Thread: my '65 109 "Big Ears" (200Tdi)

Been watching this build with great interest. The chassis came up a treat (hopefully "Ralph" wont have as much corrosion as "Smeg" did). Are you going to use just chassis black or something like "Rockcote"?. Would it be an idea to waxoyl it now while the tubs off to make it more accessible.Keep it up, great job mate.
Cheers Ian

it's getting another couple of coats of chassis black before i pull the rear electrics cable (using seven core trailer cable) through the chassis and then i have a gallon of waxoyl to squirt into the chassis using the schutz adaptor thing, which will be thinned to hopefully penetrate any rust/crud build up and vapourise and layer the top rail as well (wishful thinking i reckon) ...

i'm not sure what this "rockcote" is, but if it's anything like the stuff the army used on my 1974 lightweight/airportable chassis, i'll definitely give it a miss as it's the most rotten chassis i've had to date, it had cracked and allowed the water/mud to get behind it without falling off, i prefer the idea of paint peeling and showing where the rust is developing

Thanks for the mojo boost Ian

well the exhaust is built, 52mm straight through with a short flexi to kill any vibration down it's length (sorry no picture) with two seperation joints, quite pleased as it was simpler to build than the one on my 88" bitsa...

trailer cable has been pulled through the chassis and connected into the rest of the loom plus i've squirted about 2.5 - 3 litres of waxoyl inside the chassis, i'm letting that thicken up and then i'll get some more in there...

and finally the tub, sides and roof are back on and i can drive it around the yard without the doors being strapped to the wings, still lots to do but at least i can now lock it up

latest pictures

not felt like i've had much progress lately as it's mostly been little fiddley bits to do, all my wiring except the trailer hookup is now done and working (still not got a fan yet though) and i got my series3 wash/wipe switch so i can switch on both wiper motors without having to reach across for the passenger one (the motors themselves will be permanently switched on) and i can now use a proper sceen wash pump rather than the little manual pump, the reason i chose the series3 switch is because it won't look out of place under the dash

the seatbox and all the cab flooring/tunnel etc is now fitted so it doesn't feel like a flintstones vehicle anymore and is quite a nice place to sit, original elephant hide seating but i need to find a passenger seat squab as mine is quite badly torn, i'm just a little worried about comfort over distance even though i really do like the retro cab appearance

both my sills are fitted, i just need to attach the lower stays to stop the panel flex

a couple of problems have shown thier faces already, first i sprang a fuel leak from the injector spill pipes which had me confused for a couple of days, it turned out to be crud that had peeled from the sides of the tank return pipe and blocked it up, disconnected and blown through with an airline sorted that along with fitting new 3.2mm spill pipes between the injectors

and one of the sealed beam units decided that it would have a giggle at my expense and blow the dip filament, i need to get in the boxes and see if i can find a replacement (i don't really want to fit the H4 units that i have on the shelf)

of more concern is the waterpump which appears to have sprung a leak i don't suppose i should be surprised as the motor hasn't run really for at least two years except for a little test run or two and has been kept dry of water for the last year until very recently

and worst of all my clutch master cylinder decided to leak, yes the fluid ran down my nice and freshly sprayed footwell so it looks like i'll be carefully trying to touch that up when i get round to it

i've still got the brakes to bleed and check over as i've not even had the drums off yet

still a few fiddley jobs to do as i said earlier but i'm slowly getting there, it's just very little visible progress , i'll sort a couple of pictures out later

oops forgot this thread was here (sorry)

well i've finally got him on the road about two weeks ago and took him for the MoT test which he passed with flying colours

two days later i took him to his first show with the Series 2 Club at the Royal Showground, Stoneleigh, where he was received with lots of good comments and lots of back patting (which gave my ego a bit of a boost )

i've only put about 100 miles on him so far and nothing major has shown up apart from my modified p/s pump collapsing (was using it as an idler) so i've fitted the series alternator mount and am now driving the alt' direct from the crank

i still have to swap the diffs as i'm still on the 4.7s which means it's pretty greedy on fuel and noisewise the top comfortable speed is 40-45mph (i've had him up to 70 tho )

i've still a few jobs to do, doorseals and ventseals along with the rear window seals needing replacing but mostly he's finished (but no doubt i'll think of other jobs after posting this)

the one thing i will say is i'm most impressed with the comfort while driving, my 88" hops and bounces around at the slightest changes in the road surface, while this one just rides over them with hardly a jiggle, it looks like i'll be using it more often once the diffs are changed especially for distance work, i've got a pair of 4.3s to go in but would prefer 3.9s, if i can't find the 3.9s (rocking horse droppings) and i don't feel the 4.3s benefit me enough i'll end up with 3.54s in there

but anyway, so far i'm enjoying him and i'm looking forward to exploring Wales next year camping and laning

I've been wondering if you'd completed the project as you've been a bit quiet Any chance of some pics of the completed engine bay ??

I've just collected my 3.54 axles to swap into mine, also putting in parabolic springs, pro comp shocks and a few other new bits. Then it's time for me to think engine swaps, but I'm still not sure which one

Nissan ED33 Diesel / 5 speed box / landrover transfer case + pto or

Defender 300tdi / series gearbox or

Holden 186 / nissan 5 speed box / landrover transfer case

the engine bay isn't quite complete, i need an airbox which may yet be one from a Montego and a slim electric pull fan for cooling along with adaptors for my 52mm temperature and oil guages, i should be just about finished under there then, by the way the header tank is from a modern Rover 75 which i think is the ideal unit

a picture




the only time it has been on ramps, MoT time


on tour at Stoneleigh with the Series 2 Club






the morning after the night before at Stoneleigh


Big Ears and Zebedee together


getting close to making a start on this one now, my 1970/71 New Zealand ex-military CKD, Chalkie


i hope you enjoy the pictures, i've enjoyed building him but am definitely relieved that he's nearly finished it's been a long 8-9 months

Well done, It's a cracker!