Oliver and Colin's 1960 Series II rebuild.

Use this forum to post your description of ongoing projects. Please use the [img] - [/img] codes to display your photos rather than just linking to a photo album! Also make sure your photos are sized sensibly for the web!
Message
Author
User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Oliver and Colin's 1960 Series II rebuild.

#1 Post by obalme » Sat Mar 11, 2017 9:15 pm

About a year ago my son and I bought an old Series II with the intention to restore it. We had gone up into the bush offroading and on our way back, my son spotted it under a tarp.

Image
Image

We brought it home and began to tear it down

Image
Image
Image
Image

Giving the frame a good wash inside and out

Image

The engine and brakes were seized and it didn't shift into third or fourth, we tried quite hard to get it started. Dragging it around the farmyard.

Image

Surprisingly, the pillars of the bulkhead were in immaculate condition, but the footwells were rotten. There was also the fact that somebody had chopped a massive hole in the firewall for a Chevy Master cylinder.

Image

What was once thought to be a solid frame turned out to be quite rotten. The rear cross member had already been replaced with the C-Channel Special. After giving it a good sandblasting we discovered that a lot of the frame rail was rotten.

Image

Dreaming of a running Rover we had a look around for other vehicles. Like this 88.

Image

We decided we'd rather have a 109 for working on the farm, so we made the trip up to Lillooet for Michael Kennedy's 109 project he'd had for 20 years, but had just bought a 110. This new truck came with brand new parabolics, a tub without any dents, a repaired bulkhead, painted doors, and a bunch of other bits and bolts.

Image


That's pretty much where the project is now. We have done some repairs to the frame and they are 60% complete before we have a solid foundation.

Image

We've begun rebuilding the front axle as well, the diff seemed almost brand new. All that was needed was to renew the front pinion seal.
Image
All the other bits of the axle are repainted, so we will get that put back together in the next few days, then start on the rear one!
Last edited by obalme on Thu Nov 02, 2017 10:52 am, edited 4 times in total.
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#2 Post by obalme » Sun Mar 12, 2017 1:38 pm

Are the photos visible?
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

red90
Specialist
Posts: 1479
Joined: Mon Mar 08, 2004 7:19 pm
Location: Calgary

Re: Oliver and Colin's 1960 Series II rebuild.

#3 Post by red90 » Sun Mar 12, 2017 3:06 pm

obalme wrote:Are the photos visible?
I can't see them.

Kelster1055
Judge Dredd
Posts: 101
Joined: Wed Mar 21, 2012 12:10 am
Location: Sunny Kelowna, BC Canada

Re: Oliver and Colin's 1960 Series II rebuild.

#4 Post by Kelster1055 » Sun Mar 12, 2017 5:12 pm

Same problem here.

Sent from my XP7700 using Tapatalk

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#5 Post by obalme » Sun Mar 12, 2017 7:06 pm

How about now?
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

Kelster1055
Judge Dredd
Posts: 101
Joined: Wed Mar 21, 2012 12:10 am
Location: Sunny Kelowna, BC Canada

Re: Oliver and Colin's 1960 Series II rebuild.

#6 Post by Kelster1055 » Sun Mar 12, 2017 7:30 pm

Much better!

Sent from my XP7700 using Tapatalk

joshallen676
Beyond Recovery
Posts: 50
Joined: Tue Dec 20, 2016 4:59 am

Re: Oliver and Colin's 1960 Series II rebuild.

#7 Post by joshallen676 » Mon Mar 13, 2017 8:04 pm

Wasn't my 88 in the pictures, I wish I had time to tear her down and put her back together properly lol but she's still in one piece needing footwells and suspension mounts...AND I've found ou the rear cross member was previously welded into the wrong place and that's why my tub wont fit lol. So I'm rebuilding the engine in my other rover haha.

mepham55
Missing Link
Posts: 597
Joined: Fri Mar 26, 2004 8:38 pm
Location: Victoria, BC, Canada

Re: Oliver and Colin's 1960 Series II rebuild.

#8 Post by mepham55 » Wed Mar 15, 2017 9:58 am

Great looking project! Is the new frame a station wagon frame? I think I can see the 2 raised pillars which hold the rear tub of a station wagon. If so, you'll need to remove them to fit your 109 full tub.

Matt

1955 S1 107”
1959 S2 SWB
1961 S2 SWB
1966 S2a SWB
2006 LR3

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#9 Post by obalme » Wed Mar 15, 2017 12:20 pm

Thanks Matt, will double check to make sure the frames match.

Josh, I will amend my post
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

mepham55
Missing Link
Posts: 597
Joined: Fri Mar 26, 2004 8:38 pm
Location: Victoria, BC, Canada

Re: Oliver and Colin's 1960 Series II rebuild.

#10 Post by mepham55 » Wed Mar 15, 2017 12:41 pm

Had another look at the pictures, I think I'm mistaken the frames look the same.

Matt

1955 S1 107”
1959 S2 SWB
1961 S2 SWB
1966 S2a SWB
2006 LR3

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#11 Post by obalme » Wed Mar 15, 2017 1:15 pm

Instead of working on the axles, we did some more welding on the frame. The front suspension bushings had a hairline crack around them so we fish plated around them to fix that.

After spending quite a long time trying to pull the relay out the top, we realized it would've never come out.

Somebody had decided to weld it in...

So we had to remove the front cross-member


We welded on a bar to keep the frame rails in place.

Image

Then took the torch to it.

Image

New One ready to be welded in place

Image

If you look closely, you can see a small weld.

Image

It's funny, because the relay on the other frame came out really easy.
Last edited by obalme on Sat Nov 25, 2017 10:13 pm, edited 1 time in total.
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

joshallen676
Beyond Recovery
Posts: 50
Joined: Tue Dec 20, 2016 4:59 am

Re: Oliver and Colin's 1960 Series II rebuild.

#12 Post by joshallen676 » Wed Mar 15, 2017 10:43 pm

obalme wrote:Thanks Matt, will double check to make sure the frames match.

Josh, I will amend my post
No worries mate, just don't want to take credit for something I didn't do haha


Sent from my iPhone using Tapatalk

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#13 Post by obalme » Thu Mar 23, 2017 7:45 pm

Got some work done on the axle's swivels yesterday.
Image

Today, we pretty much finished all of the repairs on the frame.

Image

Test fitting a bulkhead
Image

We also patched a few holes in the rear crossmember. But I forgot to take photos.

I now have to deal with the final frame repair. The shock absorber mounts are extremely worn out. Someone must've forgot to change the bushings on their shocks.

Image

It is like this on both sides, is there a replacement part available or do I need to fabricate my own? We have the old ones.
Last edited by obalme on Sat Nov 25, 2017 10:17 pm, edited 1 time in total.
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

BuckBlue90
Bumper Sticker
Posts: 140
Joined: Fri Sep 14, 2012 8:12 am
Location: Maple Bay

Re: Oliver and Colin's 1960 Series II rebuild.

#14 Post by BuckBlue90 » Fri Mar 24, 2017 8:43 pm

You could just cut off the stubs and drill and tap for a grade 8 bolt.
Eric.

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#15 Post by obalme » Sat Mar 25, 2017 9:26 am

That sounds like a good idea, I'd rather not fiddle around trying to make my own.

Isn't that the way they're mounted to the Defenders?
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#16 Post by obalme » Tue Mar 28, 2017 10:29 pm

Got some more work done over the weekend.
Put in new outer wheel bearings and stub axle races
Image

Rebuilt the front halfshafts with new UJs, distance pieces, bearing races and seal races. It all went back together quite easily with a 30 ton shop press.
Image

Since now I'm waiting for more brake parts progress on the front axle has been halted, so I began taking apart the rear one.

Found an old piece of oily paper inside the hubcap, maybe to prevent oil getting out?
Image

Also some writing on a halfshaft I can't decipher
Image
All the rear halfshafts
Image

I pulled the left side halfshaft out and it looked as if someone had chopped a little bit off the end, so I pulled the one from the donor axle, and it looked brand new! The lower one looks like someone took the grinder to it to make it fit.
Image
Last edited by obalme on Sat Nov 25, 2017 10:25 pm, edited 1 time in total.
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

User avatar
ANDYD
Defender of the World
Posts: 2162
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: Oliver and Colin's 1960 Series II rebuild.

#17 Post by ANDYD » Fri Mar 31, 2017 9:02 pm

Looking like good forward progress .....

I once had a bunch of old Series Parts from Australia marked in boxes from Dufor Automotive. They were a company that made Series parts way back in the good old days.
I wonder if the first word written on you diff shaft is "DUFOR"?

-Keep up the good work...
Andy
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
obalme
Half Shaft
Posts: 137
Joined: Thu Oct 05, 2006 9:11 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#18 Post by obalme » Sun Apr 02, 2017 10:00 pm

That seems to be correct. It looks like "DUFOR" then a part number.
-1960 Series II Pickup
-1987 Defender 110
-2007 LR3

User avatar
cbalme
Half Shaft
Posts: 133
Joined: Fri Apr 14, 2017 2:05 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#19 Post by cbalme » Fri Jun 16, 2017 2:51 pm

Not much forward progress over the past few months, got the rear axle taken apart, just need the time to put it back together. Picked up a Chassis from Bern, it's in really good condition, but was modified to fit a Station Wagon, so I'll have to chop off some of the brackets and weld new ones in, The rear crossmember is a little bent and battered in some places so I'll replace that with the one I have now. After a quick inspection this frame seems really solid! It's been undercoated, if I break some of it off it reveals some nice gloss black paint, which may be original. The outriggers for the gas tanks are slightly bent so they need beaten back into their correct positions.

I'm wondering whether it would be worth Galvanizing?
Colin

User avatar
cbalme
Half Shaft
Posts: 133
Joined: Fri Apr 14, 2017 2:05 pm
Location: Cobble Hill

Re: Oliver and Colin's 1960 Series II rebuild.

#20 Post by cbalme » Fri Oct 06, 2017 11:01 pm

Not much progress over the summer. Mostly fixed boats and messed about at work. Never had the time but I'll hopefully find some more. I did get the rear axle refurbished with new seals and brakes. The drums were too far out of spec so they were replaced with new ones. The front axle needs brakes and the hubs reassembled. Then I'll have good axles but no solid chassis to put them under...

The issue I'm facing now is removing the old undercoating. My strategy right now is to use a Tiger torch and heat it up so it just sort of melts off. The frame just seems to be coated in tar. Is it even worth removing? Becuase underneath it is fresh paint so can I get away with just repainting the parts without the undercoating or should I spend a week taking it off? If it doesn't come off now it never will is my thought on it.
Image

I did discover a small crack in the frame underneath the body outrigger but it isn't from rust, most likely military abuse. The fuel tank outrigger will need replacing because it is bent very badly. The rear cross member has a dent in it which will need sorting. I have a new cross member but this one is held on so well I am afraid it will never be as strong as the original.
Image

On the subject of previous posts and their unviewable photos. When I find the time I'll switch all the photos over to a different hosting site that isn't Photobucket. I reckon they're doing this because people only use them for this photo linking feature nowadays. If you are using Google Chrome there is an extension you can download that bypasses this feature and makes all the old photos visible again. I'm quite annoyed by their decision.
Colin

Post Reply