My IIA refresh...

[akelly]

Well I've been "refreshing" my IIA shorty for about 3yrs now so I thought I'd share some pics on the progress.

Here's where it was back in 2017. Hadn't been driven for about 5yrs because I just got too busy, moved interstate twice, and it languished in a carpark in Sydney.
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I got it shipped home to Melbourne (from Sydney) and noticed the bulkhead had started to rot in a few places.

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After having a crack at cutting it out and patching it got out of hand because there was way too much work to do. The car has a 6cyl IIA bulkhead and a few other bits of butchery to make things fit around that. So I wanted to get a 4cyl bulkhead and fix it properly. I never managed to track down a decent one, so I found a good 6cyl bulkhead and chopped the centre section out, fabricating a 4cyl centre panel out of sheet steel to weld in. Harry built me some new floor pans and other bits for it too.

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I also attacked the doors to cut out the bottom frame rot, but again that got out of hand because it was much worse than it initially appeared. So I sourced some half decent SIII doors that just needed the bottom frame replaced, but in the end bought some brand new ones instead.

Fast forward to now and I'm on the final big push to get the car back on the road. It's not going to get the full paint job I initially planned just yet, because we're moving house in a month. So it will be a bit of a rat rod until next year. A few progress pics.

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It's getting twin 16 gallon fuel tanks, I'm leaving the holden in there for now but I have an original diesel to go back in once its rebuilt. I have a set of stock rims and Michelin XLZs ready to bolt on. There's a toro overdrive in there too.

Left to do are:

- front axle rebuild (I have new swivel hubs and all the stuff ready to bolt in)
- all brake shoes and wheel cylinders replaced (it has an XA falcon master cyl and booster that are engineered and will stay for now)
- new front brake lines (the old ones were rusted badly)
- finish off the bulkhead centre section (needs to be bolted in the chassis to make sure everything is square before I weld it up)
- replace the bolts being used as shackle pins (!) with proper pins
- weld in the fuel tank outriggers
- replace LH bulkhead outrigger (old repair is shoddy and bent)
- replace the wiring loom (I have a new vinwire loom ready to go in)
- bolt everything back together....

and I have a month to get it done. No pressure!

Will add progress here daily or as it happens.

Cheers,

Adam

[akelly]

so today I've been sorting out fixings that I previously tumbled clean. Some of these will get replaced because they're knackered, others will get zinc plated. I bought a Janes Kits plating kit some time back and have done a few bits and pieces, they turn out very nice.

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About 10yrs ago I bought a set of good SIIA steel rims and got them sand blasted and hot zinc sprayed. They've been stored under various houses since then waiting to get painted. Just so I can stop moving them around I grabbed a rattle can of Dulux 'Hog's Bristle' to spray on them so I can fit up the Michelin XLZs that are also under the house. Then I can get rid of the 15" sunraysiers that are on it now. Paint came out ok and will do for now. Oh, and I know the wheels should be body colour on a 71 model, but I'm not a rivet counter and I like the limestone wheels look much better.

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Also spent a bit of time measuring up to replace the LH bulkhead outrigger. Tomorrow I need to do a parts run for some brake line nuts - the old ones are all rounded off - then I can get the lines made up and finish off that job.

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[akelly]

had a bit of running around to do today. Dropped the flywheel off to get machined and a new bearing installed. It's some kind of custom made thing with holden starter gear but land rover size clutch face. Will be putting a 9.5" clutch in to replace the 9" one that was in there.

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Then I picked up new shackle kits and installed the front ones. It has military 'style' hangers and slightly longer than stock plates, but I replaced them with stock plates and moved the fronts up to the 'civilian' hole. Nothing tightened up until I have it all back on it's wheels and do a lap around the block to settle down.

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Rear set came in this lovely old box.

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Cricket training starts in a minute so that's it for today.

[akelly]

got stuck into the outrigger moving today. Had to remove the LH bulkhead outrigger because it's bent backwards about 3/4". Have a new one on the way from Landybitz.

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Other side is fine but after I cut away the fuel tank outrigger I found a couple of pin holes, so patched them up. A bit rugged but they'll be behind the tank out of sight.

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Also been churning through the fixings in the zinc bath. Wont be doing this for every nut and bolt because it's pretty time consuming, but while I have the patience I'll get a bunch done and save some money.

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[akelly]

A few updates from today. Pulled the rear drums off and both sides have an oil leak. The distance piece where the seal runs is knackered, so I've ordered all the bits to replace them and the seals. The bearings are almost new, I did them less than 1000km ago (although that was about 8yrs ago in time).

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Next job was to check out the old diff centre. Years ago I swapped in a range rover centre to see how it would go on the highway. It was great but around town it was a clutch killer. So I'm swapping back in the old 4.7:1 centre, but it's looking shabby from sitting in the shed.

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So I gave it a semi-teardown and cleaned it all up. Needed a backlash adjustment but otherwise it's all good now.

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Well I wouldn't drive it across the Simpson, but it will do until next year when it gets a full rebuild.

Other than that I just washed parts and sorted out some more fixings. Fingers crossed the outrigger arrives tomorrow and I can weld that on and get moving with the bulkhead.

[akelly]

not a great deal to update today. Did the rear stub axle distance pieces and cleaned everything up to go back on.

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Cleaned up the extractors with a wire wheel and painted them.

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Now waiting for some bolts and loctite to arrive so I can finish off the rear end. Still no sign of the bulkhead outrigger... hoping for a weekend delivery.

[akelly]

unfortunately another few days with not much to update. Made up the front brake lines in copper coated steel line with new nuts. After having a heart attack seeing what places want for decent brake line p-clips I decided to design and 3D print some that 'snap' in the brake line. Turned out OK so I made up a twin version as well. They're screwed to the chassis with a 5mm pan head bolt.

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I know someone will tell me that's not where the brake lines run - well it is on my car because I like it this way.

[akelly]

another quick update - I hate my "universal" clutch alignment tool and somewhere along the way I've lost the gearbox input shaft I had for this job. So today while I was printing the brake line clips I thought "maybe I can print a clutch alignment tool?"

So I did a quick sketch and printed a small prototype. Fits like a glove. So tonight I'll print a full length one.

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[cjc_td5]

I like your brake line clips. It's a slippery slope printing all sorts of bits and pieces for a project isn't it!

[akelly]

yeah I've printed a few bits and pieces for the defender but mostly I make drone and electronics project stuff. Did the full size clutch tool overnight and it printed great.

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More delays thanks to the chassis outrigger not arriving this week. Parts I ordered from the UK on the same day as the outrigger have arrived. Some Australian suppliers really not making their case for further business at the moment.

[JDNSW]

You know, there is no real need for splines on the tool - I made mine on the lathe! An emergency one made in the middle of the Simpson in 1966 was a bit cut off a broom handle plus layers of insulating tape.

[bemm52]

I know someone will tell me that's not where the brake lines run - well it is on my car because I like it this way.

I also ran my brake lines where I thought best to keep them out of the way but I had a few minor clashes around the front of the vehicle and saw some wisdom in LRs original routing
I also ran the wiring for the rear lighting outside the chassis rather than through it

Cheers Paul

[cjc_td5]

You know, there is no real need for splines on the tool - I made mine on the lathe! An emergency one made in the middle of the Simpson in 1966 was a bit cut off a broom handle plus layers of insulating tape.Pretty much how I did my last one. Some aluminium tube with wrapped insulation tape to correct the diameter.

[akelly]

Today's update: got the rear end back together, diff centre in, brakes, hubs etc... Waiting for drums to come back from machining. I didn't use the garbage locktabs on the stub axle bolts - just locktite. And I forgot to grab split pins when I was at the shops.... job for tomorrow.

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Chucked the rear main seal in some oil so I can fit that tomorrow then get the flywheel and clutch back on ready for the motor to go in.

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Getting there but the delay on the bulkhead outrigger delivery is really starting to be irritating. I'll finish off the brake lines tomorrow and do the front brakes. I have swivel hub rebuild kits but no time to do them right now, they'll have to wait until next year.

[akelly]

big day today. Started with fitting up the RHS 16 gallon tank, which promptly fouled on the shackle pin and doesn't fit. I cannot see for the life of me how anyone who had one of these tanks made here in Melbourne could have fitted it to the car. So anyway I marked out the area that fouls and a mate is going to notch both sides out for me so they actually fit.

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so stymied on that task I got on with painting the rims. After testing the "hogs bristle" rattle can the other week I then found a tin of "classic cream" I must have bought at some point for this job, so I mixed it up 4:1 and shot a few coats on the rims. I haven't painted with a gun for about 25yrs but after watching a few youtube vids (the gunman is very good) it came back to me no worries.

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Really pleased with how they look. I think the weather looks crook here tomorrow, so I'll do the back side on Wednesday.

Then I got on with replacing the rear main seal in the 186. I was pleased to find an alloy cam gear in there, and everything looks to be in good order. A new bottom end gasket set and I gave the waterpump a birthday while I was on a roll - just needed a good cleanup after sitting for years.

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Last bit of stuff today was printing a new wheel for the magna tex indicator switch. I did a CAD model of the whole wheel assembly then kind of eyeballed the dimensions for the wheel. Printed in TPU, which is a flexible material a bit like stiff rubber. Looks OK, will see how it works when I get to putting the dash together.

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Now I'm buggered so that's it for today.

[gromit]

big day today. Started with fitting up the RHS 16 gallon tank, which promptly fouled on the shackle pin and doesn't fit. I cannot see for the life of me how anyone who had one of these tanks made here in Melbourne could have fitted it to the car. So anyway I marked out the area that fouls and a mate is going to notch both sides out for me so they actually fit.

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I've got one fitted and I parted out a diesel shorty with one fitted some years back.
It's close against the shackle pin (tank has to be dropped to remove the pin) but there is clearance.


Colin

[akelly]

engine back in today. Fitted up the new 9.5" clutch, used the printed alignment tool - worked great.

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Not much else to report today.

[EDIT]

late update from mate who is notching the fuel tanks for me. He's finished one side. Looks great.

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[Johnno1969]

I'm really enjoying this thread. Great work - keep it up!

John

[Johnno1969]

P.S. I've been carrying around a cut-off section of broom handle for years for aligning clutches. But that printed one certainly is impressive. :)

[akelly]

A few updates from the last couple of days. Been battling with an issue where the bellhousing and gearstick foul on the tunnel cover and diaphragm. Previously it had a butchered 6cyl bulkhead and tunnel cover and they've been cut and modified to make things fit. After swearing for a couple of days with a tape measure and spirit level I worked out the issue - the holden motor is kicked up at the front as it would be in a holden. This kicks the gearbox up and back and causes all the drama. So I pulled the engine mounts and lowered the engine to where it the gearbox sits level - then my welder mate came and took the engine mounts away to modify them to suit.

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The bulkhead outrigger finally arrived so I glued that in. I chopped the plate off it comes welded to and stuck it direct to the chassis as per original. I'm not the best welder but it's nice and strong and the grinder makes it look nice.

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Now I'm finally able to finish the bulkhead. I just need to make a strip to fill in this gap between the centre section of the bulkhead and the diaphragm. I'll get that done tomorrow.

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That will let me bolt everything back on for the front.

Other minor job this morning before it rained was to clean up the brake drums and paint them. I've done all the wheel bearings, kits through the front wheel cylinders and new rears, new gaskets and replaced all the distance pieces on the stub axles. I have new front swivel hubs to go on but I'm running out of time before we move house, so that's a job for later.

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A few things still left to go and not much time....

Oh, and if you're after any IIA parts keep an eye on the for sale section because I have a bunch of stuff that is excess to requirements now and needs to get gone fast...

[4bee]

You know, there is no real need for splines on the tool - I made mine on the lathe! An emergency one made in the middle of the Simpson in 1966 was a bit cut off a broom handle plus layers of insulating tape.


That sounds like the work of a true Series Land Rover owner.

The good old Micro metric Insulation tape.


When all else fails, Bodge it.:TakeABow:

[4bee]

big day today. Started with fitting up the RHS 16 gallon tank, which promptly fouled on the shackle pin and doesn't fit. I cannot see for the life of me how anyone who had one of these tanks made here in Melbourne could have fitted it to the car. So anyway I marked out the area that fouls and a mate is going to notch both sides out for me so they actually fit.

166497

so stymied on that task I got on with painting the rims. After testing the "hogs bristle" rattle can the other week I then found a tin of "classic cream" I must have bought at some point for this job, so I mixed it up 4:1 and shot a few coats on the rims. I haven't painted with a gun for about 25yrs but after watching a few youtube vids (the gunman is very good) it came back to me no worries.

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Really pleased with how they look. I think the weather looks crook here tomorrow, so I'll do the back side on Wednesday.

Then I got on with replacing the rear main seal in the 186. I was pleased to find an alloy cam gear in there, and everything looks to be in good order. A new bottom end gasket set and I gave the waterpump a birthday while I was on a roll - just needed a good cleanup after sitting for years.

166491166492166493166494

Last bit of stuff today was printing a new wheel for the magna tex indicator switch. I did a CAD model of the whole wheel assembly then kind of eyeballed the dimensions for the wheel. Printed in TPU, which is a flexible material a bit like stiff rubber. Looks OK, will see how it works when I get to putting the dash together.

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Now I'm buggered so that's it for today.


If you find you need a bit of extra grip for the wheel use a piece of Velcro wrapped around the steering wheel tube although with a "new" wheel you should be ok.

Thanks for an excellent rundown on your progress through the ages.

[akelly]

Ok so today I finally finished off the modifications to the bulkhead to convert it from a 6cyl to 4cyl. I have to stress that it's not a faithful reproduction of every aspect of a 4cyl bulkhead, I just replaced the centre section so I could use 4cyl floor panels and gearbox covers and perhaps later on fit a heater. Pics are from my final test fit with everything tacked in place, its back on the bench now having been fully welded but I ran out of time to fit it today.

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Getting the curved piece right was very time consuming, but the process was enjoyable. I wish I had more time to spend on it right now but I'm racing to get the car mobile so I can load it on the trailer to move house.

I keep meaning to make a bending brake but I just improvised today with some steel bars and a planishing hammer...

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Then I bent the section around an old 6cyl diaphragm cover to get the correct shape...

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I don't think I'll get a job in a body shop any time soon, but the end result fits nicely so that's good enough.

The other job today was test fitting the modified engine mounts. I had to do a bit of chopping to make them fit around the extractors but otherwise they fit great. Have to do a couple more mods to give access to the lower bolt on the LHS mount, so that will happen tomorrow and they'll be fully welded. The extractors were custom made years ago in place on the car and unfortunately to get the bolts in the engine mount they have to be removed from the head to give enough room - can't do much about that now.

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Tomorrow I need to pack up the workshop for the removal so there's not much more I can do for a while. Time blew out on me thanks to waiting 2 and a half weeks for a part from Brisbane, plus complications from weird mods done by someone else previously that had to be undone. I'll get it on the trailer Thursday once the new engine mounts and fuel tanks are ready, then I can do a bit more over the holidays after we've moved out of here.

Oh, one last pic - my printed magna tex wheel came up alright I think.

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[4bee]

Ok so today I finally finished off the modifications to the bulkhead to convert it from a 6cyl to 4cyl. I have to stress that it's not a faithful reproduction of every aspect of a 4cyl bulkhead, I just replaced the centre section so I could use 4cyl floor panels and gearbox covers and perhaps later on fit a heater. Pics are from my final test fit with everything tacked in place, its back on the bench now having been fully welded but I ran out of time to fit it today.

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Getting the curved piece right was very time consuming, but the process was enjoyable. I wish I had more time to spend on it right now but I'm racing to get the car mobile so I can load it on the trailer to move house.

I keep meaning to make a bending brake but I just improvised today with some steel bars and a planishing hammer...

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Then I bent the section around an old 6cyl diaphragm cover to get the correct shape...

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I don't think I'll get a job in a body shop any time soon, but the end result fits nicely so that's good enough.

The other job today was test fitting the modified engine mounts. I had to do a bit of chopping to make them fit around the extractors but otherwise they fit great. Have to do a couple more mods to give access to the lower bolt on the LHS mount, so that will happen tomorrow and they'll be fully welded. The extractors were custom made years ago in place on the car and unfortunately to get the bolts in the engine mount they have to be removed from the head to give enough room - can't do much about that now.

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Tomorrow I need to pack up the workshop for the removal so there's not much more I can do for a while. Time blew out on me thanks to waiting 2 and a half weeks for a part from Brisbane, plus complications from weird mods done by someone else previously that had to be undone. I'll get it on the trailer Thursday once the new engine mounts and fuel tanks are ready, then I can do a bit more over the holidays after we've moved out of here.

Oh, one last pic - my printed magna tex wheel came up alright I think.

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Looks fine to me comparing it with a new black one I have.

[akelly]

not much cooking today on the landy, spent the day packing up about 1/2 the workshop and listing stuff for sale on gumtree and here.

Mate dropped off the tanks he notched out to clear the shackle bolt heads. Did a fantastic job. I wish the guy who made the tanks could weld this well. I grabbed some RedKote to throw in the tanks so will do that tomorrow.

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Other than that nothing to report. Hoping to weld up the front tank mounts tomorrow and get them installed, along with the new engine mounts.

[akelly]

well things got very hectic and I ran out of time to get everything done before our removal, so here's where I'm at:

Got the bulkhead done and bolted up.

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Got most of the front back together but ran into some shortages of captive nuts in the bulkhead, so the passenger door is on but not the drivers.

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Loaded it on the trailer and headed north. This is our stopover at Thredbo. Cannot recommend towing a series landy up there from Albury - spent quite a bit of time in low range working the gears and doing about 20kph. Meant we got to take in the scenery though and my 7yo daughter was loving all the wildlife, including a black brumby running down the road in front of us.

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But the defender did well and got us to Culburra Beach safe and sound. We'll be here about a month before heading up to Qld. Probably no more updates on the Series IIA for a little while - have a few other priorities to take care of.

[Johnno1969]

Thanks for a terrific thread so far and I look forward to seeing more of the rebuild in the future.

Meantime, Merry Christmas and good luck with the move!

John