3 problems under the bonnet were a broken stud on the inlet manifold, a leaky radiator & a leaking power steering pipe.
The radiator was easy; as I had modified the housing I had the original re-cored.
The broken stud on the manifold was at the rear where the heater pipe flange attached.
The manifold had to be removed, & this was a good thing as the seals at the front & rear of the valley gasket looked a bit naff.
The broken stud was replaced & the manifold replaced with new seals & gasket.
The carbs were stripped & inspected & look in good fettle.
Everything was reassembled & the engine restarted O.K. with no oil or water leaks.
I knew what the problem with the power steering was; the earlier metal reservoirs have a ½ & 5/8 inch diameter outlet pipes, whereas the newer plastic ones are 12 & 16 mm.
The flexible pipe for a ½ inch outlet would not seal on a 12mm outlet. This was easily solved by putting some heat shrink sleeving on the 12mm outlet to increase it's diameter
I now turned my attention to the front bodywork.
I had planned to modify series wings to take defender arches, but the more I looked at it the more I decided that it would be difficult to make a good job of it. I had one damaged wing that J.W. had given me to use as reference for the arch shape.
I showed it to my cousin Robbie & he reckoned that he could panel beat it back to shape. Another wing was sourced from ebay.
The damaged wing was knocked back into shape & filled, a series style heater hole was cut into the other wing, & then both outer wings were painted yellow along with the nearside front wing.
The front wings were subsequently fitted.
I had been thinking about the mud shields, & decided that I could probably modify series ones, & using 2 on each side (one fitted upside down) they would come down low enough to protect the bulkhead out riggers.
I mentioned this to J.W. when I went to buy a pair of seat belts & he produced a pair of good second hand series mud shields that he donated to the cause.
One of the original pair I had was a bit naff, but Dave H had a good one that he also let me have.
One needed a little chopping to fit; one needed major surgery to fit around the heater.
The naff one I had was used for material to modify the others; so 5 series mud shields were used in the construction of 2 hybrid mud shields.
After trial fitting the mud shields were removed for painting.
I then fitted & wired up the nearside indicator & sidelight.
The doors needed replacing, but I had planned to do this after I had got the vehicle on the road, but they look a bit odd so I decided to paint them yellow. I removed them to prepare & then found I was running low on paint so I went to Histon to buy some more - shock horror - the place had closed down. Briefly, this paint is American & searching the internet has found no other U.K. sources & although it has caterpillar yellow in brackets on the tin there are several caterpillar yellows & I am struggling to find a match.
I thought now would be a good time to fit the bumper, but when I offered it up to the chassis it wouldn't fit. A bit of research showed that I had missed the fact that the chassis had to be modified to fit a series bumper.
I had realised that the fixing bolts were vertical rather than horizontal, but had not realised that the chassis was a different cross section.
So out with the grinder again.
That sorted, the bumper could be fitted.
I had known for a long while that I needed an electric fan, & although a 16-inch would be ideal I only had the space for a 12-inch. This was obviously better than nothing so I decided now was the time to get one, & time would tell if it was adequate or not. The good old Internet came up with some, a few of which gave dimensions. I selected one that came with a capillary operated switch & placed an order. When it arrived the dimensions were not as stated. Hack sawing a bit out of the shroud allowed me to fit it. Unfortunately where the capillary tube goes into the top hose has not sealed correctly & I have a leak, but this will have to wait.
The bonnet was the next item to receive my attention, or in this case items. The original bonnet had a good frame but mediocre skin, & Daan's bonnet was the reverse. After measuring the position of rivets I decided they were interchangeable so drilled/ground rivets out & separated frames from skins. The flanges on Daan's skin were damaged where it attaches to the frame at the back of the bonnet so I cut sections from the other bonnet to use as repair sections. A lot of the rivets used originally where steel, so I decided to bolt the bonnet back together as aluminium rivets may work loose. I found some nice domed socket head screws that when painted will look very similar to the original rivets. The frame & inside of the skin were painted black & then reassembled. All the front holes matched up, but the ones at the rear didn't & it took a lot of filing to match them up. All the bolts & rivets were fitted & the outer skin prepared for painting.
I have not been able to find any matching yellow paint, so have painted the doors & tops another yellow temporarily.
After a bit of rubbing down & priming the bonnet was top coated.
Then the door cappings & bonnet hinges were painted silver & black respectively.
The doors & tops were then fitted.
After much deliberation about what to do about the heater air intake I reluctantly gave in & bought a Defender wing top air scoop, cut a hole in the chequer plate & fitted.
The spare wheel mount was now fitted to the bonnet & the bonnet fitted.
Next the last mud shield was fitted. Foam strip was put along the top of the rad panel & door seal along the edges of the bonnet to fill the gap left by raising the bonnet 10mm.The spare wheel was now mounted on the bonnet & the bonnet supports adjusted.
I then cut a piece of metal out of the remnants of the rear door & fabricated a steering column cover, painted & fitted it. Next a bracket to mount the washer bottle was made from a spare headlamp surround & a blanking plate for the Rad panel was formed from another odd piece of material.
These were duly painted & fitted along with the washer bottle & appropriate piping.
The fan was wired up but I am not convinced that the switch functions correctly.
Off to ECCV for wiper arms/blades/splined adaptors.
James only had Defender style splined adaptors, which are designed for spindles with a flat.
After phoning around I eventually got the correct series parts from John Richards. After fitting I found that the wiper arms park in the upright position, so as a short-term solution I cut through the self-park wire.
I then cleaned up the series heater duct & glued a plastic pudding basin to the back of it to make it look like the original heater duct.
The horn (an old Klaxon) was fitted & connected.
Number plates where the next item to fit, followed by new air filters.
When I came to fit the spare wheel clamps I found that they were for the narrower SWB rims, but these were easily extended with some tube.
To quote another old fart, "I don't believe it!" Is it really ready to go to the DVLA for an inspection?