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Thread: Anybody got a Lightweight?

  1. #51
    Join Date
    Jun 2009
    Location
    Bacchus Marsh Vic.
    Posts
    3,238
    Quote Originally Posted by DieselDan View Post
    It's been a while, so thought I'd post an update of what's happening.
    In short, not a lot!
    Been slow going trying to find the time to work on it. Managed a few days over the Christmas hols and over Aus day long w/e, but that's about it.

    So..... jobs completed thus far:
    New seat belts;
    Reverse light activated with switch on the bottom of the gear stick.
    Half completed brake pipe renewal.

    The last one of those has turned into a bit of a saga. Mine has a dual master cylinder and a 5-way split pwda valve thingy.
    A general search for series 3 dual master cylinder brake systems usually leads to 1980 twin leading shoe systems and a 4 way split pwda.
    This got me scratching my head slightly and wondering if I had some bastardised brakes due to it being built in 1975 but then released into civilian world in 1980 and some previous owner fitting some weird brake combo.
    Anyway further searching led me to find a reference to a 1975 optional equipment catalogue which had this pic of the brakes, which is exactly what I've got!

    So, now knowing that the brakes seem to be correct (10" single leading shoe with dual master and 5-way pwda) I've got all new brake pipes bent and flared, bagged a new freebie pwda from the old man, fitted a new servo and am deciding whether to rebuild the master cyl or just get a new one! Wheel cylinders were new before it was in storage in the UK, but they're cheap enough so might replace them.
    Then the fun job of bleeding the brakes and not getting the valve in the pwda to throw a wobbly begins!
    I made similar discoveries when doing the brakes on ours, a mix of Series2(imperial) at the wheels and Series3(metric) pipes ect.. made buying the rear flex hose interesting, the front is now civilian flex hoses.
    Cheers, Kyle



    The Good Oil.
    When did you last visit?
    http://www.aulro.com/afvb/good-oil/



  2. #52
    Join Date
    Jul 2011
    Location
    Yarrawonga, Vic
    Posts
    5,935
    Mine is 1973 and has Dual circuit Master and PWDA as standard. The valve is just a shuttle valve to illuminate the dash lamp to let you know if one of the circuits is leaking. Not a bad idea.

    Single leading 10" front and rear is standard on all lightweights.

  3. #53
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    Thanks fellas,

    Glad I'm not the only one who struggled trying to get their head around this!

    So the dual master, 5-way pdwa and 10" single drums seems standard on S3 Lightweights from '73 at least!

    One more thing I've realised I need to do is move the rear number plate to the middle of the tailgate because we don't have square rego plates!
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  4. #54
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    Thought it was way past due for an update, so here's what's what!

    Number plate fixings and light are moved to the tailgate.
    I was about to start bleeding the brakes weeks and weeks ago, but before I did, I just thought it was worthwhile double checking the brake cylinders.
    Good job I did, two of the four leaked and one was seized solid!
    So, all new cylinders and shoes and then start with the bleeding.
    To my complete and utter surprise, this has seemingly gone without a hitch.
    I've got a piece of clear tube with a one-way valve in the end, which I put in a jar, and attached the other end to each cylinder.
    With the door off, this meant that I could push the pedal by hand and look at the tube to see when the bubbles stopped.
    In amongst all of this, I discovered quite a lot of rot in the LHS door support pillar portion of the bulkhead, so I attended to this too.

    Now that the things that my VASS engineer mate told me to sort are all finally fixed, today was the final inspection day and he's happy with my workmanship, hurrah! Even commenting what a top job I've done on the brake pipes.

    So now it's on to getting it road worthy.
    Looking at the state of things, there's 3 areas that I reckon will fail - leak at the back of the Tcase/hand brake drum, dodgy looking steering tie-rod end and rear tyres that are rock hard and cracked to buggery.

    Trying to find tyres that I like is consuming more time than I thought!
    The current rear tyres are original 205R16 Michelin XM+S from an old Rangie (one of each from the picture below) and the fronts are remoulds in a copy of the pattern on the right. I do like the look of these, almost kinda like rally cross tyres and even have holes in them for studs!
    michelins.jpg

    Anyway, these are now unobtanium, although I have found that a company in the UK is remanufacturing the pattern on the right. For over 150 quid a pop!

    Since I've got the original 5" wide Lightweight rims, I really need to keep to the 205R16 size, which limits the choice a bit.
    But I have found these from Jax, which don't look too bad.
    Tracmax.jpg

    Thoughts?
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  5. #55
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    New canvas!
    Needs a few sprinkles with the hose pipe to seal/season it up.
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  6. #56
    Join Date
    Jun 2009
    Location
    Bacchus Marsh Vic.
    Posts
    3,238
    Quote Originally Posted by DieselDan View Post
    New canvas!
    Needs a few sprinkles with the hose pipe to seal/season it up.
    Under Covers one?
    Iíve been thinking of theirs for ours, getting a good reputation as they cut off the original pattern.
    Cheers, Kyle



    The Good Oil.
    When did you last visit?
    http://www.aulro.com/afvb/good-oil/



  7. #57
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    No, it's an Exmoor Trim one.
    Never had an Undercover Covers one, so can't compare, but very happy with the quality of this one.
    The parts place where I bought all the replacement plugs/leads/dizzy cap, fuel pump/filters etc. in order to get it running ready for export are also an Exmoor Trim dealer, so made sense just to get everything at once.
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  8. #58
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    It lives!
    Sort of.
    Took it out for a spin ready for a roadworthy check, but I seem to have a fuel starvation issue and it conked out in the middle of a junction!
    Typical.

    After holding up an inconvenient amount of traffic, someone helped me push it to the side of the road and then gave us a tow!
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  9. #59
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    Oh and does anyone have any military style side/indicator lights going spare?

    I only realised why everyone was still coming right up behind me at the junction, even though I had the hazards on, was because the left rear indicator is cactus. Everyone thought I was still planning on turning right!

    The metal internals inside the rubber housing have disintegrated!
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

  10. #60
    Join Date
    Jan 2012
    Location
    Geelong
    Posts
    741
    Taken just prior to it failing to proceed...!
    Dan

    '14 Def 110
    '75 Lightweight
    '98 300Tdi Disco (gone)
    '80 2Dr Rangie Classic (gone)

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