay.

    Oaks, to repair that gemors and all the poor connections they made is going to be another huge work. In fact, I don't really know which side to go. I need to get it on the road and through the test, and I do not know If I just have to do my own looms and put in a new fuse box or spend the time and do a proper repair.

    This is the kind of kraaines that puts a vehicle on fire...

    So, today I will spend some time trying to source the best splice connectors I can and get a couple of meters of heat shrink.

    This is not the kind of repairs you can do with tape.


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    Last edited by biltong; 2021/04/25 at 04:45 AM.
    “The price of stability is unpreparedness.”

  14. #89
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Would it not be worthwhile to hit up a scrapyard for a complete harness?
    Cheers,
    John Kilfoil

    Rover P6
    Land Rover Discovery II Td5 Manual
    Range Rover P38 HSE
    Moto Guzzi LeMans
    Aprilia Tuono V2

  15. #90
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Quote Originally Posted by JohnnoK View Post
    Would it not be worthwhile to hit up a scrapyard for a complete harness?
    Unobtanium. Many harnesses are molested. Sad state of affairs.

    I can assure you with my prior experience selling Landy spares, I know all the guys who knows all the Defenders on the scrap heap.
    “The price of stability is unpreparedness.”

  16. #91
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Is that the single nut wheel bearing or two nut, if single did you use the same spacer or did to dial gauge to get the correct spacer for pre load on bearings

    this is why I do every job on my Landy my self don’t get any one to do anything as they never do a proper job

    you getting there slowly
    Last edited by clivemd; 2021/04/25 at 09:08 AM.
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  17. #92
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Quote Originally Posted by clivemd View Post
    Is that the single nut wheel bearing or two nut, if single did you use the same spacer or did to dial gauge to get the correct spacer for pre load on bearings

    this is why I do every job on my Landy my self don’t get any one to do anything as they never do a proper job

    you getting there slowly
    I used the single nut, but removed the spacers.

    And no, I did not use my dial gauge. Did it like I have done for the past 30 years. Tensioning a wheel is like the "feel" you get when you fasten a bolt in aluminium.
    “The price of stability is unpreparedness.”

  18. #93
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Quote Originally Posted by biltong View Post
    I used the single nut, but removed the spacers.

    And no, I did not use my dial gauge. Did it like I have done for the past 30 years. Tensioning a wheel is like the "feel" you get when you fasten a bolt in aluminium.
    normaly when they remove the spacer they go to the double nut
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  19. #94
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Quote Originally Posted by biltong View Post
    Unobtanium. Many harnesses are molested. Sad state of affairs.

    I can assure you with my prior experience selling Landy spares, I know all the guys who knows all the Defenders on the scrap heap.
    lucky I have a brand new TD5 bulk head wiring harness spare but has the 2 fuse box not 3 fuse box by the gear leaver which I was wanting
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  20. #95
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Yes, but it is not a must.

    Quote Originally Posted by clivemd View Post
    normaly when they remove the spacer they go to the double nut
    “The price of stability is unpreparedness.”

  21. #96
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Quote Originally Posted by biltong View Post
    Unobtanium. Many harnesses are molested. Sad state of affairs.

    I can assure you with my prior experience selling Landy spares, I know all the guys who knows all the Defenders on the scrap heap.
    How urgent is it?
    I go back to work in Gabon tomorrow and I can ask one of my colleagues to get me one for you from the UK, but I am only back at the end of June.
    Cheers,
    John Kilfoil

    Rover P6
    Land Rover Discovery II Td5 Manual
    Range Rover P38 HSE
    Moto Guzzi LeMans
    Aprilia Tuono V2

  22. #97
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Day finished.

    So last night I though long and hard how I will repair the wires and as said, ferrules and heat shrink was my preferred method.

    I went to the electrical warehouse this morning and bought many meters of heat shrink and three different sized of ferrules.

    As I had a hard look at where to start, I realised that at least the loom was not melted anywhere, which is a good place to start.

    I started with repairing the most obvious places and as I went along I found it did not take much time to cut, crimp and shrink.

    Soon I was following all the places where tapework was sloppily done, and pulled that all off.

    Most of the tape could be replaced with heat shrink, and in the places where I had to use tape, I used good old Nitto tape that properly stretch when you roll it.

    After a few hours, we decided it is time to test and I installed the battery.

    This included to have the left head light back on the original loom.

    Surprisingly, everything worked. Wipers, all the lights, all the etc and no hot lines anywhere.

    The only thing that did not work, was the hooter. We found a blown fuse, replaced that and got a pop out of the horn. At least there is power. Some spookpis and the horn hooted for a moment, but it is essentially buggered and has to be replaced.

    Right, so the wiring is back to factory. At least if I now want to add extra power points and things for the radio, central locking etc, I can to it the right way, put in a small fuse rail and do a complete new loom that is not spliced into the harness.


    We are far over budget on this project, both in term of money and time.

    Is it wort it? It depends on your reasons I guess.

    The reasons I want these vehicles, are very personal and they need to take us very long into the future.

    This means we need to know the vehicles very well both mechanically and electrically and we need something that is right.

    Although this is a code 3 vehicle, and from that perspective probably not worth the effort, we had to start somewhere.

    For us, I think this was a good call.
    Last edited by biltong; 2021/04/27 at 04:43 AM.
    “The price of stability is unpreparedness.”

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  24. #98
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Yesterday, again a hickup.

    As we wanted to install the gearboxes, I had to sort out the links for low/high range and CDL.

    Obviously no surprise, but the bushes were so kapot that it was not possible to even get a selection on CDL.

    Under normal circumstances, I would simply have started up the lathe and made them, but sadly the lathe is still in another place for storage.

    To install those bushes with the boxes in place, is not a kind of sukkel I am willing to do. Today I either need to source, or have bushes machined. Since I not have three Landys with the same sestup, six sets please of I have to make.


    At least there was lots of other work to continue with, and we decided to replace the suspension bushes on the radius arms of Blink Tank.

    The above was an interesting exercise. As you know, Blink tank was crabbing as the rear axle was twisted by 1⁰.

    As we removed the LHS radius arm, it was clear there was some stress there as I had to hammer out the front bolt.

    As the old bushes came out, we could clearly see the cracks in them.

    With the bushes replaced, we found that the holes did not match, and we had to pull the axle forward by about 6mm for the bolt to slide in.

    However, on the RHS, the holes all lined up immediately.

    I believe the issue on Blink Tank is now sorted - with standard bushes and not the bloody expensive custom "off centre" bushes as suggested by the suspension guru.

    Mean while, the GF painted the roof lining with PVA. It starts to look good, and this solutions will be "rolled out" to the rest of the pannels.

    Cobus pulled in the wiring for the central locking, and on testing found that the rear actuators needs to be repositioned, as they can lock, but not unlock the doors.

    We also filled the front steering balls with lots of grease.
    Last edited by biltong; 2021/04/28 at 06:45 AM.
    “The price of stability is unpreparedness.”

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  26. #99
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Yesterday, I had to excuse Uncle Ben for a few days to sort out one of his own cars, so we are now short of a capable pair of hands.

    However, I managed to put back almost all of the bolt-on items on the engine so that it can be ready for the big day.

    I sourced the gear link bushes for the TC and we hope to mate that all today.

    Cobus painted the roof lining, and the door trim panels and fixed the front seats so that the normal adjustments works smooth again.

    I also got new headlight units.

    All that I can say is: What a journey it has been up to now.
    Last edited by biltong; 2021/04/29 at 06:39 AM.
    “The price of stability is unpreparedness.”

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  28. #100
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    Default Re: Project 2: Defender 130 V.3-Amigos ??

    Today, we could mate the gearbox and transfer, test the three switches and make sure the HR/LR/CDL lever works perfect.

    That took some time.

    We then moved the boxed in under the vehicle and matched the plugs with the wiring harness.

    No surprise, there was one wire wire we could not match, and we found that on this model the Low Range Switch was not connected to the ECU.

    What made it confusing, was that the wire was plugged into the ECU, but nothing came out of the loom. I opened the loom, and found no wire there.

    Back in the cab, I pulled on the wire and found there was only a stub left, the rest was cut off.

    From prior experience, I know that some Defenders did not have this switch connected. We will pull in a new wire for this reason that when I put in a NNN ECU, there are two maps for throttle response - handy to make the low range smoother.

    We will also pull in wires to activate the Cruise Control on the ECU.

    We also found some more plugs with broken wires that needs to be repaired - although I have no idea yet what it connects to.

    By now, we are pretty tired, so I called it a day just after lunch.

    I have been working on this van 7 days a week from day 1 and we are on week 4 now.

    Do know that we should be well familiar with the Defender after this rebuilt. I guess just about every single problem a Defender can probably have, this one had.
    “The price of stability is unpreparedness.”

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