Thread: Ben's 120 build.

I decided to strip the bulkhead down completely to do a proper repsray.

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It only took about 5 hours to get there, which was surprising. There were only 3 or 4 bolts that needed the grinder. The rest pretty much fell out. The bulkhead was pretty much completely rust free and only needed a small crack cleaning up with the welder.

I have access to a blast and paint facility so the bulkhead was in its new colour pretty quick.

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I've also cut a hole in the passenger for a Ministry of Defender Aircon, it should arrive in a week or so and we will find out if the hole is in the right spot then.

I've managed to get the bulkhead back on so I could start with all the bits bolted to it... I feel like the bulkhead is going to be 80% of the whole project at this point.

The wiring is going to be redone, so I can add some fuses and upgrade the wiring to the lights/aircon etc.

While the bulkhead was in bits, I resprayed the pedal boxes and had the master cylinders rebuilt. I also sent the inner guards off to be regalvanised.

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I may have also come across some hydraulic bumpstops.. The probably won't get bolted on because they're ridiculous, but they might...

The wiring upgrades are taking a bit longer than I would have planned, But I'm tying to do it all right the first time.

Here's the new fuse box I've made. It's the standard bracket, but with the god awful glass fuses removed and a Bussman 15712 fuse box in its place. It's a great design because it's dual bussed, so I can have a permanent power circuit and an ignition switched circuit without too much wiring to get there.
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I've added relays for the low beam, high beam and spot lights and integrated it all into the original harness. I've also chopped up the original harness, kept the good bits and replaced the bad bits.
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I've also taken the opportunity to simplify some of the wiring. The reverse lights no longer go through the oil pressure switch and are just an additional ignition switched circuit. All of the factory heater wiring has been removed. I've also removed the interior light/dashboard illumination switch. The fog light wiring has been repurposed with a genuine fog light switch to control the spot lights and the main power feeds have been upgraded to 16mm.

A little side project for the Ministry of Defender aircon is a 3 speed fan switch. The standard blower switch is only 2 speeds, but the new blower has 3. One of my plans is to try and keep the cabin looking pretty standard, so I want to modify the switch to give me 3 speeds. Turns out it is really quite simple.

Here's the switch contacts disassembled. The end two bits with the terminals are speed 1 and speed 2 for the original blower. The rest of the travel is there so the fresh air vent can be opened and closed. The air con unit I'm using is permanently recirculating so we can use this space for an additional contact.
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20mins on the laser and we have a new contact.
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I made a couple of rivets up in the lathe and then refitted the contacts to the switch mech
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