Remove A/C. Replace with vents.

[D110V8D]

Ok here's a project a few of you early 110 owners may be interested in.
It involves removing the factory fitted (in Australia) air conditioning system in favour of the original Land Rover cooling system.........the vents in the firewall.

So most air conditioned 110 County's look like this inside...


http://img222.imageshack.us/img222/9519/cimg00058xg.th.jpg (http://img222.imageshack.us/my.php?image=cimg00058xg.jpg) http://img254.imageshack.us/img254/5421/cimg00163ye.th.jpg (http://img254.imageshack.us/my.php?image=cimg00163ye.jpg)

So the first thing you will need to do is remove the dash. All of it.:eek:

It will then look like this.......

http://img223.imageshack.us/img223/8242/p12301273px.th.jpg (http://img223.imageshack.us/my.php?image=p12301273px.jpg) http://img254.imageshack.us/img254/285/p12301134mi.th.jpg (http://img254.imageshack.us/my.php?image=p12301134mi.jpg) http://img223.imageshack.us/img223/9818/p12301361kj.th.jpg (http://img223.imageshack.us/my.php?image=p12301361kj.jpg)

Now you can see the vent covers that are spot welded to the firewall.

http://img254.imageshack.us/img254/7803/p12301387kt.th.jpg (http://img254.imageshack.us/my.php?image=p12301387kt.jpg)

More on this part later.....

Next remove the old air con/heater assembly from the engine bay along with the compressor and condensor etc. Check your workshop manual for detailed instruction on this part.;) Once removed it should look like this...

http://img254.imageshack.us/img254/2274/p12301307lp.th.jpg (http://img254.imageshack.us/my.php?image=p12301307lp.jpg) http://img254.imageshack.us/img254/9330/p12301310jf.th.jpg (http://img254.imageshack.us/my.php?image=p12301310jf.jpg) http://img254.imageshack.us/img254/5092/p12301338jg.th.jpg (http://img254.imageshack.us/my.php?image=p12301338jg.jpg)

Make sure you block off the heater hoses from the engine with some "bling" glass stoppers like the ones I made.:D :D ;)

So.....whats next?

The bottom section of the dash should look like this......

http://img222.imageshack.us/img222/958/p123011218vl.th.jpg (http://img222.imageshack.us/my.php?image=p123011218vl.jpg) http://img252.imageshack.us/img252/5715/p123011318hy.th.jpg (http://img252.imageshack.us/my.php?image=p123011318hy.jpg)

You'll notice that the air conditioning ducting system is attached to the bottom section of the dash. Unscrew it from the bottom section. It will then look like this......

http://img149.imageshack.us/img149/2135/p12301149op.th.jpg (http://img149.imageshack.us/my.php?image=p12301149op.jpg) http://img149.imageshack.us/img149/3328/p12301154sd.th.jpg (http://img149.imageshack.us/my.php?image=p12301154sd.jpg)

Next week we will attach the "new" dash tray (which will replace the air con duct system) ,fit the "new" heater assembly from a Defender and then drill out all those spot welds from the firewall. :D

Stay tuned for the next update.

[hiline]

my my Mick you have been busy :D

[D110V8D]

Pig 2.0 in the making mate.:D :D :D ;)

[hiline]

Pig 2.0 in the making mate.:D :D :D ;)


NOOOOOOOOOOOOOOOOOOOOO

Dont do it ;)

[D110V8D]

Well......not a pig this time.;) :D :D

A true Land Rover. Not a Pretender.:p :p :p

[sclarke]

YAY.................

Mick is building a Defender......

sadly it will never be the same......

I have a disc rear end that would look Trick in that.......

[tam242]

D110V8D

I recently did this to my 110, with care you can drill out the spot welds without touching the bulkhead metal. If anyone interested i have a document covering all the parts required for conversion.

[JDNSW]

........
It involves removing the factory fitted (in Australia) air conditioning system in favour of the original Land Rover cooling system.........the vents in the firewall.

........

That airconditioning system is not peculiar to Australia - it was fitted to the 110 wherever aircon was fitted.

John

[EchiDna]

D110V8D

I recently did this to my 110, with care you can drill out the spot welds without touching the bulkhead metal. If anyone interested i have a document covering all the parts required for conversion.


that would be a most useful document tam242!! :D

[D110V8D]

That airconditioning system is not peculiar to Australia - it was fitted to the 110 wherever aircon was fitted.

John

:oops2: :oops2:

Maybe someone else should write up this tutorial.

Tam242...... where were you a couple days ago!:eek:

Post that list, post haste!:cool:

[Bigbjorn]

D110V8D

I recently did this to my 110, with care you can drill out the spot welds without touching the bulkhead metal. If anyone interested i have a document covering all the parts required for conversion.

Suttons-P&N make special twist drills for drilling out spot welds in sheet metal. Developed for the smash repair industry, ythey take out the weld and leave the other panel undamaged. Ring Suttons 1300 or 1800 number for your nearest agent.

[D110V8D]

Nice one Brian.:) :cool:

Thanks.

[1103.9TDI]

Been there, don't forget to keep your clock.....:D

[tam242]

Sorry for delay

You must save it too your computer or it wont open???

[rangieman]

Sorry for delay

You must save it too your computer or it wont open???


it just opened on mine and i didnt save it:p

[D110V8D]

Sorry for delay

You must save it too your computer or it wont open???


I tried both ways, the rangieman way and your way tam242.

It aint workin. I am pretty ham fisted when it comes to computers though.:D :D :D

Any suggestions?

[sclarke]

he download ok

[EchiDna]

works fine for me :)

[D110V8D]

An update....

I've removed the panels which are spot welded onto the firewall. Not as bad as I thought it was going to be. I looked for a spot weld specific drill bit but all I could find was a "mini" hole saw. It was designed for removing spot welds but the diameter was too big (6.35mm) and it would have left behind the actual spot weld. I didn't like that idea so I went with a high speed steel (for drilling stainless and high tensile steel) drill bit.

So what happened??

Not alot. I managed to drill out most melds without breaking through the firewall itself. Some did break through though. I'll try and get someone to mig weld the holes up for me.:) The panels came out without too much hassle. A light tap on them from the outside after drilling all the welds out soon had them in the bin.:D :D

I obtained a series 3 firewall for next to nothing, and I have all the levers, vent flaps, flywire etc from it to fit up to the 110. Unfortunately the bottom dash "tray" doesn't match the 110 one so I'm still chasing one from a 110 (non air con) or a Defender.

So all in all it's coming together. A trial fit of the top dash assembly showed that most of the holes to screw it to the firewall actually line up, which is great. The steel vent lever support panel will need a groove cut in it to allow for the steering column support brace. Other than that it all looks good.

I'm happy.:D

I'll get some pics up through the week.

[sclarke]

Well done....... keep us up to date.....:)

[D110V8D]

Ok. I have drilled out the spot welds holding in the blanking plates in the firewall. There are approx 35 to 40 welds in each plate.

It's not hard to do, you just have to be careful not to drill through the firewall outer skin. Unfortunately this is not as easy as it sounds.:( The skin is only 1mm or so thick. I have some holes to repair.

http://img132.imageshack.us/img132/6799/p2230115ry3.th.jpg (http://img132.imageshack.us/my.php?image=p2230115ry3.jpg) http://img120.imageshack.us/img120/3842/p2230116fa7.th.jpg (http://img120.imageshack.us/my.php?image=p2230116fa7.jpg) http://img120.imageshack.us/img120/3377/p2230118gc2.th.jpg (http://img120.imageshack.us/my.php?image=p2230118gc2.jpg)

Once you have drilled out all the spot welds (look carefully as some are very hard to see) a light tap from the outside will soon have them out.

I have decided to just bog up the holes with some filler. I don't think there is any structural issue with a few holes in the vent surround of the firewall. I hope there isn't anyway!:eek: :eek: :D

Next up I fitted the flywire screens from a series 3. These fit in nicely and are secured with pop rivetts. The only thing to note is one of the mounting points on both screens will have to be removed or it will foul on the steering column support bracket. The screens are still very secure even though one mounting point is removed.

http://img132.imageshack.us/img132/3469/p2230113xy9.th.jpg (http://img132.imageshack.us/my.php?image=p2230113xy9.jpg) http://img120.imageshack.us/img120/7924/p2230114ol6.th.jpg (http://img120.imageshack.us/my.php?image=p2230114ol6.jpg)

These screens are very easy to bend/damage. Be careful. One of mine was already damaged from the donor firewall. I have fitted it to the drivers side. Out of sight.......mostly.

Next on the list is mounting the series 3 vent lever support panel (fascia panel) to the 110 dash pad. Four self tapper type screws and you're done.

http://img365.imageshack.us/img365/3812/p2230120mn2.th.jpg (http://img365.imageshack.us/my.php?image=p2230120mn2.jpg) http://img365.imageshack.us/img365/5862/p2230121ot8.th.jpg (http://img365.imageshack.us/my.php?image=p2230121ot8.jpg)

It fit nicely onto the underside of the 110 dash pad/top. Also I forgot to mention you will need to cut a 'keyhole' in the vent support panel. This will allow the steering column support brace to pass through.

http://img132.imageshack.us/img132/3011/p2230122uo1.th.jpg (http://img132.imageshack.us/my.php?image=p2230122uo1.jpg)

The key hole is cut just to the left of the heater duct mount.

This is what it'll look like assembled.

http://img132.imageshack.us/img132/2514/p2230119ex5.th.jpg (http://img132.imageshack.us/my.php?image=p2230119ex5.jpg)

More to come this arvo..........

[D110V8D]

Ok here is the main assembly fitted up the firewall.

http://img170.imageshack.us/img170/1673/p2230124kd5.th.jpg (http://img170.imageshack.us/my.php?image=p2230124kd5.jpg) http://img170.imageshack.us/img170/3813/p2230127fg4.th.jpg (http://img170.imageshack.us/my.php?image=p2230127fg4.jpg) http://img170.imageshack.us/img170/2980/p2230125ft8.th.jpg (http://img170.imageshack.us/my.php?image=p2230125ft8.jpg)


You can also see here why the keyhole/slot is necessary in the vent support panel.

http://img472.imageshack.us/img472/359/p2230128gd5.th.jpg (http://img472.imageshack.us/my.php?image=p2230128gd5.jpg)

Still more to come.........

[D110V8D]

And the rest of the dash re installed.

http://img407.imageshack.us/img407/9093/p3090153vq2.th.jpg (http://img407.imageshack.us/my.php?image=p3090153vq2.jpg) http://img263.imageshack.us/img263/4371/p3090154rf7.th.jpg (http://img263.imageshack.us/my.php?image=p3090154rf7.jpg) http://img263.imageshack.us/img263/1504/p3090155jw7.th.jpg (http://img263.imageshack.us/my.php?image=p3090155jw7.jpg)

Still a couple things to finish off inside. But it's all there.

And outside...

I did a trial run fitting a flap.

http://img263.imageshack.us/img263/1483/p3090156kh5.th.jpg (http://img263.imageshack.us/my.php?image=p3090156kh5.jpg)

Everything lines up nicely. Just need to attach the brackets to the firewall now and its done. Oh and paint the flaps too of course.

I was thinking of painting them black, so it still looks like it's an air con model but it really isn't.

Almost done.:D :D :D

[LRHybrid100]

Looking good there Mick!!!

I was only talking to Scotty last night about this project and wondering hwo it was going!!!

Another option to get that older Series feel that I know you like would be to use a SIII dash top and bottom and remove all the covering to give you just the metal - Scotty did this on his Hybrid and painted the whole dash and firewall the same as the outside, looks very neat.

LRH

[LRHybrid100]

I can get you some pix if you want?

LRH

[D110V8D]

Yeah I'd like to see that mate. Post em up!:D

[LRHybrid100]

No worries Mick - will get some pix over the weekend

LRH

[LRHybrid100]

hey Mick, just read my PMs:blush: - sorry mate

LRH

[sclarke]

Mick,
Are you putting a Fender Dash in it????

Looks good...

as for attaching the vent hinges...... i think pop rivets will be the neater idea. As per our convo today, the Fire wall is triple skin, PITA to weld with mig, Brazing will burn to much paint.

Mmmmm you only need a few small welds....
Lets try the mig.....

[D110V8D]

To late Steve. It's done.:D

Series 3 and county dash combo.

The flaps are attached. just need to paint the brackets/pop rivets and it's completed.

http://img72.imageshack.us/img72/1944/p3100140mh2.th.jpg (http://img72.imageshack.us/my.php?image=p3100140mh2.jpg) http://img72.imageshack.us/img72/2456/p3100141aw5.th.jpg (http://img72.imageshack.us/my.php?image=p3100141aw5.jpg) http://img72.imageshack.us/img72/8035/p3100142jv5.th.jpg (http://img72.imageshack.us/my.php?image=p3100142jv5.jpg)

So thats that. Not the best tutorial on the planet but never the less I think you get the idea.

It's a bit of a ball buster of a job but it's well worth it in the end. There would be better ways of doing a couple things, probably easier to use a complete Defender dash assembly, instead of a series 3 county combo like I have. But I went for cheaper and easier to get.

Also some people no doubt will prefer to weld the brackets onto the firewall rather than pop rivet them. I dont think it looks out of place, but it's certainly not factory.

Now onto other things..........:D

[sclarke]

Well done....
Best i come over for a Beer tonight

[Zcoota]

D110V8D

I recently did this to my 110, with care you can drill out the spot welds without touching the bulkhead metal. If anyone interested i have a document covering all the parts required for conversion.

Howdy,

Just wondering if the welds need to be drilled from the outside or inside? I can’t quite tell which suede of the bulkhead the blanking plate has been fitted .....

cheers

[Zcoota]

Howdy,

Just wondering if the welds need to be drilled from the outside or inside? I can’t quite tell which suede of the bulkhead the blanking plate has been fitted .....

cheers
Disregard....read all the posts and worked it out .....lol....

[Zcoota]

Well started drilling out spot welds and it turn s out I don’t have a blanking plate welded in there. It’s a double skinned panel, looks like I’ll be cutting the hole out. Anyone seen this sort of thing before?