The Grey Ghost - a Rolling Restoration

[grey_ghost]

Hi All,

I thought that it was about time that I created a thread - showing the restoration of my 1961 Series 2.

It is a rolling restoration (and far from complete). I am an absolute beginner at this and have already received a lot of help from this forum.

In no particular order (and it's hard to take photo's of some of the mechanical stuff)..

Loaded and ready for the trip home:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0263.jpg

Broken down on the way home...
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0270.jpg

At Home:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0019.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0020.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0021.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0022.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0023.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0024.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0026.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0027.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0028.jpg

Hand Brake Lever
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0278.jpg

Wheel - Before Cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0281.jpg

And After Sanding/Cleaning (did this to all 5 wheels):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0285.jpg

Hi-Low Boot (what remains of it...):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0299.jpg

Gear Lever Boot (what remains of it...):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0300.jpg

Old vs New Gear Lever Boot:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0301.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0302.jpg

Hi-Low Boot & bracket:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0303.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0304.jpg

Behind Instrument Panel - Wasps nest?
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0305.jpg

Underside of Gear Box - missing a rubber grommit (since installed):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0306.jpg

Underside of Gear Box - before cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0011.jpg

Underside of Sump - before cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0013.jpg

Underside of PTO/Gearbox - during cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0014.jpg

Hand Brake - before cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/SANY0015.jpg

Top of Petrol Tank - before and after cleaning, painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0311.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0312.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0496.jpg

Top of PTO - before and after cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0314.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0319.jpg

Front Valance - before and after (painted):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0320.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0340.jpg

Second Hand Bull Bar - before, then cleaned:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0322.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0326.jpg

Original (Broken) Lights:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0325.jpg

Rear Backing Plate - Before, Cleaned:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0327.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0329.jpg

Crank Handle - Before & Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0331.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0385.jpg

Puller that I used to remove the very stubborn drums:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0343.jpg

Axle Caps soaking and painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0349.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0360.jpg

Wheel Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0352.jpg

Seat Panels Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0353.jpg

Wheel Nuts Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0355.jpg

Drum Before, Cleaning, Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0357.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0367.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0380.jpg

Old Lights being removed:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0364.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0365.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0368.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0369.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0370.jpg

New Lights being installed:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0371.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0372.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0374.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0375.jpg

Top of Seat Box - Cleaning,Sanding needed here:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0405.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0406.jpg

Broken Axle Straps & plates before, painted, installed:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0422.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0443.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0501.jpg

Front Diff - Before/After cleaning:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0430.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0433.jpg

Various Chassis - Before, Cleaned, Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0434.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0491.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0492.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0438.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0431.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0432.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0439.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0440.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0441.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0451.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0495.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0500.jpg

We have mirrors:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0444.jpg

New Rear Brake Lines (and master cylinders re-sleeved):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0452.jpg

Rear Prop Shaft - before/after:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0453.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0455.jpg

Rear Brakes Installed:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0464.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0465.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0466.jpg

Leaf Springs - Before, Cleaned, Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0476.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0480.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0481.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0479.jpg

Rear Shocker - Before & New Installed:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0485.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0493.jpg

Floor Panels - Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0490.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0499.jpg

Leaf Spring Removal - what a task... Have installed new no photo yet.
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0503.jpg

Interior Bits Before & Painted:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0522.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0507.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0526.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0536.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0528.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0529.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0531.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0532.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0534.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0559.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0560.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0561.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0564.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0594.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0598.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0599.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0602.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0656.jpg

Passenger Door - Before, during and after:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0510.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0511.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0512.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0513.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0514.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0515.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0516.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0517.jpg

Removing vent rubber:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0521.jpg

Exterior Panels:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0530.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0533.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0551.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0562.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0565.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0573.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0574.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0596.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0597.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0604.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0644.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0655.jpg

Brake Line Protection Plate:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0539.jpg

Seats - Recovered (and bottoms painted):
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0549.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0567.jpg

Brake Res - Before & After:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0570.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0572.jpg

Engine Bay:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0583.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0584.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0645.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0585.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0600.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0613.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0620.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0621.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0622.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0628.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0646.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0635.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0636.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0639.jpghttp://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0640.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0652.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0653.jpg

Top of Gearbox - Before/After:
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0587.jpg
http://s1155.photobucket.com/albums/p549/tomb1971/The Grey Ghost/IMG_0633.jpg

[VK3UTE]

Thanks Grey Ghost! It's great to see your progress, keep the pics coming:)

Cheers Simon

[carby]

Top notch. Ive done these things sporadically and lamented not taking a before shot so I could share the transformation.

Keep it coming! You have inspired me to shoot mine before I start the sodablasting.

c

[JayBoRover]

Good on ya Grey Ghost for taking the time to share your project with us.:)
How about telling us a bit about it? Do you know anything of the history? It looks like a fairly good one to start from.

[grey_ghost]

Hi All,

Unfortunately I don't know much about the Grey Ghost.

I Purchased it off e-bay from a farmer in Benella (country Vic).

His name was Frank and he's 80 years old, still working 400 acres of sheep.

He was the second owner, and had never had it registered.

He bought it off another Benella farmer and "drove it home via the paddocks".

He was selling it because he just didn't need it anymore.

I took it for a test drive, trying all gears and making sure that it worked in Hi and Low range. I crawled underneath it looking for rust (which there wasn't much apart from surface rust)

I picked it up in March 2011 and have been slowly working on it since.

It's a 1961 Series 2 - with it's original engine still in it.

I discovered that it was a series 2 via a website (Sweedish I think - can't remember now). I also discovered that it was a Series 2 because of the rear wheel master cylinders - mine are 3 bolt, and apparently only Series 2 had them. I've been told that Series 2A onwards have 2 bolt?

That's about it for the moment.

Regards,
The Grey Ghost.

[Lostkiwi]

Looking through those pic's makes me want too start another one!!:);)

Looking good T B keep the pic's coming:thumbsup:

[gromit]

I discovered that it was a series 2 via a website (Sweedish I think - can't remember now). I also discovered that it was a Series 2 because of the rear wheel master cylinders - mine are 3 bolt, and apparently only Series 2 had them. I've been told that Series 2A onwards have 2 bolt?



Grey Ghost,

Looks like you've done a lot of work on it so far.

Did you manage to get replacement rear wheel cylinders, it looks like it from the photos. I've overhauled the cylinders on my '60 Series 2 but only as a temporary measure (pistons are pitted). I tried locally to get replacements with no luck so was considering longer term changing the backplates to the later type with 2 adjusters (2-bolt wheel cylinder) or machining up stainless pistons.

I notice yours has a PTO on the gearbox but couldn't see if it was connected to anything.

Good to see another one making it back onto the road, it'll be a while before mine hits tarmac but at least it's moving and the brakes should be working again soon....


Colin

[grey_ghost]

Hi Grommit,
I got my rear wheel cylinders re-sleeved by a company in Melbourne.
As you can see from the pictures - they did a fantastic job (look brand new).
I did find some replacement units in the UK - for $150 pound, EACH.
I could not find local replacements, despite ringing every company that I could think of.
I also contacted all of the Australian Ebay sellers and everybody said "No Longer Available".
I had read (on this forum) numerous arguments about "replacement vs re-sleeve".
I went the re-sleeve because I didn't have any choice!
I also investigated changing the backing plates - but I decided to give the re-sleeve a go and see how that went.
I haven't bled the brakes yet (which I am told can be fun).

The PTO isn't connected to anything - I haven't even tried it yet to be honest. Another thing to add to the list of jobs!

Regards,
The Grey Ghost

[wrinklearthur]

I haven't bled the brakes yet (which I am told can be fun).

Hi Grey Ghost

When you do your bleeding of the brake, I would reverse bleed them from the wheels back to the reservoir, this forces any air bubbles upwards and out of the high spots in the brake lines.
.

[gromit]

Hi Grommit,
I got my rear wheel cylinders re-sleeved by a company in Melbourne.
As you can see from the pictures - they did a fantastic job (look brand new).
I did find some replacement units in the UK - for $150 pound, EACH.
I could not find local replacements, despite ringing every company that I could think of.
I also contacted all of the Australian Ebay sellers and everybody said "No Longer Available".
I had read (on this forum) numerous arguments about "replacement vs re-sleeve".
I went the re-sleeve because I didn't have any choice!
I also investigated changing the backing plates - but I decided to give the re-sleeve a go and see how that went.
I haven't bled the brakes yet (which I am told can be fun).

The PTO isn't connected to anything - I haven't even tried it yet to be honest. Another thing to add to the list of jobs!

Regards,
The Grey Ghost


Thanks for that info.

They looked a bit thin in the wall section to re-sleeve. My bores were OK but the pistons need to be replaced at some point.
I spoke with 4-Wheel Drives and was told they hadn't been available for years, the last Repco ones he sold were $250 each !

I believe they are from a Rover car so it might be possible to get them via the Rover club. That section with the cover plate on the side that the shoes rest against is for the handbrake mechanism on the car. I'm just not sure which model Rover.....

Apparently the problem is usually that the bleed nipple shears a section out of the back and then they are useless. Pistons can be re-made and the later kit fits (except for the boots which are a bit tight).

Colin

[bob smith]

Tom.
A lot of work, and still a bit to go. Looking really good.Good luck and hopefully you will be driving around in the not too distant future.
Regards Bob Smith

[grey_ghost]

Hi All,

Work has been crazy this week - so not as much work done as I would like.

This week (so far) - I have installed a tail gate (kindly donated by LostKiwi) :)

Tail Gate - BEFORE:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0672.jpg

Tail Gate - During Sanding/Cleaning:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0675.jpg

Tail Gate - After adjusting (3 hours) and Painted:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0676.jpg

Tail Gate - Chains Installed (new nuts, bolts, washers, etc):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0679.jpg

Radiator - Before:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0629.jpg

Radiator - AFTER being Re-cored:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0677.jpg

Regards,
The Grey Ghost

[JDNSW]

You are putting a lot of work in to it!

Is there a reason you did not use the standard scroll hooks to connect the tail gate chains to the tailgate? Should be noted that the chains should be inside a canvas tube to prevent rattles and paint wear (took me about half an hour each with some scraps of canvas and a sail needle and palm - turn it inside out after sewing for neatness).

John

[grey_ghost]

Hi John,

There are a few reasons why I didn't use the standard scroll hooks:

* I don't have any !
* I don't know what they even look like!!

:(

This is my first Series Land Rover, and I haven't seen another one as a reference!

Could you possibly post a pic?

Thanks for the tip - I had thought about covering the chains. I was just going to try and purchase a plastic sleeve from Bunnings (or someplace). But Canvas would certainly suit the car much better. Thanks again for the tip!

Regards,
The Grey Ghost

[Recy Mech]

Best I could come up with at short notice, I give you one scroll hook:

http://i587.photobucket.com/albums/ss319/reccymech/332445-LOWER-TAILGATE-CHAIN-HOOK.jpg

[grey_ghost]

Hi Recy Mech,
Thanks for the picture - (silly question) is this a scroll hook from a Series 2?
How does it attach to the chain (at one end) and the bracket on the tail-gate at the other end?
Regards,
The Grey Ghost

[Recy Mech]

I posted the piccie and straight away thought you ignorant pr1ck no instructions on how to at least assemble.

The plate with the holes is attached to the tail-gate. The chain is attached to the body and the 'free' ends then go around the scroll/pig-tail to attach the tail-gate. The beauty of this system is that you can adjust the tail-gate angle by selecting the appropriate link in the chain.

I hope the above is understandable.

[peterg1001]

You are putting a lot of work in to it!

Is there a reason you did not use the standard scroll hooks to connect the tail gate chains to the tailgate? Should be noted that the chains should be inside a canvas tube to prevent rattles and paint wear (took me about half an hour each with some scraps of canvas and a sail needle and palm - turn it inside out after sewing for neatness).

John

I used some fat shrink wrap from Jaycar. It slips over easily, then a heat gun gets it nice and tight.

It looks good, too.

Peter

[B.S.F.]

A piece of old bicycle tube works just as well.I never used anything else.Easy to push together when you want to shorten the chain.
W.

[JDNSW]

If you look at the top bar on this page, about the middle is "Shop". This, if you click on it, brings you a list of bits and pieces that are available from AULRO (and profits help keep the website going). In the LH column is "CD Based Manuals". The one you want is SERISIICD. This contains both the workshop manual and the parts manual, as well as various other bits and pieces.

For the work you are doing on your Landrover, you really should have this (I had the hard copy manuals before this site existed!). In many ways the parts book is as useful as the workshop manual, if not more so, as it has detailed pictures of almost every part, and shows the order and way they go together (but use a little caution - where parts have changed, the illustration often has not, just having different part numbers from a particular chassis number; this will be less of a problem with the Series 2, as they had to do a whole new book for it - and there were relatively few changes compared to the number that had accumulated by the end of 2a production!).

Hope this helps,

John

[Lostkiwi]

Thats a good looking Tail gate:) Looks a lot better there than sitting out in the paddock!!
The radiator also looks good ... mine is in a bad way!!!:( but at this stage is not leaking [touch wood]
I have to start looking for a replacement Anyone suggest a good place in Aussie to buy a complete radiator?......or can you buy just the core?

Keep those pic's coming

[grey_ghost]

Hi John,
Thanks for the suggestion - I hadn't looked at the shop section.
I've purchased the SeriesIICD - to add to my existing collection (you can never have too many manuals in my opinion - as sometimes they have different pictures which always helps). I already have the Haynes Workshop, Haynes Restoration & also an original "Land Rover Series II and IIA Workshop Manual" (c) 1958. I also think that it's a great idea to support this great web-page.

Hi LostKiwi,
The TailGate was a god-send. Looks great now that it's finally installed & painted! I had my radiator re-cored after trying to decide the "old vs new" argument. It certainly wasn't cheap to re-core it...

:)

Regards,
The Grey Ghost.

[peterg1001]

I had my radiator re-cored after trying to decide the "old vs new" argument. It certainly wasn't cheap to re-core it...



I went to the local radiator place, and they had a look and told me not to bother, it would be cheaper to replace. I think Gary CLR has got new ones for $350.

Peter

[drifter]

I went to the local radiator place, and they had a look and told me not to bother, it would be cheaper to replace. I think Gary CLR has got new ones for $350.

Peter

Just be careful buying his ones. They are for the Series 3 and are not as thick as the ones used in the Series 2. They also have different diameter hose attachments. You will need the Series 3 radiator hoses from him if you ever expect the hoses to attach to the engine AND the radiator.

Been there, done that.

Edit: AAANNNDDDddddd you will find that, because the radiator is thinner, the rear face of it doesn't protrude as much into the engine bay (hence also the need for the Series 3 hoses with the longer sections) and the fan shroud will not line up with the fan too well. The shroud doesn't fit low enough on the radiator and, at its lowest setting, will be attacked by the fan when you first hit that starter button. Been there, done that, too.

[akelly]

Great stuff Grey Ghost - you've shamed me into getting back into my IIA!

Cheers,

Adam

[grey_ghost]

Hi All,

I managed to do some small jobs last night (once the boss had fallen asleep..!)

Replaced the thermostat rubber pipe (soapy water worked a treat - thanks guys)
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0680.jpg

It's not the final solution (I'm trying to find some canvas, which will look the part). $8 from Clarke Rubber - works a treat!
https://www.aulro.com/afvb/

Got some ute tread strips from pfillery - before:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0682.jpg

And after sanding/cleaning:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0685.jpg

That's about it for this update.

Regards,
The Grey Ghost

[peterg1001]

You'll find that the old gal on the tread strips oxidises very quickly, and will look pretty shoddy in six months time.

If you spray them with etch primer, then paint them with Killrust Aluminium paint (the brush-on variety), they'll be indistinguishable from gal and will look tops.

Peter

[wrinklearthur]

You'll find that the old gal on the tread strips oxidises very quickly, and will look pretty shoddy in six months time.

If you spray them with etch primer, then paint them with Killrust Aluminium paint (the brush-on variety), they'll be indistinguishable from gal and will look tops.

Hi Peter

I have seen brass object highly polished then spray painted with clear coat of lacquer, which has lasted for years.
I wonder if that would work for Galvanised items ?
.

[grey_ghost]

Hi All,

I got up early this morning. Sanded & cleaned the ute tray floor. I am still trying to decide about the tread strips - I think that I will be painting them, but which colour? Grey (the same paint colour as already used), Aluminium (as a highlight) or Black (as a highlight). What ever colour is chosen - I will use etch primer and a rust inhibiting paint (like rust-guard or kill-rust).

The photo's here show some missing tread strips - which I plan to install soon. I will also mask-up and paint the existing strips.

Ute Tray - During Cleaning:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0689.jpg

Ute Tray - After Painting:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0691.jpg

Regards,
The Grey Ghost.

[peterg1001]

The photo's here show some missing tread strips - which I plan to install soon. I will also mask-up and paint the existing strips.


You might consider drilling out the rivets, removing the existing strips and cleaning and painting everything separately.

You'll get a much better job.

Peter

[wrinklearthur]

You might consider drilling out the rivets, removing the existing strips and cleaning and painting everything separately.
You'll get a much better job. Peter
Hi Grey Ghost

Seeing where you are at, I would second what Peter has said, get some new rivets and remove the remaining strips to paint the floor in one go.

Before you paint, would you be interested in a little experiment for me?
looking at those sharp little dents in the floor, I would like to know if they can be flattened back.
Using a jack and an insulator ( piece of hard wood ) push up on the point of the dent under the floor, then using some freeze spray (the type they sell at JayCar for electronic fault finding) , spray the centre of the dent to freeze it.

I am wondering if this would take some of the stretch out of the material around the dent.
.

[Casper]

Hi Grey Ghost

Seeing where you are at, I would second what Peter has said, get some new rivets and remove the remaining strips to paint the floor in one go.

Before you paint, would you be interested in a little experiment for me?
looking at those sharp little dents in the floor, I would like to know if they can be flattened back.
Using a jack and an insulator ( piece of hard wood ) push up on the point of the dent under the floor, then using some freeze spray (the type they sell at JayCar for electronic fault finding) , spray the centre of the dent to freeze it.

I am wondering if this would take some of the stretch out of the material around the dent.
.
The short answer would be NO.

This is the long answer why,

The freeze spray would shrink the Ally in the short term while it was cold but it would just go back to the same size it was before when it warms up to room temp again and if you have taken the dent out then it will push back out either where it came from or somewhere else in the panel causing distortion and deforming the panel.

The best way to flatten a panel like that out is to either use an English wheel with 2 flat rollers (rather hard to get completely flat) which will effectively spread the stretched metal out through the whole panel or a panel roller, (3 wide rollers, 2 bottom and 1 top that is normally used to roll sheets into a cylinder but I have used them to roll sheets flat before) or to replace the entire panel.

You can try just a hammer and dolly as long as they are not too deep but again, it's alloy, it stretches a lot more than steel and you need somewhere for that stretched metal to go.

Cheers Casper

[grey_ghost]

Hi All,
Last night a mate and myself built a removable Merbau floor for the Grey Ghost.
The theory being - it's removable, it helps protect the tray floor and above all else it looks good! I will regularly remove it, and then house down/sweep the tray floor.

3 hours work:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0700-1.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0702.jpg

To the victors the spoils! (About 8 each) :wasntme:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0696.jpg

Regards,
The Grey Ghost

[pfillery]

Looking good Tom!

Nice idea too. I plan to go the marine carpet in my S3 but the wooden floor has got me thinking now. Hmmmm.

[Wolfman_TWP]

Looking good Tom!

Nice idea too. I plan to go the marine carpet in my S3 but the wooden floor has got me thinking now. Hmmmm.

If you are going to go for a wooden floor. Just make sure that it's properly sealed (The wood). As wood has a tendency to soak up water. And that adds more weight to the Landy. A friend had a tabletop with a metal frame and wood in the middle of it, and it got really heavy in the back when it rained. Due to the wood being unsealed, and it soaking up the water .. So he replaced that with checker plating.. (Much lighter)

Wolf

[grey_ghost]

Thanks for the advice - couldn't agree more.
I am going to lightly sand the wood, and the coat it (all over, top/bottom) with a MINIMUM of 2 coats of Linseed Oil.
Plus (if I can convince the wife) the Grey Ghost will be kept in the garage as well...
The company car can stay out in the rain...
:wasntme:
Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Got up early today and did some more work on the Grey Ghost.

Received Spare Wheel Holder parts (thanks pfillery) last night:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0708.jpg

And now after light sanding/cleaning:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0715.jpg

Did the first (of many) coats of Linseed oil:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0711.jpg

And lastly discovered this at Bunnings last night. I have lightly sanded/cleaned all of the tread strips and given them a coat of this.
Only time will tell how well it lasts - I will post a picture once the strips have dried (at least 2 coats):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0714.jpg

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Managed to do a little bit more work today.

There was some OLD foam underneath the battery in the bottom of the battery box:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0718.jpg

And now there is some new foam:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0719.jpg

Sanded, Cleaned, Masked, Painted - Drivers door:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0727.jpg

Sanded, Cleaned, Painted - Rear Cross Member:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0729.jpg

That's about if for this weekend.

Regards,
The Grey Ghost

[The ho har's]

OH WOW...


thanks for directing me to this thread Tom:D

The Grey Ghost looking absolutely fabulous:)

same colour as my 'jack', pic in sig;)

Mrs hh:angel:

[grey_ghost]

Hi All,

I did a fair bit of work on the Grey Ghost over the weekend - thanks to a mate who always lends a hand!

In Summary:

* Remove 4 x existing tread strips (drill out pop rivets) from ute tray
* Sand/Clean/Paint 4 x existing tread strips
* Sand/Clean/Paint - Radiator Cap (clear coat)
* Sand/Clean Bonnet bracket
* Bonnet - reinstall 4 x rubber strips
* Re-Fit bonnet (with new bonnet retaining clip)
* Install bonnet protection strip
* Install Radiator, cowling, support bracket, all new hoses.
* Paint inside drivers door
* Install Drivers Door (new hinge kit, grease, cut/fit new lock, sand/paint brackets, adjust).
* Install Passenger Door (new hinge kit, grease, cut/fit new lock, sand/paint brackets, adjust)
* Refit drivers rear U-Bolts.
* Make 1 x tread strip for top of tray
* Clean Gal on underside of ute capping.
* Clean spare wheel bracket.
* Assemble/Install Drivers Vent

That's what I can remember anyway!

Tow Bar - Before:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0733.jpg

Tow Bar - After: http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0753.jpg

Radiator (Re-cored). Install + new hoses. Painted Cowling, fan blades. Install new Fan Belt: http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0739.jpg

Door Handle Brackets (Before/After): http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0737.jpg

Install Door Handles - new (including a lock). Had to modify door slightly: http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0743.jpg

Radiator Cap (Cleaned/Painted Clear Coat): http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0745.jpg

Bonnet Bracket (Cleaned): http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0746.jpg

Bonnet Strip Installed: http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0747.jpg

Bonnet (Painted black on the underside, grey on top): http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0748.jpg

[akelly]

It's not the final solution (I'm trying to find some canvas, which will look the part). $8 from Clarke Rubber - works a treat!
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0681.jpg

Hey mate - just a note on the chain covers. I did something similar on mine, but used bike tubes. The problem with anything 'watertight' like rubber or the treated canvas you have used is that the covers fill up with water and rust the chain, then when you open the tailgate you get rusty water spilling all over the place! I recommend punching a couple of holes around the halfway mark of the covers to prevent this.

Cheers,

Adam

[grey_ghost]

Hi All,

I did more more work on the Ghost this weekend...

Installed all of the tread strips (approx 100 rivets later):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0765.jpg

Installed the spare wheel holder:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0771.jpg

Removed the door stoppers:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0763.jpg

Removed washers, nuts, bolts for door stoppers and clean (old vs new):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0772.jpg

Sand/Clean/Clear Coat - Battery Holder brackets and Door Stoppers:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0776.jpg

Sanded/Cleaned/Painted - Drivers Foot-well:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0768.jpg

The pop-riveting was fun - I'd never used a pop rivet gun before...

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Did some cosmetic work during the week..

Removed the Grill:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0783.jpg

http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0781.jpg

Sanded it down, painted with 3 coats of clear coat, new Fly-Wire:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0791.jpg

Installed (with repainted original Land Rover badge):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0793.jpg

That's about it for the moment,
The Grey Ghost

[grey_ghost]

Hi All,

Another cosmetic job - which still took over an hour to do.

Oil Dip Stick (before):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0798.jpg

Sanding (by hand), cleaning, 2 coats of Clear Coat (after):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0799.jpg

Regards,
The Grey Ghost

[Lostkiwi]

Looking really good now!!:cool::thumbsup:..Keep going

Must be getting closer too hitting the road?

[VK3UTE]

Loving the thread thanks Grey Ghost, fantastic inspiration!:)

keep it coming

Cheers Simon

[grey_ghost]

Hi All,

Managed to do some more work on the car this weekend - fitting the work in around a wedding and the usual chores...

I decided to remove the cover for the steering box (before):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0801.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0800.jpg

Spent about 2 hours sanding & cleaning it:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0809.jpg

http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0807.jpg

And then painted it:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0817.jpg

Installed the sanded/cleaned/painted towbar (all new bolts/nuts/washers):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0819.jpg

Installed the sanded/cleaned/painted front valance + bull bar:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0811.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0814.jpg

Installed the drivers floor repair panel (new nuts,bolts,washers) and installed sanded/cleaned/painted go! pedal:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0816.jpg

There are basically 4 big jobs left:
Re-install brake/clutch pedal boxes (I'm not too worried about that)
Replace clutch slave cylinder (nervous)
Bleed clutch + brakes (has me worried)
Tidy-up wiring (has me worried)

I don't suppose any Victorian members feel like a day showing a beginner how it's done?!? :wasntme:

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Managed some more work on the Grey Ghost this weekend - finished painting the chassis (the inside of the rear cross member).

The Bigger news is - thanks to a very generous bacicat2000 - we started removing the old wiring, running new wiring.

When I say we - I really mean HE!

Here is a pile of the old wiring stripped out of the car:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0868.jpg

A MASSIVE thank you to bacicat2000! :D

Progress is slow but steady!

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

With help from a friend - we had a massive day working on the Grey Ghost yesterday.. The car is getting very close now...

Windscreen wiper - BEFORE:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0756.jpg

Windscreen wiper - AFTER (cleaning, serviced, re-greased, painted):
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0873.jpg

Fuses covers - removed and cleaned:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0871.jpg

All Seat Knobs + Buffers installed:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0882.jpg

Seats (have been re-covered) are now in:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0875.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0877.jpg

Steering wheel/horn (sanded, cleaned, painted) - back on:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0879.jpg

All new gear knobs:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0880.jpg

Pedal Boxes in:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0889.jpg

Number plate light ready to go:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0891.jpg

Sand/Clean/Paint - bonnet arm:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0894.jpg

Sand/Clean/Paint - starter button:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0897.jpg

Install various rubber for gearbox cowling:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0895.jpg

And last - a bit of fun:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0886.jpg

In summary the list of jobs done yesterday (it was a big day):
* Modify seat bracket and re-fit
* Install seat buffers and seat knobs
* Install seats
* Paint horn surround
* Install steering wheel/horn
* Install number plate light
* Install windscreen wiper - grease internal, clean and paint outside bracket before fitting.
* Fit front chassis bush and tighten all suspension points
* Sand/Clean/Paint - bonnet arm
* Sand/Clean/Paint - starter button
* Install Battery Holder
* Install new Gear Knobs
* Fit various rubber to gearbox cowling
* Clean + fit fuse covers

Regards,
The Grey Ghost! :p

[Ozdunc]

Looking fantastic.

Can I ask what paint you used and how you applied it?

Does the paint have a rust inhibiter in it?

Cheers
Duncan

[grey_ghost]

Hi Duncan,

This is what I've been doing - it works for me, but I'm no expert.

* Clean the surface thoroughly.
* Strip off any surface rust and/or existing paint.
* Clean the surface thoroughly with a de-greaser.
* Clean/dry with a soft cloth.
* Spray the paint on with a can - leave to dry out in the sun.
* Wait 24 hours
* Clean with a soft cloth.
* Apply a second coat.

I use these plastic wheels attached to an electric drill to remove surface rust/paint.

* The blue one gets rid of surface rust, but you have to be careful because it will also eat into soft metal.
The blue one doesn't last very long either - especially if you are using it on sharp edges.

* The red one is much softer and is more flexible. I tend to use the red one for taking off paint.

I have tried various paint strippers also - but I have yet to find one that I like.

Here are the plastic wheels:
https://www.aulro.com/afvb/images/imported/2015/12/90.jpg

I have been using WhiteKnight "Clear Guard" for a clear coat:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0714-1.jpg

I have been using White Knight Rust Guard Epoxy Enamel Top coats on the rest of the car. Always a minimum of 2 coats.

Here is a link to WhiteKnight -

White Knight Paints - Metal (http://www.whiteknightpaints.com.au/specialty-paints/metal/)

Only time will tell - but the paint is looking good so far...

Regards,
The Grey Ghost.

[geodon]

Well done Ghost!

Pls help a fellow restorer. For the life of me, I can't see where the bonnet prop plate bolts into the engine compartment! Can you post a photo when it's in? I can't see anything resembling a bolt pattern for it!

Steering wheel: did u paint the rim? I was going to get it powdercoated.
Thnx,
George

[grey_ghost]

Hi Geodon,

Is this the bracket that you are talking about?

I took this photo standing from the passenger side of the engine bay - looking across at the front/drivers side of the car:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0899.jpg

And here is a close-up of the actual bracket:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0900.jpg

I was lucky with my steering wheel - I didn't touch the rim (it is in remarkable condition). I thought about it, but I wasn't entirely sure what type of paint to use. I am going to have to work out what to do with my next project though - the steering wheel isn't in as nice a condition...

I hope that this helps.

Regards,
The Grey Ghost

[geodon]

Steering wheels:

Powdercoating is not possible. Too much heat (200 deg C). I have to do something as that rim will leave black marks on my hands ( like the Fergy does!)

Not sure how to go now.

Probably this way:

http://www.aulro.com/afvb/series-i-land-rover-enthusiasts-section/99544-series-one-steering-wheel-cover.html

[incisor]

Steering wheels:

Powdercoating is not possible. Too much heat (200 deg C). I have to do something as that rim will leave black marks on my hands ( like the Fergy does!)

Not sure how to go now.

Probably this way:

http://www.aulro.com/afvb/series-i-land-rover-enthusiasts-section/99544-series-one-steering-wheel-cover.html

You can get cans of black polyeurthane wheel paint and slowly build up and not get black on your hands

Know a guy that used it and he is very happy with it thus far

[VK3UTE]

Hi All. I had the same problems with Mary's steering wheel:mad:

I sanded, filled the cracks with body filler, wiped it all down well with prep wash and applied 5 coats of enamel sanding between each coat using a pressure pack. As I understand it they were painted with enamel originally anyways. Looks like new now and no dirty sticky Hands when I drive her.

Needless to say, the more coats and the better the preparation the better the finish

I will take a few pics and post them

cheers Simon

[VK3UTE]

A good result I think:D
http://www.aulro.com/afvb/members/vk3ute-albums-mary2-picture3375-img-2350.jpg

http://www.aulro.com/afvb/members/vk3ute-albums-mary2-picture3376-img-2351.jpg

Cheers Simon

[The ho har's]

hh restores steering wheels, fills the cracks then he uses 2PAC. He has done series ones as well.

This is 'herc's' the 101
https://www.aulro.com/afvb/images/imported/2012/04/131.jpg

Mrs hh:angel:

[geodon]

2Pac (as afar as I know) is not a DIY endeavour? Like it's deadly without a spaceman suit & forced air ventilation in a booth??

VK, what was the brand of rattle enamel can & what grit did you use? Wet or dry?

[VK3UTE]

I just used Wattyl Killrust epoxy enamel and rubbed it back with about 800 grit dry, just very lightly between coats allowing 24 hour drying time

Cheers Simon

[The ho har's]

2Pac (as afar as I know) is not a DIY endeavour? Like it's deadly without a spaceman suit & forced air ventilation in a booth??


That's correct, and he does every day at work;):)

Mrs hh:angel:

[Homestar]

Soooooo, I've been sitting here patiently waiting for an update...:p Did the Grey Ghost make it to the Mechanics for its Roady and other things? Is it running? So many questions... what are the answers???

Don't keep me hanging mate - have you got any news you can pass on?:D

Cheers - Gav

[grey_ghost]

Well.. Ahh.. Errr.

I went down to the Mechanics on Saturday morning (as excited as a school kid).

"Sorry - the workshop is full at the moment, it will have to be sometime next week"

I went home, cleaned the Grey Ghost a little...

And that's it - unfortunately I'm still waiting...

I will chase the Mechanic up if I haven't heard anything by Wednesday.

:(

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Not a lot to report - the Grey Ghost is at the mechanics, and he has been "slowly" working on it:

* I got him to install the Clutch Slave Cylinder

* I got him to bleed the Clutch

* He's having fun bleeding the brakes - interestingly the fronts are fine, it's the rears that are giving him trouble....

* He recommended (and I have ordered) - new Engine Mounts and new Gearbox Mounts

* The Grey Ghost didn't want to start initially, but after he pulled out the plugs and cleaned them up, it "starts first time and purrs like a kitten now"

* His apprentices (and a customer that once owned a Series 3) are amazed at how great a 50 year old car looks.

Hopefully not too much longer now...

Regards,
The Grey Ghost

[grey_ghost]

Hi All,

Not much more to report... I made the mistake of saying to my local mechanic "this is a weekend car, give it a full service, check all of the work that I have done, and give me a road-worthy."

That was 8 weeks ago...

In that time The Grey Ghost has had:
Full Service
New Battery
Installed a new Clutch Slave Cylinder
Bleed Clutch
Bleed Brakes (a pig of a job according to the mechanic)
5 x New Tyres
1 x New Battery
New Engine Mounts
New Gearbox Mounts
Swivel Pin Repair Kit / Gaskets
New Front Bearings
1 x Tie Rod

So hopefully, fingers & toes crossed, I get to finally bring The Grey Ghost home soon.

I have held off posting pics until I have the RWC in my hands!

Regards,
The Grey Ghost.

[Homestar]

Hang in there - it sounds like it is almost done. The wait will be all worth it when you have the RWC and can screw the number plates on.

Looking forward to seeing it on the raod - Gav:)

[Disco Muppet]

Wow, fantastic job mate!
I spent most of my uni lectures browsing ebay pages for series landies :angel:
Honestly, If I thought I could hide it in someway that would stop my mother from killing me, inventing re-animation and reviving me just to kill me again if I dare bring home another Landrover I'd do it! :D :D
Looking forward to seeing the Ghost when it's finished :)
Cheers
Muppet

[grey_ghost]

Hi All,

The Grey Ghost still isn't ready - but it is getting very, very, very, close.

The mechanic now believes that he has found the problem with bleeding the brakes.

The mechanic found that when he clamped the rear flexible brake line off (and thus the rear brakes) - the brake pedal was rock hard and worked perfectly. From that he deduced that the problem was with the rear fixed brake lines (which are brand new) or the wheel cylinders (which have been re-sleeved). When he removed the bleed nipple, he noticed that there was marks on the underside of the bleed nipple and thought that there should be a ball bearing in there to make those marks... Checking one of the front wheel cylinders confirmed this to be the case!

The mechanic thinks that when you loosen off the bleed nipple, the bearing moves and allows fluid/air to move around it - and out of the bleed nipple.
Then when you tighten up the bleed nipple, the ball bearing is forced up inside the end of the bleed nipple, and thus closes off bleed nipple from any air getting in..

What happens when the ball bearing is missing? Even though the bleed nipple is closed, he ends up sucking air back through the lines...

He discovered that both of my rear wheel cylinders are missing the ball bearings, although he can see marks on the underside of the actual bleed nipple..

I checked my old (damaged) wheel cylinders - and some of them have a bearing, some don't... I took down all of my spare wheel cylinders, in the hope that he can take the ball bearings from the spares and use in the ones on the car.

Is all of the above correct? It sounds plausible to me..

Is there a standard ball bearing size for the wheel cylinders? (This Landy is a 1961 LWB, but I am already working on my 1960 SWB and so am wondering if I will have the same issue...)

Fingers crossed! Closer..

Regards,
The Grey Ghost.

[JDNSW]

Your analysis sounds correct. I'm not sure whether all bleed nipples have ball bearings - these are shown in my Series 1 book, but not in my Series 2a book, and I suspect both their presence may not be uniform, particularly if you have aftermarket cylinders. Same goes for the size. One thing that is certain, is that if it looks as if it should have a ball, it needs one! The ball will be used because it provides a hard, accurate sealing surface, which would otherwise be expensive to produce on the screw - although I suspect improved manufacturing methods may make this less expensive in more recent years.

John

[wrinklearthur]

Like John, I have found both types across series 1's and series 2 / 2A's

The conical end type bleed nipples will allow reverse pressure bleeding, but the ball bearing type will not as the ball is forced into it's seat.

I had forgotten about that bit of fine detail till I read your post, thanks.

.

[jazzaD1]

this is a great thread! it makes me want to restore an old series landy, however I still have a disco I need to get on the road!

[grey_ghost]

Hi All,

I got home from work last night - and "The Grey Ghost" (my 1961 LWB Series 2) has finally returned from the mechanic, with a Road-Worthy-Certificate !!!

:D :D :D I will register The Grey Ghost over the next 2 weeks!

The project has taken just over 1.5 years and over that time here are the parts that I have replaced:

ELECTRICAL:
Battery
Head Lights
Parkers
Blinkers
Brake Lights
HTC Leads, Distributor Cap, Points
Re-Wired

MECHANICAL:
Radiator Hoses (Top + Bottom), By-Pass Hose
Fan Belt
4 x Tyres
Machined Drums
Drum Screws, Drum Springs (Front + Rear)
Flexible Brake Lines, Fixed Brake Lines (Front + Rear)
All new Drum Shoes (Front + Rear)
Axle Straps
Wheel Cylinders (Front + Rear)
Clutch Slave Cylinder, Clutch Master Cylinder
Brake Master Cylinder
Clutch + Brake Pedal return springs
Shock Absorbers (Front + Rear)
Shackle Pins, Shackles, U-Bolts, Chassis Bushes
Suspension Bump Stops (Front + Rear)
Air Cleaner Hose
Speedo Cable
Engine Mounts, Gear Box Mounts
Seat Belts
Swivel Repair Kit (Gaskets, Pins, Bearings)
Oil Filter, Fuel Filter, Full Service (All oils, grease nipples, etc)

RE-CONDITIONED:
Re-Core Radiator
Tail-Gate
Bull Bar
Seats
Front + Rear Leaf Springs
Seat Brackets
Ute Tread Strips
Spare Wheel Holder
Series 3 Rear Backing Plates

COSMETIC
Wing Mirrors
Bonnet Rubber
Main Gear Stick Boot, Hand Brake Boot, Hi-Low Boot, 4WD Boot.
Vent Rubbers
Bell Housing Grommit
Floor Screws
Prop Shaft Boots
Mud Splash Panels
Passenger + Drivers Door Handles (with locks)
Gear Knobs (Black, Yellow, Red)
Seat Buffers
Countless: Pop Rivets, Nuts, Bolts, Washers, Screws
Door rubber
Mabu decking

THANKS
I would like to thank the following people for their help - in no particular order:
pfillery
Bob Smith
Lost Kiwi
Dinty
Incisor
Grommit
VK3UTE
All of the members of AULRO for their help, knowledge and support!
Please forgive me if I have missed anybody.

An extra special thanks goes too:
Shaun Hartley
bacicat2000

Here are some before pictures:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/SANY0021.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/SANY0026.jpg

Here are some pictures of the finished beast (the tyres are the only thing that have since changed)
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0909.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0915.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0916.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0918.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0925.jpg

And parked next to another member of the family:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0932.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_0928.jpg

Regards,
The Grey Ghost!

[isuzutoo-eh]

Congratulations! She's lovely and shiny :)
A real credit to your efforts and those of your helpers.

[stevep]

it looks great - well done !!:):thumbsup:
i like the seats - I might have to come over & pinch them, they are the right colour for mine.

regards
Steve

[VK3UTE]

Well done mate, great effort she looks fantastic. :D
Get those plates and take her for a Sunday cruse:cool:

[stuee]

Mate, it looks fantastic! Well done.

[Johnno1969]

Looks brilliant! Well done.

[Homestar]

Well done mate - patience is a virtue. You got there in the end, and I'm sure it was all worth it. Once you have it registered, I'll pop up to help you pull the engine out of Roger, and take the Grey Ghost for a sneaky test drive...:)

Cheers - Gav

[Disco Muppet]

Mate, that looks absolutely stunning!
Congratulations, you should be proud of the fantastic work you've achieved! :thumbsup::clap2:

[Lostkiwi]

Well done:)
Looks fantastic happy motoring

[jakeslouw]

It's a BEAUT, I reckon you got it just right.

[incisor]

very nice bit of kit...

you have done well!

[pfillery]

Fantastic work Tom. Finally all the effort, hard work, blood sweat and tears and parts sourcing expeditions have paid off.

I like the look and nice to see some of my donor car's parts breathing new life into the old girl.

So when will we expect to see a start on the next project? Love the mini too, used to have a moke years ago, there is something about them.....wish I could still fit into one comfortably but at 6'2" it is a bit hard.

[grey_ghost]

Hi All,

Finally got the number plates from Vic-Roads, installed and took the Grey Ghost for a test run...

The car has a bog standard 2.25 petrol engine. It has had a full service - all oils/filters replaced.

Unfortunately not without some issues....

When going up a steep hill (bitumen road, not massively steep - I normally go up this hill in 2nd gear in 1976 Mini) - the Ghost, coughs and splutters like he isn't getting enough fuel. The car kangaroo hops and then eventually stops. It doesn't stall - you put it back into 1st, give it some revs - and take off again, like nothing happened... Suggestions?

After completing the test drive (not far - maybe 10kms) I drove home and parked. When I touched the front and rear wheels - he actual wheel face, the area around the wheel nuts - the steel is warm to the touch. Is this normal?

Here are some photo's:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_1825_zpsca66d243.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_1823_zpsfe721fb1.jpg
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_1822_zpsef5c57cf.jpg

Regards,
The Grey Ghost...

[wrinklearthur]

The car has a bog standard 2.25 petrol engine. It has had a full service - all oils/filters replaced.
When going up a steep hill (bitumen road, not massively steep - I normally go up this hill in 2nd gear in 1976 Mini) - the Ghost, coughs and splutters like he isn't getting enough fuel. The car kangaroo hops and then eventually stops. It doesn't stall - you put it back into 1st, give it some revs - and take off again, like nothing happened... Suggestions?

That does sound like from your description that the motor is starving for fuel,
how is the gauze filter on the tank pickup?


After completing the test drive (not far - maybe 10kms) I drove home and parked. When I touched the front and rear wheels - he actual wheel face, the area around the wheel nuts - the steel is warm to the touch. Is this normal?

When I have adjusted the brakes or the wheel bearings, I do the same check for heat at the hubs after a run.

cold; means it has settled down and all is good. :D
warm; maybe a high spot on the brakes or the new bearings are a still a bit tight, check it again sometime but leave alone. :)
hot; and maybe only on one wheel, probably wants looking at as something needs it's adjustment letting off a bit as it is too tight. :(
Too hot to touch; not good, there is something needs to be fixed straight away before you go on again. :o
Burning the paint off; get someone else to do the work and hand your mechanics ticket in. :eek:

[JDNSW]

Engine problem sounds as if it is fuel - likely causes, as suggested, the strainer on the pickup in the tank, or the strainer on the pump, or an air leak anywhere between the pump and the tank - usually, but not always, shows up as a slight fuel leak, but could be a tiny rust hole in the pickup inside the tank. But I have had similar symptoms that turned out to be the points closed up, and could also be any ignition problem such as HT leads - spark is good enough except when engine is asked to work hard with more mixture and higher compression pressures.

Back wheels - warm to touch, no great worry, but if you can't keep your hand firmly on it, needs investigation. Most likely dragging brakes - jack up the wheel should turn freely (out of gear and handbrake off) - apply and release brake, should still turn freely. Don't forget to chock front wheels before jacking up a back wheel.

John

[grey_ghost]

Hi All,

I decided to give the Grey Ghost a minor present.

I installed a leather steering wheel cover - man that was a job! It took about 2 hours but I am happy with the result, and won't get black/sticky hands in winter anymore!

http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_2249_zpsc720cf4a.jpg

[Lostkiwi]

Looks good
Where did you pick that up from TB?

[grey_ghost]

Hi Lost,

I got it from the usual suspect - fleabay!

Here is the link -

FOR LAND ROVER 2 SERIES TOP QUALITY ITALIAN LEATHER STEERING WHEEL COVER BLACK | eBay (http://www.ebay.com.au/itm/FOR-LAND-ROVER-2-SERIES-TOP-QUALITY-ITALIAN-LEATHER-STEERING-WHEEL-COVER-BLACK-/250911673194?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3a6b804b6a&_uhb=1#ht_1083wt_804)

Cheers,
The Grey Ghost

[grey_ghost]

Hi All,

A few weeks ago I took the Grey Ghost for a drive, and noticed that the water pump had expired..

So off with the pump and a reconditioned one has been installed. (I have the "rare" 8 bolt water pump, which is a bummer as both of my Series II are in the same boat)

Took the car for a spin - everything went well, until I noticed this a few hours later:
https://www.aulro.com/afvb/

I have changed it for a spare, and will get it looked at next weekend!

[jakeslouw]

Only the bottom bit is flat, mate! :)

[ezyrama]

Turn it around and it should come good:cool:

[Sitec]

Hi All,

A few weeks ago I took the Grey Ghost for a drive, and noticed that the water pump had expired..

So off with the pump and a reconditioned one has been installed. (I have the "rare" 8 bolt water pump, which is a bummer as both of my Series II are in the same boat)

Took the car for a spin - everything went well, until I noticed this a few hours later:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_3615_zps3d490475.jpg

I have changed it for a spare, and will get it looked at next weekend!

Hi GG.. Not sure where you can get them, but there are available Ser 2 wheel nuts that are the same outside diameter as the Series 3 types.. Those old reversible Ser1/2 nuts have a horrible habit of pulling thru the holes on the wheels.... :)

[grey_ghost]

Hi All,

Well - it's been a long time since I have updated much on the Grey Ghost...

I mainly use the Grey Ghost for fire-wood and rubbish tip duties around the property.

Checking the radiator - it was almost bone dry. I filled it up with water and took the car for a spin. When I got back and stopped the car - I thought that I had a leak, but water was coming out of the over-flow pipe. I will wait for the Grey Ghost to cool down and check the water level again - something to keep note of me thinks.

I decided to pull out the wood floor that I had built for the tray:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_4584_zpsec56e66e.jpg

The next thing that I did was wash it and leave it to try:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_4585_zps05e11935.jpg

And finally - after a thick coat of Linseed Oil:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_4587_zps16379f3b.jpg

The next job was to remove the spare from the Left Front Passenger side, and replace it with the repaired tyre. There was nothing wrong with the spare - apart from the fact that it's a completely different tread pattern to the other three wheels. Now it's back to normal and everything is oki doki.

I then decided to give the spare wheel a paint touch up:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_4591_zpsfb098dae.jpg

Then figuring that I had come that far - I also painted the other 4 wheels (carefully) in situ:
http://i1155.photobucket.com/albums/p549/tomb1971/The%20Grey%20Ghost/IMG_4593_zps0d4f5a72.jpg

The next step (although no photos) was my compressor. The belt needed adjusting. I've never adjusted the belt but figured that it couldn't be that hard, even for a novice like me. 10 screws later and I had the cover off. 4 nuts later and I had adjusted the fan belt. I tested it with the cover off - and then re-assembled. No photo's - but another job done.

I then checked the tyre pressures on all 5 tyres - and topped up 2 tyres with the new quieter compressor. :wasntme:

That's all for the Grey Ghost today!

[Mick_Marsh]

I almost dropped in. Drove past your place twice today. Maybe it was good i didn't stop. You would have given me a job or two to do.