That sounds like the work of a true Series Land Rover owner.
The good old Micro metric Insulation tape.
When all else fails, Bodge it.:TakeABow:
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Ok so today I finally finished off the modifications to the bulkhead to convert it from a 6cyl to 4cyl. I have to stress that it's not a faithful reproduction of every aspect of a 4cyl bulkhead, I just replaced the centre section so I could use 4cyl floor panels and gearbox covers and perhaps later on fit a heater. Pics are from my final test fit with everything tacked in place, its back on the bench now having been fully welded but I ran out of time to fit it today.
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Getting the curved piece right was very time consuming, but the process was enjoyable. I wish I had more time to spend on it right now but I'm racing to get the car mobile so I can load it on the trailer to move house.
I keep meaning to make a bending brake but I just improvised today with some steel bars and a planishing hammer...
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Then I bent the section around an old 6cyl diaphragm cover to get the correct shape...
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I don't think I'll get a job in a body shop any time soon, but the end result fits nicely so that's good enough.
The other job today was test fitting the modified engine mounts. I had to do a bit of chopping to make them fit around the extractors but otherwise they fit great. Have to do a couple more mods to give access to the lower bolt on the LHS mount, so that will happen tomorrow and they'll be fully welded. The extractors were custom made years ago in place on the car and unfortunately to get the bolts in the engine mount they have to be removed from the head to give enough room - can't do much about that now.
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Tomorrow I need to pack up the workshop for the removal so there's not much more I can do for a while. Time blew out on me thanks to waiting 2 and a half weeks for a part from Brisbane, plus complications from weird mods done by someone else previously that had to be undone. I'll get it on the trailer Thursday once the new engine mounts and fuel tanks are ready, then I can do a bit more over the holidays after we've moved out of here.
Oh, one last pic - my printed magna tex wheel came up alright I think.
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not much cooking today on the landy, spent the day packing up about 1/2 the workshop and listing stuff for sale on gumtree and here.
Mate dropped off the tanks he notched out to clear the shackle bolt heads. Did a fantastic job. I wish the guy who made the tanks could weld this well. I grabbed some RedKote to throw in the tanks so will do that tomorrow.
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Other than that nothing to report. Hoping to weld up the front tank mounts tomorrow and get them installed, along with the new engine mounts.
well things got very hectic and I ran out of time to get everything done before our removal, so here's where I'm at:
Got the bulkhead done and bolted up.
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Got most of the front back together but ran into some shortages of captive nuts in the bulkhead, so the passenger door is on but not the drivers.
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Loaded it on the trailer and headed north. This is our stopover at Thredbo. Cannot recommend towing a series landy up there from Albury - spent quite a bit of time in low range working the gears and doing about 20kph. Meant we got to take in the scenery though and my 7yo daughter was loving all the wildlife, including a black brumby running down the road in front of us.
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But the defender did well and got us to Culburra Beach safe and sound. We'll be here about a month before heading up to Qld. Probably no more updates on the Series IIA for a little while - have a few other priorities to take care of.
Thanks for a terrific thread so far and I look forward to seeing more of the rebuild in the future.
Meantime, Merry Christmas and good luck with the move!
John