Freezing fog outside & an email from Malta have prompted me to update the story.
Im keeping a journal that I can refer back to when I write this drivel, & I see that I have scrawled 8 pages of notes since the last instalment, so I think I will have stick to just the important points if I am going to finish this before Xmas.
Basically, every thing is cleaned & if necessary painted before fitting.
The heater fouled the n/s inner wing bracket, so a lump was chopped out of the bracket & the heater fitted.
The brake & clutch master cylinder assemblies & accelerator pedal were fitted to the bulkhead.
The exhaust front pipes were painted & refitted & then the rest of the exhaust was fitted had to make up a bracket for the rear twin pipes found suitable bits at Billing.
The 3 flexible brake pipes were fitted.
I bolted the Rad panel in place & offered up the wings the heater intake on the n/s wing fouls the 90 heater easily resolved remove the intake & think about that later & it will also need a lump chopped out to miss the suspension turret, & I had marked that out what now seems like years ago!
The o/s wing fouled the much larger diameter 90 servo so the mechanical designer in me came to the fore & I calculated what shape it needed to be, made 2 wooden formers, clamped them either side of the wing & attacked it with a nylon mallet & beat it into a new shape.
I hope anybody over seas reading this doesnt take this too literally we English have a way with words!!!!
Any way, Im quite chuffed with the result I may even include a picture!
The holes for attaching the top of the wings are in a different place on the 90, but again this is trivia that I will overcome later.
Took steering box to Ely Cross Country Vehicles (ECCV) & asked James to recon it, he stripped it & said shaft was pitted & he could sort it if I could get it skimmed, so I took it to an acquaintance with a lathe who sorted it for me.
Bought a 90 V8 throttle cable & clutch steel pipe neither fitted without modification.
The throttle cable was too short so I fabricated an extension piece from the ends of the donor Rangies throttle cable & re-bent the clutch pipe so that it came inside of the bulkhead so that it didnt foul the n/s exhaust manifold.
I Fitted new pistons & seals to the brake callipers & fitted the callipers to the hubs.
I had previously said I was going to fit 90/110 front callipers & the hole sizes were smaller than Rangie, well this is not generally true, someone had drilled the Rangie callipers oversize to fit the 90 hubs, so the shouldered bolts I had been trying to buy didnt exist!
Getting some tubular sleeves turned up enabled me to fit the 90/110 callipers using standard Rangie bolts sort of mix & match with an adaptor
I then fitted the brake pressure regulator to the o/s foot well support bracket & made up & fitted the steel brake pipes.
Wipers needed series to fit screen but wanted 90 motor with 2 speeds easy remove drive mechanisms from both motors & swap over.
Choke cable I have several settled on using the original Rangie fitted where the bonnet catch normally goes it will need shortening - will probably use diesel glow plug light as choke warning light (artistic licence).
Fitted wiring harness back into bulkhead gives more a few more problems to think about connecting a 90 harness to a Rangie well thats what chocolate block was invented for!
Fitted heater box to i/s of bulkhead.
Removed overdrive from Rangie gearbox, & then removed intermediate shaft expecting cluster of transfer gears to fall into my hands, instead a lot of individual gears/thrust washers etc. fell onto the floor .
I think I found everything, but when I referred to the manual to find out how to install it in the 101 box it mentioned end float & shims & I thought humm I can probably do this but I would rather have someone who knows what they are doing do it for me.
I popped over to ECCV to pick up the refurbished steering box & asked James if he did house calls. What have you in mind? he asked with a grin.
I explained the problem better have a look at the gears he said got em in the boot was the reply.
Basically gears & thrust washers Knackered.
James got the necessary bits & came over & fitted the txfr gears, diff with new bearing, & overdrive I got the impression he knew what he was doing!!
I fitted the steering box - 4 bolts no flies on me!!
Next problem was connecting the steering box to the column original RR shaft much too short.
An appeal to club members to measure their steering shafts got a response from Steve M. I figured that by using a long U/J at each a 90 shaft would just fit.
I then fitted the transmission brake & the prop shafts.
I then came to fit the handbrake & found that the bolts that held the pivot bracket to the gearbox casing fell into the holes initially I thought that it was stripped threads, but it transpired that the holes in a 101 gearbox are tapped a larger size than those in a Rangie.
I found some suitable bolts, & had to cut a small piece out of the bracket so that I could get a socket on to the larger bolt head.
I then clamped the windscreen brackets into position & double & treble checked their position before marking thro the bulkhead the position of the holes I needed to tap into them you may recall I chopped the brackets off of the series bulkhead & welded plates into the back of them.
I had decided that the series rear tub was in too poor a condition to use so I phoned a local supplier of second hand parts to be quoted £235 + VAT!
If I cant get something at Old Sodbury Ill look to buy another vehicle & break it.
I made the most of a day of autumn sunshine by taking the rad panel outside & cutting some holes in it to increase air flow to the rad.
Went to Old Sodbury what a wonderful day!!
Looking down the rows of sellers waiting to go in I didnt spot a single LWB tub There must have been 8 or 9 rows of 30 40 vehicles in each
When we (as nobody from the club was interested in going Lainey came along to watch the stall while I had an occasional wander) had parked up I noticed a 110 tub 2 pitches away.
Closer examination showed damage to the rear panels, but I could replace these with the ones from the series tub to retain the series look, & also this tub had a fuel filler in approximately the right position.
Not wanting to go home empty handed I snapped it up for 50 quid.
On the stall behind me I found a 90 steering shaft for a tenner.
On my various forays around the sale I only saw one other LWB tub, a very sorry looking series.
On reflection, I suppose the chances of picking up a decent series tub now are probably slim.
Not only did I manage to buy the 2 parts that I needed, but we sold enough parts from the donor vehicles to pay for them, the pitch, our fuel, & came home with a profit.
The steering shaft fitted a treat.
Next up was to remove a piece from the inner wing to clear the steering shaft.
Having got the wings to fit I thought it would be sensible to try the bonnet.
I have 3 bonnets, I used the standard one as it is smaller & therefore easier to lift in the confines of the garage.
It rested neatly on top of the servo, which also was virtually flush with the side.
After much deliberation I decided that the defender bonnets must be fitted higher up the bulkhead.
I fitted the bonnet to the old series bulkhead & measured 17mm up to the bend in the bulkhead.
A shopping trip to Ely a few days later gave me the opportunity to scour the car park for defenders & I spotted one & estimated the bonnet was only 6-7mm below the bend.
On returning home I satisfied myself that I can shorten the series hinges (vertically) by 10mm.
Thats the Z axis sorted then, now for the Y
I had measured both the basic & deluxe (I believe that is what the extended nose versions are called) bonnets as the same width, but as I was searching for every last mm I decided to put them together to see if there was any difference. The width at the bulkhead was the same, but the front is wider which means that the taper is different which means that it is wider at the servo which means thats the one I will be using!
When I say one I mean two, as the one that came with the donor has a good frame & a naff panel & one that I got from Daan has a naff frame & a good panel .
Looking at the vehicle sitting in the garage, it doesnt look that much different than it did 3 months ago, but Ive convinced myself its all coming together & I am aiming to have it sitting on its wheels by the end of the year.