Every 3 years

[Dinty]

Well I have spent the past couple of days making sure all the Land Rovers are up to scratch. This year I'm having them pink slipped:o:( and they have to be spot on!.
As usual SWMBO said why bother so early, something will go wrong before the due date:(, bad vibes I said, also told her to get lost LOL, well it wasn't long before what she said hit home. 'Lady' my Series2 C/R, the starter wouldn't engage:(, methinks Gee I hate pulling starter motors out, anyway out with the crank handle from behind the seats.
Prime the fuel system (hopefully) engage starter handle in the crank dog, carefully pull it over until handle is at the 6<<>>7pm position and pull like crazy upwards, a small fire and stop, so I took the air horn off the carburettor and tip a small quantity of petrol down the throat, carefully pull handle around to the same position, hey it fires, no wait a minute it didn't fire it ran backwards and hit my Right hand about 4 times before I could pull it away:(:(:mad:, geez that hurt, and it still does around 24hrs later:( anyway it did eventually start off the crank handle and the starter motor problem turned out to be nothing more than a flat battery.
Roll on through the day getting different Landies out of their long sleep (some haven't turned a wheel since the 25th April 2012, all seemed to be going well until I was putting them away again, the gunbuggyshh!!
brake master cylinder decided it was time to give up working and leak all over the floor:p bugger I thought, anyway I had to re-arrange my 'Rubic's Cube again so I could work on it, and today I did just that.
I used my tried and tested method of draining brake fluid from the reserviour by using a s/hand (used) syringe from work
http://i659.photobucket.com/albums/uu319/DJM110/new/91ff0e80ed301701f02eae2f3c65ffc7.jpg't=1350195496
it takes a little time but a lot less mess:angel:.
Next out with an air hose and my 3/8" butterfly rattle gun n sockets loosen off the 6 x 5/16"UNF bolts that hold the brake pendant assembly, undo (carefully) the fittings on the side of the reserviour to M/cyl, then remove the 6 bolts lifting out (with some degree of difficulty) the brake assembly.
Set it up in the bench vise and proceed to remove the bolts that hold it into the housing
http://i659.photobucket.com/albums/uu319/DJM110/new/64b5d04a9f5ba4d28077d29fa2dd75e7.jpg't=1350195559
Once it has been removed I cleaned all the crud out of the housing and put it aside for the time being. Some time ago I bought 4 CV type M/cyls from a dealer in the UK, this is the last one (note to self buy a few more). The Land Rover had a 109" CB M/cyl fitted?? anyway it is US.
I always run the correct size tap/s into the threaded holes, as sometimes just the smallest burr can cause you a heap of trouble, 3/8"UNF first
http://i659.photobucket.com/albums/uu319/DJM110/new/ab3027a388b78fe5a8b9ea9559e24a17.jpg't=1350195734
always hold the cylinder upside down, so if there is any debris it will succumb to gravity, next the 7/16"UNF
http://i659.photobucket.com/albums/uu319/DJM110/new/40bc8bb94f57a3ec4d0d979f26206911.jpg't=1350195787
A quick look under the right hand wing, showed some flakey paint etc, so I scraped it off, and not having any O/Drab paint I used brushable ?? You know the stuff LOL:D just to protect it
http://i659.photobucket.com/albums/uu319/DJM110/new/87546dbaebe3363173c0d6788e2fc0c2.jpg't=1350195848
While that was drying, back to the housing, by running a 5/16"UNF tap through the 6 holes, I like to be able to screw things up with my fingers
http://i659.photobucket.com/albums/uu319/DJM110/new/4b400c721b6a94cf438c8e1fe3e6ed52.jpg't=1350195908
then refit the new M/cyl to the housing, the bottom bolt is always a source of delight, trying to get it into a hole that isn't straight down LOL, anyway a short length of mild wire wrapped around the bolt allowed me to position it while SWMBO put the washer n nut on
http://i659.photobucket.com/albums/uu319/DJM110/new/2070c5a6c719ee88a617f60507011d06.jpg't=1350195970
and thast about as far as I got today, as I don't have any 1/4"OD bundy tubing, it will have to wait until later in the week when I can get hold of some, anyway cheers Dennis:angel:

[Dinty]

Meanwhile 2 days later SWMBO had been to Maitland and purchased a few lengths of 3/16" & 1/4" bundy tubing, yesterday (Tues) I double flared one end put the male fitting on it and that was about all I had time for, this afternoon I had from 1500hrs until now to do what I needed to do.
Out with the tubing bender and made a 90 deg bend, then work out roughly where to cut the tubing off, so I could then see where to bend it again to meet up with the brake reservoir.
This was done with a degree of difficulty as the Gunbuggy still has the wings on
anyway this is how I measured the tubing to cut it off at the right length
http://i659.photobucket.com/albums/uu319/DJM110/new/b08700b70deed5bcac19ce06c19fdfbf.jpg't=1350455523
you can see where I marked the tubing, cut it off, fit female union nut and double flare the end, ending up with this
http://i659.photobucket.com/albums/uu319/DJM110/new/486ac2af9c7ebf3e3c2e0a10b672e744.jpg't=1350455582
that is 'Max' Digger's sleeper, he is always nosing around when I'm near the gunbuggy, anyway the new tube fitted up like the proverbial finger in a (you know)
http://i659.photobucket.com/albums/uu319/DJM110/new/a68ba63c94359217835f9e9073b0fd26.jpg't=1350455647
now tomorrow just adjust (hopefully) the outlet pipe to suit the new Master cylinder, if it doesn't line up satisfactorily, I will have to remake it, anyway cheers Dennis:angel:

[Dinty]

Well what a lousy start to the day, overcast, BOM forecast for showers etc, BOM radar showing small isolated patches around, anyway at 0715hrs I started to fill the street with Land Rovers.
It took about 1 1/2hrs or so to get them all out and ready, and wouldn't you know it, Rain rain n showers, it was a mad scramble to cover some vehicles:(:(:mad:, the street looked full with all my vehicles
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0700.jpg
and on the other side of the street
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0699.jpg
yes there are 2 vehicles missing, they were kept near cover in case of heavy rain.
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0701.jpg
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0702.jpg
But before this went out I stripped it of some of it's accessories
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0698.jpg
anyway it all went smoothly, only found a few minor problems, the pinch bolts on the drag links had vibrated loose:(:(, out with some spanners and in minutes it was fixed, everything else was OK, funnily enough it took over 2 hours to put it all away, only have to take the No5 to it's lodgings tomorrow, anyway cheers Dennis:angel:
next date for this job 2015:o

[Dinty]

Today was club registration day, I rolled up in my 110 County, a fellow club member asked ?? 'Where's The convoy??', I replied in my hand, I had them all Pink Slipped:):).
After arriving home from that venue, I removed the RHS front brake drum and shoes etc on my 109 WKSP, the wheel cylinders were new items when the vehicle was being rebuilt, but with only occasional use this is how they finish up, not very nice looking at all, add to that brake problems etc etc
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0942.jpg
down in the depths of the shed I have a full front set that has been Stainless steel lined, this will be my 5th vehicle that I have done in past 11 months, only 3 to go.
As usual 'Murphy's Law' is always applied here (dunno why!!??:(:(:() I couldn't find the 3/8"UNF bolt that I had turned down to accept the flared end of the 3/16" bundy tubing, so the system doesn't backfill with AIR, so I had to remake a rough one
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0941.jpg
those of you who have been here in the past will know what a mess my shed "was in":(, but I have been making progress (and spending big bucks:eek:) buying all manner of items that can accommodate tools/nuts n bolts etc, I must have just misplaced it, anyway tomorrow I will clean up the backing plate again, repaint if needed, fit the refurbed wheel cylinders, then start on the left side, anyway thankfully in 3 years time I will not be revisiting the brakes, now onto the oil leaks LOL LOL LOL;):D:D:p:p, cheers Dennis:angel:

[Dinty]

This afternoon after lunch I took on the job of reassembly of the R.H.S front, I would have been further along except I took pity on swmbo ;):D who had a shopping list as long as my arm (we had been away for approx 10 days) so lunch first then into it.
A quick run over with a wire brush to remove any loose paint n dirt, spray with brake kleen, allow to dry, a quick coat of Gloss Black (White Knight (Squirts)) and your ready to reassemble.
I have learned from past experience that when refitting the 2 wheel cylinders, to fit the top one (Leading) leave the 2 x 5/16"UNF nuts loose, then fit the interconnecting pipe to that cyl, only screw it in approx 50%, then fit the bottom cyl (Trailing) and do the same with the interconnecting pipe, after you have made the connections, and everything is screwing up easily, no crossed threads, (as I have shown in the past, I always run the appropriate tap into the wheel cyl's just to make sure no burrs etc) continue to tighten it all up.
Brake shoes cleaned with Brake Kleen and allowed to air dry, check the drum to make sure it's clean, reassemble the shoes onto the brake anchor plate (aka brake backing plate), check that the cam adjusters are backed right off, tap shoes into position, refit the brake drum with the 3 x 3/8" csk Whitworth screws, spin the drum and check for any dragging, luckily for me :cool::cool:;) the drum spins freely.
After that I refitted the flex pipe from the brakes to the chassis, another quick squirt of gloss black over the exterior and it all looks like this
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0943.jpg
now for the LHS, but not today, I picked up somebody's bug while away, I have a headache+++, sore throat n cough:(:(, so tomorrow will be soon enough, cheers Dennis:wasntme:

[Dinty]

Just when you think it's safe to park up, something else calls it home ;):D
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0947.jpg
not sure what type of feathered variety it is as yet, we have Blue wrens that nest about in the trees??:)
Last Thursday I jacked the rear end clear of the floor, stands under, wheels/brake assemblies off, it was certainly cleaner than the front, they were not seized, but no point in just doing half a job:D
http://i659.photobucket.com/albums/uu319/DJM110/IMG_0945.jpg
I took both rear wheel cylinders to the usual brake place, have them back next Thursday when Im working in the area.
In the meantime, I have moved forward on this little job, mounting an Isuzu alternator onto the Land Rover engine block
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0949.jpg, I missed out getting a few different length A belts, I think I have the pulleys lined up, bit in my mind I think it would be easier to see any misalignment with the belts fitted, anyway no rush on this job :p;), cheers Dennis:angel:
ps who ordered the HEAT WAVE:(:(:mad:
pps I have placed an order for 4 lts of Protec Cam/Green, we will see what transpires,,.

[Blknight.aus]

did you want a double grove crank pully for that thing?

[Dinty]

Yes please, I don't have a spare one, cheers Dennis

[Dinty]

Well, I'm no further advanced with the brakes on my 109Wksp Land Rover. The rear wheel cylinders were sent away a week last Thursday, I should have had them back by Wednesday of last week, but somehow my wheel cylinders and another customers full set for a Morrie Minor bits have gone missing:o:(:mad::mad:.
No fault of the brake service, the courier is at fault, gawd knows where they are??!!!.
Meanwhile I had placed an order for this, no issues getting it!!
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0962.jpg
it arrived yesterday, this afternoon I cleaned up the 2 front wheels, brake fluid and paint doesn't mix, in fact they hate each other, the inside of the rims were pretty ordinary, so a good clean with flap sander (die grinder) and some elbow grease, a quick coat of etch prime and 1 of O/D

http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0963.jpg
a little while later they both had 2 coats of O/D on them,
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0964.jpg
all we need now is the brake wheel cylinders, so I can finish this job, cheers Dennis:angel::(

[Dinty]

Well after the wheel cylinders had a free weekend in Sydney ??!!somewhere the errant items returned home today to be reunited with the rear end ;) they look a better than they did 2 weeks ago

http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0970.jpg
I think it was $132.00 to have them sleeved in Stainless Steel, they have now been reunited with the backing plates etc, looking pretty smart as well
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0971.jpg
tomorrow after work I will fit up the brake shoes and start the bleed process, I didn't want to get too dirty this afternoon, cheers Dennis:angel:

[Carzee]

Hey up there, you have been busy. Just read the Sawmill saga. Unbelievable result! You should get a gong. You are the best.

So is this Workshop ready for action again or are you taking a break for Christmas shopping? ;)

cheers!

[Dinty]

Continuing on (as you do LOL) I'm not having any joy with the brake system on my 109.
This is what has transpired over the past day, remove brake pendant assembly
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0993.jpg
it has become apparent to me, that for some reason the piston is sticking in the M/cyl:(:mad:. After taking it apart and stripping it down in my humble opinion the rubber seal (on piston) looks to be of dubious quality, and has grown a little in size, thereby causing the piston to stick in the cylinder
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0992.jpg

Anyway back to issue at hand, I noticed that the push rod didn't seem to have enough length, so a quick look around and I found these 2 items
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0991.jpg
but being rolled threads I wasn't keen to use either of them, I did eventually find a genuine one on an old CB cylinder and fitted it.
A quick try with it set up in the pendant holder, soon showed a fault, the retaining washer that holds the piston etc, the opening wasn't big enough for the 5/16" push rod (remember the other rolled thread) this was noticed while operating the assembly by hand, it appeared to jam at the downward stroke, well it ?? might have had just enough clearance, anyway I opened it up using a 11.5mm drill.
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_0994.jpg
I've put it together without the seal and reassembled the cylinder in the pendant setup and all appears to work without getting stuck anywhere, the next issue is where to source a kit for this cyl.
My usual brake service closed yesterday for xmas, I did try another couple without any joy, so it looks like this job has hit a wall until late next week or the 2/1/13, anyway cheers Dennis:(

[Dinty]

Well the brake service company has re-opened and we drove to East Maitland to try our luck with a new seal, after much tooing n froing with parts books we came up with (I hope:)) is the correct seal, I fitted it soon after arriving home.
I run up the compressor so I could clean the bore of the Master cylinder
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_1006.jpg
a light lube of brake fluid and the piston and seal slide in the bore, like the proverbial finger;), but best of all, the piston and seal move freely in the bore and the return spring has enough grunt to bring the piston back to rest :D:D
Five minutes later (with help from swmbo) I had it fitted to the pendant and touched it up with Gloss Black paint, just need the paint to dry and I will refit it
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_1007.jpg, fingers crossed that I don't have any issues bleeding it, LOL cheers Dennis:angel:

[Landy Smurf]

looking good Dennis, love your work

[Dinty]

After a period of nothing happening due to work commitments, I have still to properly bleed the system. I have located the source ?? where the air is by using my Girling brake hose clamps, the air ?? lock is in the rear.
I have tried using my MityVac vac/bleed system but it seems to be pulling air around the bleed nipples, so I have been fiddling with trying something else, a Pressure bleeder. I used to own a Girling pressure bleeder but it was stolen from me about 27 years ago when I split with my 1st wife, anyway it's gone who knows where.:(:(:mad:
I found a suitable piece of Aluminium round bar to use as a lid that I can tap into to apply air pressure. I determined that the thread size on the M/cyl reservoir appeared to be 8TPI
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_1018.jpg
now I know that this particular thread wasn't screw cut, more like pressed/rolled, but I had a plan in my head how to get around that issue, anyway after much tooing n froing on my lathe, this is how it finished
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_1020.jpg
and it doesn't cross thread, it is fairly smooth with engagement, I'm fairly happy with the result so far
http://i659.photobucket.com/albums/uu319/DJM110/new/IMG_1023.jpg
it still needs to be reduced in size at the top, but at the moment it's comfortable for my arthritic hands?? anyway cheers Dennis:angel:

[drifter]

Hey up there, you have been busy. Just read the Sawmill saga. Unbelievable result! You should get a gong. You are the best.

So is this Workshop ready for action again or are you taking a break for Christmas shopping? ;)

cheers!

Good grief! It's himself....

[Dinty]

The pressure brake bleeder I ordered from the United States has cleared customs in Sydney:):), it will probably take until Thursday before I get it:o :(, meanwhile the Wksp Land Rover just sits around waiting LOL:( anyway there is always something else to be done in the meantime, cheers Dennis:angel:

[Dinty]

The pressure bleeder arrived today:), I was pleasantly surprised to see that it has a cap to suit Land Rover Yeh :):) I thought, but a quick look at the thread type and it was clear to me that it wasn't going to suit the S2A, and I was correct :(, anyway on the upside it does suit L/R from S3>>110, quite a bit of kit with it, I won't be doing anything with it as yet, because I will now have to buy/steal from any of my other air tools the snap on fitting for the air hose, anyway the unit
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1082.jpg
cheers Dennis:angel:
big storm brewing outside,,.

[Dinty]

Well after looking at the snap on fittings that came with the brake bleeder, nothing I had was interchangeable!!!:(, isn't always the same.
I had a scrounge about in my brass shelf and came up with 2 suitable pieces of brass hex that I could make into what I needed, this is what I needed to copy
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1083.jpg
after a short period of time it looked like this
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1085.jpg
a quick check to see if it would fit n seal
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1087.jpg
and it did, it was a neat fit, not loose or wobbling.
Next to make a right angle adaptor from brass hex and cut a thread into the alloy brake M/cyl top I make a few weeks ago
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1088.jpg
I needed to make a gasket to suit the inside of the alloy cap, some thin rubber sheeting was found and cut to suit, all items screwed into place, damn !!!! :mad::( an AIR leak.
It was determined that it was coming from under the gasket, after looking at the job for a while, I put the alloy cap back in the lathe, set it off the mark against No1 jaw, put in a tool that I could cut a groove for the gasket to seat into, this was done without too much fuss, cut another slighly larger dia gasket, try n fit, remove trim a snippet, try n fit, this time as snug as, gasket sitting flat, well lets give it a try with some pressure.
I pumped the brake bleeder to 5psi, fitted the cap to an old M/cyl holding two fingers over the outlets, open the inline valve, success:D:D
no air leaks and holding 5psi, as can be seen in the image
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1089.jpg
anyway thats enough excitement for one day, I will have to buy some brake fluid in the morning and try it out on my 109 Wksp truck, cheers Dennis:angel:

[Dinty]

Well a mixed bag of results today, I used my new pressure bleeder, it works well the downside was my alloy adaptor allowed a weep of brake fluid out between the top of the M/cyl etc, it was no big deal, I'm putting it down to the thread wasn't as clean as the one (M/cyl) I had been playing with, anyway here is an image of it all connected up with 5psi of air behind it
http://i659.photobucket.com/albums/uu319/DJM110/IMG_1090.jpg
anyway after adjusting the shoes the brake pedal moves down approx 2", the vehicle stops in a straight line :) cheers Dennis:angel:

[Dinty]

From 2012 to 2015, 3 years it seemed like 3 weeks and here we go again, anyway as usual I had checked this n that in the weeks leading up to the 14th November, on the day the weather looked miserable, my neighbor was away so I was able to utilize his undercover areas (read 109 workshop truck/gunbuggy in there) all went well all vehicles recorded a reasonable brake meter reading the only fault and it happened while being looked at, lhs headlight gunbuggy blew the filament on low beam ??? anyway all sorted now and all parked up again, hopefully get them all out for a run before X-mas and give the DBG one's a wash, here is a short clip taken the day before (13thNov)
https://www.youtube.com/watch?v=MNDC_KlOUck
cheers Dennis
yes I'm breathing heavy cause other people's exhaled smoke = emphysema