FFR Refurb

I've been dragging my heels on this one, mainly because of so many other projects, jobs the wife wants done, taking kids to Cubs/Scouts/Venturers etc. etc.

Just had some rims media blasted, then I painted in camoflage green and fitted some Steeltreks.

The drivers door is off and the skin removed to take out a crease, need to get that re-assembled and then painted.
Doortops have been re-painted just need to fit new Bailey channels and re-glaze then onto the brakes.....

https://www.aulro.com/afvb/images/im...17/01/1129.jpgDSCN4150 by Colin Radley, on Flickr

https://www.aulro.com/afvb/images/im...17/01/1130.jpgIMG_0890 by Colin Radley, on Flickr

Colin

The passenger door is nearly finished.
De-skinned, frame straightened, large dent removed from skin then re-skinned. Doesn't look too bad.
Just need to strip, paint & fit the top capping then re-glaze the doortop.

https://www.aulro.com/afvb/images/im...17/01/1127.jpgDSCN4166 by Colin Radley, on Flickr

https://www.aulro.com/afvb/images/im...17/01/1128.jpgDSCN4201 by Colin Radley, on Flickr



Colin

Found I had some time on my hands tonight so using some leather offcuts I made some seat restraining straps.

There's one strap on each seat base.
https://www.aulro.com/afvb/images/im...017/08/235.jpgDSCN4469 by Colin Radley, on Flickr

Two straps on each seat back.
https://www.aulro.com/afvb/images/im...017/08/236.jpgDSCN4472 by Colin Radley, on Flickr

I thought I'd also make some straps for the seat bases on my Series I. I have a tool for slitting leather into strips so the offcuts had one straight edge cut and then I reduced them to 7/8" strips.
Then using a Stanley knife, hole punch & a couple of chisels.....the straps slowly appeared.
https://www.aulro.com/afvb/images/im...017/08/237.jpgDSCN4473 by Colin Radley, on Flickr

The more I made the better they got. Finally 9 for the FFR and 4 (only need 3) for the Series I, as I haven't checked the length they aren't cut down yet.
https://www.aulro.com/afvb/images/im...017/08/238.jpgDSCN4478 by Colin Radley, on Flickr

I need to get some more leather. I can buy it already slit down to any width I want but by using offcuts the above straps cost less than $3 plus my time & having the tools available.

You can buy them ready made http://www.exmoortrim.co.uk/leather-straps.html but they would have to be cut down for the FFR and they are black not brown as original......

Next....the seatcovers ! I got some green vinyl years ago and have an industrial sewing machine I just need to find the time and enthusiasm.



Colin

Always on the lookout for parts I collected a NOS 6-cyl water pump tonight.

https://farm2.staticflickr.com/1951/...9633b4fa_c.jpgDSCN4943 by Colin Radley, on Flickr

https://farm2.staticflickr.com/1946/...436a9254_c.jpgDSCN4942 by Colin Radley, on Flickr

https://farm2.staticflickr.com/1958/...75067d02_c.jpgDSCN4944 by Colin Radley, on Flickr


Brass or bronze impeller and the fat O-ring has the copper support 'washer' inside.

County brand who were around before **itpart & Bearmach from memory.


Colin

Due to having free time since Covid 19 I've been working on the FFR occasionally.
This has been a long term project with no rush.....

Painted a replacement brushbar (original bent), straightened the bumper & front airlift points and painted.
Steering box removed and O-ring replaced. Found a few loose bolts from the previous owner !!

Then decided I need to work my way round the brakes again. Three were done years back but I didn't strip the swivel hubs so time to pull the axles apart, replace seals etc.

I'm working in an open sided shed with no lights so it's a case of remove parts during the day, move parts to another shed and strip/paint/re-assemble then back to the open shed to re-fit. It also entails a lot of walking backwards & forwards because there is always a tool I've forgotten.

I ended up replacing the UJ in the drivers side half-shaft, both wheel bearings and the swivel hub seal.

Currently checking out the steering track rods and then onto the other side of the front axle......


Colin



Colin

Passenger side swivel hub stripped, cleaned & ready for paint.
Lots of bolts to clean, threads to clean out (some blocked with plugs of silicon). Half a kilo of oily mud scraped off before I could degrease everything.

Needs a new swivel seal and I had to replace the Railko bush and pin. Just at the limit of my 20tonne press pressing it out and had to use some heat to fit the replacement.
With all the front axles I've overhauled this is the first Railko bush I've had to replace, the pin had rusted and worn the bush quite badly. Happened to have a bush & pin in stock......

This swivel hub is earlier than the drivers side. The seal retainer bolts are BSF whereas the other side was UNF.
Drive shaft seemed OK so once everything is painted it's re-assemble, re-shim and down the back shed to re-install.



Colin

Front hubs done, steering box back in place.
Refitting the brackets that hold the steering column to the bulkhead was 'fun'. Not a lot of room but fortunately I was removing the master cylinder & booster anyway.

Pedal box stripped out & painted. Interestingly found that if the pedal is fully depressed an oil hole lines up with a hole in the pedal box (has a plastic blanking plug fitted). I countersunk the hole to give it a better chance of catching oil as it's dripped in (as if I or anyone else will be lubricating the pedal pivot !).

Tonight I took the master cylinder apart as I have a repair kit in stock. Someone has attacked the pistons with Vice Grips or similar and there has been some corrosion internally. There is a small pin that holds one of the two pistons in position, this has been damaged and inserted when the piston was in the wrong position damaging a seal and the seal support plate (fortunately new ones in the repair kit).
I have enough parts to fix it and the corrosion seems to be between where the seals sit in the bore, problem is the damaged pin so it looks like I might have to make one. Instead I headed down the back shed and found a new master cylinder I sourced from India (about US$25) some time back, a mate who imports from India included it in one of his shipments. Took it apart and it looks identical even down to the nylon 'circlip' that holds the outer piston in place so I'll fit that instead.
I fitted a new Girling reservoir that I sourced from the UK years back. Where it sits close to the gap between bonnet & wing UV light gradually breaks down the plastic and it goes all powdery. I replaced one on Wallit which died in the same manner.

Need to re-fit the steering wheel and cowling so I can re-attach the link arm to the steering relay in the correct position then on to stripping out the rear hubs & brakes.


Colin

Lockdown is a PITA, keep running out of things and difficult to source parts at the moment.

I need some insertion rubber to make a gasket for the pedal box, usually 'in stock' but I'd run out. Maybe I'll fit the pedal box in a few weeks time !

Went to fit the steering damper, no rubbers. I have a new steering damper in stock but I'd already pinched the rubbers from that so need to order some.

Rear brake shoes had been covered in oil, fortunately I found some re-lined shoes in the shed. I'll have to get the oil covered ones re-lined at some point in the future.

Picture attached of the Indian master cylinder fitted with a new Girling reservoir and the innards of the original.
I made a pin for the old master cylinder from a nail which will do the job perfectly. For those that are old enough, I found a box of nails purchased in the UK in the days when you paid for them by weight. Filled a bag and they were weighed when you went to pay.
Modified the head slightly (it was too big & too shallow), cut to length and it's as good as a new one.
I'm sure someone reading this will be having kittens over using a nail to fix a master cylinder !

Had a good look down the bore of the old master cylinder and I think it really needs sleeving. The rust pitting is quite bad in two spots so I'll use the Indian one for now.

Offside (drivers side) hub stripped & degreased ready for prep & paint.


Colin

If you still need insertion rubber, Colin, then pm me your address and I can post you some.
Got **** loads of off cuts, just give me dimensions and I'll see what I've got.

Quote:

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Originally Posted by DieselDan

If you still need insertion rubber, Colin, then pm me your address and I can post you some.
Got **** loads of off cuts, just give me dimensions and I'll see what I've got.

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Thanks Dan.

Colin