Thread: County Firewall & Pillar rust repair

Are you using the die grinder to cut the holes???

Originally Posted by isuzurover

Are you using the die grinder to cut the holes???

No, I'm mostly angle grinding, then using the die grinder to finesse
It was handy for working on the bottom of the pillars, now I know how a dentist feels !!

I've finished the passenger side, it was only minor, I welded back the tab I bent out to have a gawk inside the pillar. Then a coat of tetrosyl - after rust treating & priming the inside.



Then the driver side had a piece of angle welded in to support it better.



Then some smaller angle to hold the door seal.



On to the upper part of the driver side footwell. I made a template out of cardboard for the rusted out bit. Also I welded in a plate to fill in the cut out rusty panel.




Then some flashtac weatherproof aluminium/bitumen tape to seal it all up properly. If you put the heat gun over this it fuses really well. ( not necessary in Northern Australia I guess) Have to go sparingly with this stuff- not cheap




The doors are coming along pretty well. I decided to just replace the lower frames & part of the upper, leaving the middle alone as it is fused to the skin pretty well.
I have made some bracing where these are getting welded together as I can't weld it on the side next to the door, so this will make up the strength- and then some. I'll do the 3 sides.




I drilled a couple of holes which adds further strength. Not the finished product but you get the idea.




Cheers,
David

good to see another one live on to see another day, instead of being having the isuzu parts removed and stuck in a rangie or defender. You are aware that the 4 and 5 speed bellhousings are both different?
Andy

Originally Posted by andrew e

good to see another one live on to see another day, instead of being having the isuzu parts removed and stuck in a rangie or defender. You are aware that the 4 and 5 speed bellhousings are both different?
Andy

I knew they were different bellhousings, what I did'nt know is how rare they are & what they cost , plus I needed another clutch plate & slave cyl rod ( longer).
I'll be doing a seperate tutorial on this process if I get inspired..
David

All you need is the bellhousing. The clutch you can make out of a v8 rangie clutch with an angle grinder, just grind the center down a bit. The rod make out of any bit of steel shaft. I did the 5 to 4 a few years ago when my main shaft went pop.

You should be able to swap someone for the 5 speed bellhousing for the 4, as the 5 speed is more rare, and with mods can fit an r380.
I bought my 4 speed bellhousing for $350, and sold the old 5 speed one for $400.

Andy

Originally Posted by andrew e

All you need is the bellhousing. The clutch you can make out of a v8 rangie clutch with an angle grinder, just grind the center down a bit. The rod make out of any bit of steel shaft. I did the 5 to 4 a few years ago when my main shaft went pop.

You should be able to swap someone for the 5 speed bellhousing for the 4, as the 5 speed is more rare, and with mods can fit an r380.
I bought my 4 speed bellhousing for $350, and sold the old 5 speed one for $400.

Andy

That purchase might have been some time ago. Firstly, I rang Ritters as it might have been a new part, no go, they referred me to Fred Smith.Before going to Fred I rang 5 wreckers around the countryside, the most knowlegeable referred me to Ritters . So Fred came up with a s/h housing, clutch & rod for $1200.00 (ish).
Well he does have 17 vehicle registrations to maintain

There should be a few ex army ones pop up by now, mine was one, and i got it from peter at range parts in toongabbi. It was slightly damaged though, the piviot point for the clutch rod was chewed out, nothing i couldnt fix though.

Andy