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

  1. #1
    Join Date
    Jul 2010
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    my '65 109 "Big Ears" (200Tdi)

    i bought this motor about 18-20 months ago, a little by chance and with a little luck (i had sortof been looking for a 109) it was advertised at least 12 months before i was led to it on a general old car/custom forum and i pounced on the opportunity to take a look and strike a deal



    it came complete with a spare bulkhead to rebuild and pretty straight panels all round, a mint condition Aeroparts winch (just needs a new baseplate) and an engine that runs like a sewing machine (2.25 petrol), i had found a fair bit of corrosion round the chassis that needed/needs attention but i had plans for it and a few bits to find/buy, so i've spent the next year basically preparing to start work/buying odd parts...

    i started off by buying a 200tdi discovery which i promptly stripped of any parts i wanted and stashing in my garage


    as you can see i bought a 300tdi manifold/turbo and fitted that to the engine, i then found a pair of 4.3:1 diffs at the right price to make it worth buying them (i would have preferred 3.9:1) they're still in my livingroom (shh don't tell the girlfriend ) ....

    anyway after just about a year i decided i had collected enough parts to start (including two more land rovers ) so i dragged the spare bulkhead out and started chasing the rot out of it, i let in new metal where needed, new footwells and a drivers side foot, then had it media blasted, as soon as i got it home i broke out the paint and spraygun

    this is it just after blasting


    once that was all painted it was time to start getting serious and start sorting the rot, so it was time to start pulling it to bits (i'm working in an unsecure area so i can't just strip the whole motor) so it's off with the front panels and stash those in my garden


    and then take a look at the rot, as you can see the winchplate had rotted the crossmember (not to mention the missing dumbirons)


    out with the rot and in with new metal




    both dumbirons and the crossmember completed


    then it was time to move along a little, offside bulkhead outrigger off and rot removed


    oops where's the boat anchor gone ??


    more bits missing, chassis wire mopped right back to the tub and coated in red oxide


    front springs swapped, chassis with 2 or three coats of black on it, nice clean gearbox with new rear seal and brake shoes and my posh replacement power plant


    bulkhead back on at last, doors carefully gapped at the hinges and then all aligned with the tub nicely, so nice that the doors both close with almost effortless clicks


    now anything that can go rusty in a landrover has in this one, so everything has had to be wiremopped and painted which really does slow some of the progress down but we are getting there, heater was stripped, flushed and generally cleaned out, bulkhead matting was scrubbed and laid flat under books to get it back in usable condition, all pedals and linkages were cleaned/painted along with quite a few little clips that hold wires etc to the bulkhead (i was really getting fed up of this process)






    we've now finally managed almost to get away from the bulkhead for a while (gotta get back into it when i start building my wiring harness), i went to the Sodbury Sortout a week or so ago (autojumble) with a big list of bits, i only found a pair of shocks as part of the list but i did find a pair of "lazytong" style rivet gun , the real bonus was i found a TD5 intercooler at the right price so with a little cutting and welding i put this lot together, S2a breakfast, 200tdi radiator and TD5 intercooler


    of course that breakfast was your run of the mill rusty old thing so something had to be done


    as you can see there is a little bodging along the bottom of it but i don't care

    and after a day of cutting back the paintwork on the wing we now have this


    today i've made my exhaust downpipe out of scrap 52mm bore pipe, patched a hole in one of the turbo/intercooler pipes, i'm now in a position to consider doing the wiring, build some radiator hoses and finish the throttle linkage, i've also got to cut/form a pair of mudshields, polish the nearside wing and bonnet (there's bound to be other little jobs like an electric fan to source and fit)....

    then i can lift the tub and roof off and start work on the rear half of the chassis so far this has taken me about 5 months i think and fingers crossed i've got the hardest part out of the way

    my apologies for the long post, maybe i should have posted to here as well as to the other couple of forums when i started, but i hope you've enjoyed the read..

    anyway here's the photo album if you want to go thru random photos of my work on this project
    My 1965 109 pictures by NiteMare_08 - Photobucket
    Last edited by Lotz-A-Landies; 12th April 2011 at 04:10 PM. Reason: add 200tdi to title

  2. #2
    Join Date
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    Great work!

    The 200/300Tdi is such a sensible conversion apart from the headache around the radiator support panel (you call it a breakfast). There should be more of them!

    Is there not enough room for the original viscous fan on the water pump or are you intending upon additional cooling from the electric thermatic fan?

    One other question. When you were repairing the dumb irons why did you fit the tube between the two bumper bar holes instead of tubing the bolts? I would have thought tubing the bolts would prevent/reduce moisture getting back into the dumb irons.

    Diana

    BTW: Do you mind if I move the whole thread to the section for "Other Powered Series Landies" - I know it is a Land Rover motor in a Land Rover but still it's still a hybrid.

  3. #3
    Join Date
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    This is a fantastic job...Really impressive and neat.

  4. #4
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    lack of room requires the removal of the viscuous fan (plus it releases a little more power for where you really want it) i even cut the threads off the nose of the pump to increase clearance to the radiator core...

    a couple of reasons for putting the crush piece between the holes, but the primary reason was not being quite confident enough to tube the bolts accurately, this way i could have a bit of leeway to allow me to drill without trying to fight a tube that's slightly misaligned

    if you think this thread is in the wrong area then where you put it is up to you, i lost my dummy ages ago and mum won't pass my toys back, i'll just have to sulk

  5. #5
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    Great stuff!
    I really appreciate you posting this up.

    You've done the work in a great time-frame too.

    Kudos.

  6. #6
    Join Date
    Jan 1970
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    South Australia - Port Pirie
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    Hi there

    Looking like a sweet conversion - keep up the good work.

    All the best

    Wayne

  7. #7
    Join Date
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    multicoloured spaghetti time :loon

    ok i've been playing with stiff string and various other bits and a couple of black and white pictures and modifying as i go, we now have this, not quite finished but getting close







    i then connected a battery to see if the smoke would escape but it appears there's none in it :shock:

    there was also a bonus to be had.....














    while i was switching things on i decided to press the starter button ......


    the engine instantly started :really_excited :really_excited

    all the fuel i've got in it is the little bit in the fuel line to the injector pump :woohoo :woohoo :shock:

    (copied and pasted as this is now going on 4 forums )

  8. #8
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    Jul 2010
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    okie dokey, we've been fiddling and faffing about a little, added a few wires and have decided i'm going to add yet more

    won myself a decent condition radiator at the weekend so that got cleaned out and swapped in (it's nice to have fins between the pipes)

    but the most noticeable things i've done recently is connect the intercooler back to the intake manifold, modify the p/s pump by removing the one way valve (hopefully it'll not develop pressure now), welding the port shut and putting a feed pipe on so i can run a little oil in to lube the bearings.

    along with that i've got the clutch bled and the brakes operating after a fashion, thought i was going to have to strip the brake m/c as on the first pump the piston stuck :shock: lots of tapping it and getting nowhere had me a little worried, eventually i got my airline out and blew the piston back carefully

    anyway onto the pictures

    as you can see i've used the Series thermostat housing and two Series top hoses cut and shut (which is why i'll be adding more wires as i intend putting a thermoswitch there for the fan) big shiney pipe is the return from the i/cooler to the inlet manifold




    expecting to get myself round the scrapyards tomorrow on the hunt for bits of radiator hose to make up the bottom hose and hopefully find an expansion tank i like, plus a pull fan (dimensions are a little awkward) and maybe the bits to make up my thermoswitch adaptor..

    fingers crossed

  9. #9
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    a teeny weeny bit of progress

    [ame="http://s259.photobucket.com/albums/hh311/NiteMare_08/My%201965%20109/?action=view&current=10150588811255401_54001.mp4"]My 1965 109 :: Running video by NiteMare_08 - Photobucket@@AMEPARAM@@http://vid259.photobucket.com/player.swf?file=http://vid259.photobucket.com/albums/hh311/NiteMare_08/My%201965%20109/10150588811255401_54001.mp4@@AMEPARAM@@vid259@@AME PARAM@@259@@AMEPARAM@@hh311/NiteMare_08/My%201965%20109/10150588811255401_54001@@AMEPARAM@@mp4[/ame]

  10. #10
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    we're back to dismantling and sorting out rot :roll:









    offside spring hanger :shock:


    my jig to align the replacement crossmember




    a little tinworm


    a bit more


    oh no, tinworm squatters


    nearly all evicted


    i'm carefully dissecting the crossmember so that i can rebuild the chassis rails as both are pretty crusty ...

    got an unpleasant surprise yesterday, i lifted the canvas off the bulkhead to find the clutch master cylinder had leaked, yes it's taken paint off the footwell :roll:

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