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1965 Series IIa 109" Build

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Koopsy
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1965 Series IIa 109" Build

#1 Post by Koopsy » Mon Jan 09, 2017 5:28 pm

Hi everyone. I am new here and thought I'd start a thread on my Rover build if anyone is interested. I have been struggling to find time to work on it and hopefully this thread will be a way to keep me committed!

I picked up my 1965 Series IIa 109" 3 years ago about an hour away from me in B.C. An older gentleman's wife had fallen ill and he just couldn't work on it anymore. He started restoring it 30 years earlier by painting the frame, engine, and rust proofing the bulkhead etc. Because of this, these parts were in remarkable shape when I got it. But because he had disassembled everything, I had just bought boxes and boxes of the biggest puzzle I had ever taken on.

Thinking back now I'm not too sure why I bought it. I've always been interested in racing and muscle cars, not off roaders. There was just a draw to it, a curiosity. But now after spending hours and hours labouring with every nut and bolt, I understand. There's just something about the simplicity, complexity, history, and style of the series Land Rover that is intoxicating. I have fallen in love with a machine. And I'm sure that's why all of you are here as well.

Mind you I've never actually driven one yet...

The original plan was to get it running and just do body work and paint so I could drive it around. But after getting into the tear down, I decided to fix some rust on the frame, then repaint the frame, then repaint the motor, then rebuild the motor and so on and so on until I found myself doing a complete frame up restoration.

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franko
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Re: 1965 Series IIa 109" Build

#2 Post by franko » Mon Jan 09, 2017 7:45 pm

Nice, looks like a great start to me. Look forward to seeing more.

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ANDYD
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Re: 1965 Series IIa 109" Build

#3 Post by ANDYD » Mon Jan 09, 2017 7:56 pm

Good to have you aboard, thanks for sharing your project.

She looks nice and straight, you are off to a good start...

Enjoy!

PS - where are you located?
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

terayon
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Re: 1965 Series IIa 109" Build

#4 Post by terayon » Mon Jan 09, 2017 10:00 pm

Great work! Thanks for sharing... i'm currently restoring a '63 station wagon, so I'll be keen to keep an eye on your build.

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Jordan
'63 109 Stationwagon
2.25L Welsh Grey (leftover battleship grey)

Kelster1055
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Re: 1965 Series IIa 109" Build

#5 Post by Kelster1055 » Tue Jan 10, 2017 6:22 pm

Hey Koopsy, I
Nice looking project with greatly potential. Thanks for rescuing it.

I'm in the Cariboo region of BC so shoot me a note and we can swap parts.

I have a 1970 Series IIA 88" that I'm well into.

Thanks for posting.

Kelly

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Koopsy
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Re: 1965 Series IIa 109" Build

#6 Post by Koopsy » Tue Jan 10, 2017 7:28 pm

Thanks guys! I started the project 3 years so I'll get you up to speed of what I've done so far when I have the time.

The tear down was easy as mostly everything was just hand tight.

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Koopsy
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Re: 1965 Series IIa 109" Build

#7 Post by Koopsy » Tue Jan 10, 2017 8:01 pm

I started by cutting out and replacing rusty parts on the frame
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The bottom of the frame crossmember had run over a few rocks... so I cut that out, banged out the dents and repaired it
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The transmission crossmember had seen better days so I fabricated a whole new piece. My plan was to be able to bolt it in place to aid in transmission removal in the case of a problem but ended up just welding it back in place.

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Koopsy
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Re: 1965 Series IIa 109" Build

#8 Post by Koopsy » Tue Jan 10, 2017 8:12 pm

The next step was to replace the rear bumper/1/4 frame. It had been repaired already at some point but I wanted it to look original and proper so I bought a brand new piece. I thought for a while of a way to be able to place the new piece in the exact place of the old one. I decided to build a 'scaffolding' set up to line up the bolt holes of the old piece to the new.
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franko
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Re: 1965 Series IIa 109" Build

#9 Post by franko » Wed Jan 11, 2017 9:27 pm

Clean!

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rayhyland
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Re: 1965 Series IIa 109" Build

#10 Post by rayhyland » Thu Jan 12, 2017 11:45 pm

Very nice


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Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

The_Anachronist
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Re: 1965 Series IIa 109" Build

#11 Post by The_Anachronist » Tue Feb 07, 2017 11:27 am

Lovely. Well done - and lucky you to have such an excellent shop (and some welding skills)!

Where are you located, if I may ask? I am in Langley, while my '63 109 wagon waits in a pile in Aldergrove storage until my house reno is finished and I have a garage again...
1963 S2a 109 Station Wagon, restoration started Oct. 17, 2015.

Koopsy
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Re: 1965 Series IIa 109" Build

#12 Post by Koopsy » Fri Mar 31, 2017 9:32 am

The_Anachronist wrote:Lovely. Well done - and lucky you to have such an excellent shop (and some welding skills)!

Where are you located, if I may ask? I am in Langley, while my '63 109 wagon waits in a pile in Aldergrove storage until my house reno is finished and I have a garage again...
I am in the little town of Trail. Yes the shop is definitely a blessing while working in the winter!

Koopsy
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Re: 1965 Series IIa 109" Build

#13 Post by Koopsy » Fri Jan 12, 2018 11:46 am

Almost exactly a year from my last progress post... a lot has happened since then! I’ll try and get you all caught up...

Next I painted the frame with a chassis paint outside, it turned out better than I expected!

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Koopsy
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Re: 1965 Series IIa 109" Build

#14 Post by Koopsy » Fri Jan 12, 2018 11:52 am

I painted the axles and suspension components at the same time and assembled everything with new copper nickel brake lines along with the trans, driveshafts, and sterling linkage as well as new swivel ball boots.ImageImageImageImage The previous owner said the transmission was in good shape and he had gone through it.


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Koopsy
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Re: 1965 Series IIa 109" Build

#15 Post by Koopsy » Fri Jan 12, 2018 12:01 pm

My next step was the engine build. I had the block steam cleaned and the cylinders bored. I reused the crank and rods but bought new pistons and new bearings all around. The water pump is newImageImageImage. The valvetrain was in good shape so I reused that. I had new hardened valve seats, guides and valves put into the head as well. The assembly went well, I found the paint in lordco, I thought it was a good match and looked good! ImageImageImageImage


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Koopsy
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Re: 1965 Series IIa 109" Build

#16 Post by Koopsy » Fri Jan 12, 2018 12:07 pm

Engine in and painted wheels and new tires! (Yes the fan is on backwards) ImageImageImage


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Koopsy
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Re: 1965 Series IIa 109" Build

#17 Post by Koopsy » Fri Jan 12, 2018 12:20 pm

Next was bulkhead repair and painting. I replaced the foot wells and cut out any rust spots and patched it up. The foot well replacement was a lot more tedious than I thought! I attached a brace along the bottom to keep everything lined up. I used a portable sand blaster to get all of the old paint off. Luckily it had been coated to protect it from rusting too much by the previous owner. I used a little body filler to fill in the low spots. I had more photos but I can’t find them now. ImageImageImage




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Koopsy
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Re: 1965 Series IIa 109" Build

#18 Post by Koopsy » Fri Jan 12, 2018 12:22 pm

Another one
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Koopsy
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Re: 1965 Series IIa 109" Build

#19 Post by Koopsy » Fri Jan 12, 2018 12:29 pm

I decided on Limestone for colour and had Napa mix up some Nason single stage in as close to original limestone as they could. I chose single stage because it’s easier to apply and it’s a Land Rover... it wasn’t meant to be perfect! I set up a shelter in my shop with pvc pipe and vapour barrier with a fan sucking out air. My goal was to be able to start the engine and put it in gear to make sure everything worked so I only painted the bulkhead and radiator support for now.

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cbalme
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Re: 1965 Series IIa 109" Build

#20 Post by cbalme » Fri Jan 12, 2018 12:44 pm

Wow, that all looks really good! I like your shiny freewheeling hubs.

What are those tires? They look very good.

When I tried to repair my old bulkhead someone went crazy with the spot-welding.

Thanks for the Update, will it be on the road for Founders Day?
Colin

Koopsy
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Re: 1965 Series IIa 109" Build

#21 Post by Koopsy » Fri Jan 12, 2018 12:53 pm

cbalme wrote:Wow, that all looks really good! I like your shiny freewheeling hubs.

What are those tires? They look very good.

When I tried to repair my old bulkhead someone went crazy with the spot-welding.

Thanks for the Update, will it be on the road for Founders Day?
Thanks! It’s been a long time coming...
The tires are STA Super Traxions, they were the closest I could find that didn’t look too modern.

I’m hoping for next year to have it on the road. But I am planning to make the trip to attend founders day this year!


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bsa_m21
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Re: 1965 Series IIa 109" Build

#22 Post by bsa_m21 » Fri Jan 12, 2018 1:03 pm

All I can say is..... Your garage is waay too big and clean. :D

Great work!
Martin
=======
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle

Koopsy
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Re: 1965 Series IIa 109" Build

#23 Post by Koopsy » Fri Jan 12, 2018 1:15 pm

bsa_m21 wrote:All I can say is..... Your garage is waay too big and clean. :D

Great work!
Oh it can never be too big... I don’t think I could ever have one big enough because then I’d just keep filling it up with more vehicles and tools!


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Koopsy
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Re: 1965 Series IIa 109" Build

#24 Post by Koopsy » Fri Jan 12, 2018 4:07 pm

Here is right after I installed the bulk head
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mepham55
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Re: 1965 Series IIa 109" Build

#25 Post by mepham55 » Fri Jan 12, 2018 4:39 pm

That’s looking great! Very nice work. I like the “paint booth”, when I painted my truck I ended up painting all my tools with a nice limestone(best colour) dusting.
I agree, you can never have enough space. My garage/shop I just built is no where near big enough! I have my 1966 SWB and 1961 SWB both crammed in and now have 2 1959 SWB’s waiting outside for their turn!

Matt

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

Koopsy
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Re: 1965 Series IIa 109" Build

#26 Post by Koopsy » Fri Jan 12, 2018 4:52 pm

My goal was to start the engine and make sure everything was okay and that the transmission went into gear. I bought a brand new wiring harness with alternator conversion. It made the installation super easy and straightforward. I made my own alternator brackets as well. I had 2 radiators pressure tested and both leaked so I decided on getting a brand new one. I realized I forgot to paint the gauge and switch mounts so I cleaned everything up, painted, and put it back together. ImageImageImageImageImageImageImage


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Koopsy
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Re: 1965 Series IIa 109" Build

#27 Post by Koopsy » Fri Jan 12, 2018 5:33 pm

mepham55 wrote:That’s looking great! Very nice work. I like the “paint booth”, when I painted my truck I ended up painting all my tools with a nice limestone(best colour) dusting.
I agree, you can never have enough space. My garage/shop I just built is no where near big enough! I have my 1966 SWB and 1961 SWB both crammed in and now have 2 1959 SWB’s waiting outside for their turn!

Matt
Haha yes the floor has a nice limestone dusted rectangle on it now. I’ll be putting down a tarp and I’m definitely going to step up the ventilation when I paint the rest...

I have a ‘70 SWB outside waiting its turn. It was complete until i started robbing a few parts here and there... it’s going to have to wait until the racecar is done. I don’t know where I’ll keep everything once they’re too nice to leave outside...


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Re: 1965 Series IIa 109" Build

#28 Post by DrRangelove » Sat Jan 13, 2018 11:26 am

The standard of this build is impressive!

Koopsy
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Re: 1965 Series IIa 109" Build

#29 Post by Koopsy » Sat Jan 13, 2018 1:42 pm

DrRangelove wrote:The standard of this build is impressive!
Thanks! One step at a time


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Koopsy
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Re: 1965 Series IIa 109" Build

#30 Post by Koopsy » Sat Jan 13, 2018 1:49 pm

Over some time off at Christmas I was determined to get it running. I finished up the wiring and used an old gauge I had to make sure it had oil pressure. Getting fuel to the carb was the hardest part, we finally determined that there wasn’t a good enough seal around the sediment bowl so I made a new gasket and it made a world of difference. Once that was sorted I hit the ignition and It was the easiest engine start up I’ve ever had, half a crank and it fired right up without an issue. The carb started to leak so I’ve ordered a rebuild kit. Image


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Re: 1965 Series IIa 109" Build

#31 Post by Koopsy » Sat Jan 13, 2018 1:55 pm

So this is where I’m at now... finally...

The starter is sort of sluggish and before I could start the engine again to try and put it into gear, it was so weak it would barely turn it over. I tried to make a better ground to the frame and several different batteries but it didn’t make a difference. I’ve ordered some new brushes and I’ll give it a good clean inside. Hopefully that will make the difference. While I’m waiting for that I ran lines for the clutch and brakes. ImageImage


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Koopsy
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Re: 1965 Series IIa 109" Build

#32 Post by Koopsy » Mon Jan 22, 2018 12:17 pm

Replaced the brushes in the starter and it still turned slow so I went through all of the ground and power cables making better contact with the chassis and now it cranks like it never has before!

I received my custom gauges in the mail this week as well so I spent the weekend wiring them up. I used speedhut to create some awesome gauges to closely match the original and match the others best as possible. We also made up a little panel to house them, I think it turned out well!

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Rambler
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Re: 1965 Series IIa 109" Build

#33 Post by Rambler » Mon Jan 22, 2018 5:37 pm

Those look super smart. Wasn’t aware if the speed hut site before. Thank you. I might try for something similar. Just need the land rover logo image to include :-)
- '61 Series 2 88" (project restoration)

Sold:
- '74 Series 3 88" (now sunning itself in the Carolina's)!

Koopsy
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Re: 1965 Series IIa 109" Build

#34 Post by Koopsy » Mon Jan 22, 2018 5:41 pm

Rambler wrote:Those look super smart. Wasn’t aware if the speed hut site before. Thank you. I might try for something similar. Just need the land rover logo image to include :-)
Ya I hadn’t heard of them before and I got a set for the racecar and they worked great. You’re able to customize right on the site and then if you need other stuff done, you just email them and it’s a very reasonable price for custom work. Something I learnt this time around was to ask to have the speedhut logo removed. It’s $10 per gauge but makes them look more authentic without it. You could have them put the the smiths logo or whatever in its place! I had them put the Land Rover logo and then put the red bar from 100 degrees up on the water temp gauge like the original. They go on sale quite often as well, that’s the time to do it!


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Rambler
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Re: 1965 Series IIa 109

#35 Post by Rambler » Mon Jan 22, 2018 6:43 pm

Koopsy wrote:
Rambler wrote:Those look super smart. Wasn’t aware if the speed hut site before. Thank you. I might try for something similar. Just need the land rover logo image to include :-)
Ya I hadn’t heard of them before and I got a set for the racecar and they worked great. You’re able to customize right on the site and then if you need other stuff done, you just email them and it’s a very reasonable price for custom work. Something I learnt this time around was to ask to have the speedhut logo removed. It’s $10 per gauge but makes them look more authentic without it. You could have them put the the smiths logo or whatever in its place! I had them put the Land Rover logo and then put the red bar from 100 degrees up on the water temp gauge like the original. They go on sale quite often as well, that’s the time to do it!
Thank you very much, that is great to hear. I will wait on their sales!
- '61 Series 2 88" (project restoration)

Sold:
- '74 Series 3 88" (now sunning itself in the Carolina's)!

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