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Ok. I have drilled out the spot welds holding in the blanking plates in the firewall. There are approx 35 to 40 welds in each plate.
It's not hard to do, you just have to be careful not to drill through the firewall outer skin. Unfortunately this is not as easy as it sounds.:( The skin is only 1mm or so thick. I have some holes to repair.
http://img132.imageshack.us/img132/6...0115ry3.th.jpg http://img120.imageshack.us/img120/3...0116fa7.th.jpg http://img120.imageshack.us/img120/3...0118gc2.th.jpg
Once you have drilled out all the spot welds (look carefully as some are very hard to see) a light tap from the outside will soon have them out.
I have decided to just bog up the holes with some filler. I don't think there is any structural issue with a few holes in the vent surround of the firewall. I hope there isn't anyway!:eek: :eek: :D
Next up I fitted the flywire screens from a series 3. These fit in nicely and are secured with pop rivetts. The only thing to note is one of the mounting points on both screens will have to be removed or it will foul on the steering column support bracket. The screens are still very secure even though one mounting point is removed.
http://img132.imageshack.us/img132/3...0113xy9.th.jpg http://img120.imageshack.us/img120/7...0114ol6.th.jpg
These screens are very easy to bend/damage. Be careful. One of mine was already damaged from the donor firewall. I have fitted it to the drivers side. Out of sight.......mostly.
Next on the list is mounting the series 3 vent lever support panel (fascia panel) to the 110 dash pad. Four self tapper type screws and you're done.
http://img365.imageshack.us/img365/3...0120mn2.th.jpg http://img365.imageshack.us/img365/5...0121ot8.th.jpg
It fit nicely onto the underside of the 110 dash pad/top. Also I forgot to mention you will need to cut a 'keyhole' in the vent support panel. This will allow the steering column support brace to pass through.
http://img132.imageshack.us/img132/3...0122uo1.th.jpg
The key hole is cut just to the left of the heater duct mount.
This is what it'll look like assembled.
http://img132.imageshack.us/img132/2...0119ex5.th.jpg
More to come this arvo..........
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And the rest of the dash re installed.
http://img407.imageshack.us/img407/9...0153vq2.th.jpg http://img263.imageshack.us/img263/4...0154rf7.th.jpg http://img263.imageshack.us/img263/1...0155jw7.th.jpg
Still a couple things to finish off inside. But it's all there.
And outside...
I did a trial run fitting a flap.
http://img263.imageshack.us/img263/1...0156kh5.th.jpg
Everything lines up nicely. Just need to attach the brackets to the firewall now and its done. Oh and paint the flaps too of course.
I was thinking of painting them black, so it still looks like it's an air con model but it really isn't.
Almost done.:D :D :D
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Looking good there Mick!!!
I was only talking to Scotty last night about this project and wondering hwo it was going!!!
Another option to get that older Series feel that I know you like would be to use a SIII dash top and bottom and remove all the covering to give you just the metal - Scotty did this on his Hybrid and painted the whole dash and firewall the same as the outside, looks very neat.
LRH
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I can get you some pix if you want?
LRH
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Yeah I'd like to see that mate. Post em up!:D
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No worries Mick - will get some pix over the weekend
LRH
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hey Mick, just read my PMs:blush: - sorry mate
LRH
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Mick,
Are you putting a Fender Dash in it????
Looks good...
as for attaching the vent hinges...... i think pop rivets will be the neater idea. As per our convo today, the Fire wall is triple skin, PITA to weld with mig, Brazing will burn to much paint.
Mmmmm you only need a few small welds....
Lets try the mig.....
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To late Steve. It's done.:D
Series 3 and county dash combo.
The flaps are attached. just need to paint the brackets/pop rivets and it's completed.
http://img72.imageshack.us/img72/194...0140mh2.th.jpg http://img72.imageshack.us/img72/245...0141aw5.th.jpg http://img72.imageshack.us/img72/803...0142jv5.th.jpg
So thats that. Not the best tutorial on the planet but never the less I think you get the idea.
It's a bit of a ball buster of a job but it's well worth it in the end. There would be better ways of doing a couple things, probably easier to use a complete Defender dash assembly, instead of a series 3 county combo like I have. But I went for cheaper and easier to get.
Also some people no doubt will prefer to weld the brackets onto the firewall rather than pop rivet them. I dont think it looks out of place, but it's certainly not factory.
Now onto other things..........:D
