Isuzu C240 powered Series 3

**gromit** · 31st August 2014, 06:56 PM

Managed to get some time on Wallit this weekend.

First I had to repair the passenger side swivel housing. When I rebuilt the swivel the drain bolt wasn't correct (a bolt with an extra nut on it rather than an extra long hex bolt). I sourced the correct bolt, screwed it in and the thread stripped.....
Some time ago I managed to get a 1/4"BSF re-thread kit so today I filled the drill flutes with grease and drilled the hole out in situ then filled the tap flutes with grease and tapped it out. I flushed some mineral turps through the housing to remove any final bits of swarf.
The insert was wound in OK but then you have to break off the tang, problem is where will it end up, will I have to pull the swivel hub off ???
I used the tool for screwing in the insert, filled the slot with grease and carefully tapped it to break off the tang. As luck would have it the tang stuck in the grease so drain bolt in and top up with EP90.

Next I wired up the numberplate lamp and fixed some wiring issues. Found that a lot of water/mud had found its way in behind the cover that protects the taillights. A new grommet and a blanking grommet hopefully cured that problem.
Then the front brake flexi's were changed and the brakes bled.

Fitted the grille, not a Series III item but it looks the part.

I took the bumper off to paint the 'structure' behind it. Wallit has a military bumper and someone has reinforced the chassis between the front of the dumb irons

While the bumper was off I cut a hole in the ironwork for a starting handle. The Isuzu doesn't have a starter dog on the motor and would probably be difficult to hand crank anyway but chain drilled some holes & filed to shape before painting took place.

Then it was in with the new seat belts (still have the old seats fitted).

The inertia reels came with stalks so I had to figure out how best to mount them. The belt came with a range of brackets, nuts, extra bolts etc.

The base of the passenger seat has rotted and was damp so water must be leaking in somewhere (it's a Land Rover so it could be anywhere). I must treat the base of those DeLuxe seats before fitting and cure the leak.

Noticed that most of the bolts holding the roof on were missing (probably in a box in the back somewhere) so decided to add a few new ones to stop the roof blowing away. Might help stop the leak as well !

Found lots of other little things to do like fit the rear view mirror, I'd forgotten that the brake light switch hadn't been re-fitted so sorted that.

Next weekend the drivers door has to come off for some surgery (rotten lower frame), luckily I have a spare door to fill the hole. Also I need to replace the windscreen glass.

Colin

**gromit** · 2nd September 2014, 08:11 PM

Went out in the shed tonight to paint some mud shields for under the drivers side wing.
Once that was done I removed a mag/dyno assembly from a 1957 M100 Panther (a relic from another life). This along with some other bikes came out in a 20ft continer back in 2001.
A friend has a contact who can rebuild the magneto.

Colin

**gromit** · 8th September 2014, 04:02 PM

Didn't get time to do anything on Wallit at the weekend but did collect a few spare parts for other projects.

A couple of Series II doors & wings.

A Series II bonnet, a couple of doortops that will donate glass & glazing strips and a pair of SIIa military scone cutters.

Also got a swivel hub in good condition, a long front driveshaft, brake backplate & drum plus a 1950's ex WD Jerry can.

Need to stop collecting junk and get a few vehicles finished......

Colin

**gromit** · 14th September 2014, 08:19 AM

Pulled the drivers door off yesterday to replace the lower edge of the frame. Fortunately I have a spare door to fill the hole.

The doortop came off very easily and I've managed to get the glass and glazing strips out. Just have to drill out a few rivets and de-skin the door.

Colin

**gromit** · 14th September 2014, 04:28 PM

Found time between chores to replace the drivers side windscreen.

Carefully cut around the sealant and pushed the glass out. Removing the old sealant was time consuming.

Once cleaned out a bead of sealant was applied.

Here is the new glass after cleaning up and a new wiper arm & blade fitted.

I'm not a fan of silicone sealant (mainly because it's a pain to remove) but decided I'd use it for the windscreen.
After browsing Bunnings & Masters I was confused, found a glass sealant in SuperCheap at about twice the price so went back to Bunnings. Ended up finding a silicone sealant in the building section that is used for sealing glass in 'fences'. Nice silver colour that matches the galvanised frame.
I remember reading a thread recently where someone mentioned rubber blocks under the glass, it crossed my mind that installing screens in-situ would let the glass touch the bottom of the frame. Ended up cutting a couple of strips of inner tube rubber for the glass to sit on.

Did the job single handed because my boys were too busy playing to help.....

If I can find time next week I'll do the other side and also fit two to the FFR, that way it saves me worrying about storing sheets of glass.

Colin

**slug_burner** · 14th September 2014, 06:40 PM

Originally Posted by gromit

Found time between chores to replace the drivers side windscreen.

Carefully cut around the sealant and pushed the glass out. Removing the old sealant was time consuming.

Once cleaned out a bead of sealant was applied.

Here is the new glass after cleaning up and a new wiper arm & blade fitted.

I'm not a fan of silicone sealant (mainly because it's a pain to remove) but decided I'd use it for the windscreen.
After browsing Bunnings & Masters I was confused, found a glass sealant in SuperCheap at about twice the price so went back to Bunnings. Ended up finding a silicone sealant in the building section that is used for sealing glass in 'fences'. Nice silver colour that matches the galvanised frame.
I remember reading a thread recently where someone mentioned rubber blocks under the glass, it crossed my mind that installing screens in-situ would let the glass touch the bottom of the frame. Ended up cutting a couple of strips of inner tube rubber for the glass to sit on.

Did the job single handed because my boys were too busy playing to help.....

If I can find time next week I'll do the other side and also fit two to the FFR, that way it saves me worrying about storing sheets of glass.

Colin

Colin,

You are a machine when it comes to your Landies, can always rely on you for an update with the work you have been doing.

I need to take a leaf out of your book, do a bit regularly and progress will occur.

Thanks for an inspiring thread.

**gromit** · 15th September 2014, 04:27 PM

Originally Posted by slug_burner

Colin,

You are a machine when it comes to your Landies, can always rely on you for an update with the work you have been doing.

I need to take a leaf out of your book, do a bit regularly and progress will occur.

Thanks for an inspiring thread.

Thanks for your kind words, it's all been happening rather slowly considering I was only trying to get it back on the road but I do aim to do something on it every week.

I read somewhere that for a restoration to be completed quickly you need to do something on it every day. That could be looking up parts, preparing an ordering list, finding out how to do a job as well as physically doing work on it. I guess it keeps your focus on the task in hand.
Unfortunately I have a tendancy to collect projects and then spend time on a new project because I'm bored with the old one.....

Wallit isn't too far off hitting the road so I'll know if it's all been worthwhile soon.

Colin

**reachjatt** · 16th September 2014, 07:37 PM

Originally Posted by gromit

Did the job single handed
Colin

Hi Colin,

Just want to emphasise help is never far away... Let me know if you need a hand or two, i'll more than happy to come down...

Nav

**gromit** · 20th September 2014, 02:54 PM

Fitted the passenger side windscreen today.
Then I started taking the drivers door apart.

Drilled out rivets & removed capping.

Raised the edge of the door skin.

Door skin removed.

Just need to get a door repair section and cut & weld the lower doorframe.

Colin

**gromit** · 21st September 2014, 03:53 PM

After completing a few chores I changed the coolant & engine oil on the Defender and found some work that needs doing......

Then I made a couple of more seat bases. Wallit has DeLuxe seats but I may change the bases, then there is a set for my Series II and I might make a spare set using the foam from Wallit's seats.

Colin

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