1956 Series One Rebuild Project

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
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#51 Post by ANDYD » Fri Nov 17, 2017 5:28 pm

Re Photos

I just open them with Microsoft Office Picture Manager (as far as I know it is pre-installed on all Windows products) click on edit and resize to 900 x 600, quick and simple and uploads easy every time .......

- Cheers,
Andy
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#52 Post by ANDYD » Thu Nov 30, 2017 12:17 am

So onto the Internal Chassis Rust protection, I would of like to go with the Waxoyl product but I found it hard to get hold off and very expensive. When surfing the net for alternatives I found some good reviews for Eastwood Internal Chassis Coating which comes conveniently in large aerosol cans with a 24" tube for getting inside the chassis.
I was pleasantly surprised to find that KMS tools stock this locally and it comes in Black and Green. Green was on sale for about $25 a can, so that helped me decide!
All in all it went very smoothly, I found 3 large cans did a good two coats of the complete internal chassis and the nozzles performed as advertised and gave a 360 deg spray coverage. It is quite runny, I would of liked to of seen it a bit of a thicker mix. (they likely keep it thin so it doesn't clog the nozzle).
Once complete, I had a good look through several holes along the chassis and the coverage appeared very good. There was a couple of cross sections that I couldn't get the tube to access. I considered drilling a couple of new holes :shock: but then decided against it.

A few tips I learnt along the way,
-Tape up all the chassis holes you are not using, this will stop the paint coming out and dribbling all over the outside of the chassis and floor.
-I taped some stiff wire (old coat hanger) to the spray tube, this helped keep the tube straight and allowed for more control of where the nozzle end went.
-Do a dry run inserting the tube into all sections of the chassis before actually spraying.
-Push the tube in as far as it can go, then spray while slowly withdrawing it back to the hole.
-Keep a damp rag handy as you will get a bit of mess / runs and this stuff dries quickly.
- Its smelly and messy, use disposable gloves and respirator.
Attachments
IMG_20171125_140043.jpg
IMG_20171125_140043.jpg (145.46 KiB) Viewed 884 times
Eastwood Internal Frame Coating- Spray.jpg
Eastwood Internal Frame Coating- Spray.jpg (44.32 KiB) Viewed 884 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

Bill E.
Jacked Up
Posts: 977
Joined: Wed Mar 03, 2004 12:30 pm
Location: Tsawwassen BC

Re: 1956 Series One Rebuild Project

#53 Post by Bill E. » Thu Nov 30, 2017 3:12 pm

Andy,

Let's face it, anything with the Eastwood name must be good :wink:

The truck is looking great by-the-way

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

Re: 1956 Series One Rebuild Project

#54 Post by rayhyland » Thu Nov 30, 2017 4:56 pm

When you finish that one Andy just tell me your hourly rate, I have 5 waiting...


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#55 Post by ANDYD » Fri Dec 08, 2017 12:11 am

Ha, yes Bill, Mr Eastwood is the best!
Hey Ray, keep them safe until until I finish this one and then Ill come over and give you a hand!

Ok, this week I have been jumping around a bit on different areas of the LR, I made up and ran some new brake lines, spent some time inspecting the steering relay (not looking forward to that!) and ended up working on the fuel tank.

The fuel tank looks original so its likely 61 years old :shock: Actually pretty good shape. I have heard they can seep a bit around the seams so I filled it up with water and let it sit for a few hours. All good so far. After some research on the web I decided to give it a tank sealer treatment, mainly just because the previous owner had stripped it down of all fittings and cleaned it inside and out, its off the vehicle and probably never a better / easier time to do it.
I went again for the POR-15 (no I don't have shares in the company!) just because it has good reviews and available locally.

Basically the process goes like this;
Step 1- Pour in the Degreaser mixed 50/50 with hot water, seal up all openings on the tank with duct tape and then pick up the tank and slosh it around for 30 mins. Pour out and rinse out well with a water hose.
Step 2- Pour in the Metal Prep, seal up all the openings on the tank with duct tape and then pick up the tank and slosh it around for 30 mins. Pour out and rinse the tank out with a water hose.
Step 3- When the tank is totally bone dry (a heat gun can help with this) Stir up the tin of Tank Sealer and pour it into the tank. Once again seal up the tank with duct tape, roll the tank slowly onto all four sides, then the two ends, repeat this a few times for 30 mins. Remove the duct tape from one of the holes and drain the excess tank sealer out. Let the tank dry / harden for at least 4 days.

That's it, it was nice and easy to handle a small Land Rover tank for this process. Now I feel better a bit more confident that my 61 year old tank will keep my precious fuel on the inside of the tank...
Attachments
IMG_20171201_194507.jpg
IMG_20171201_194507.jpg (200.54 KiB) Viewed 806 times
IMG_20171201_201411.jpg
IMG_20171201_201411.jpg (182.02 KiB) Viewed 806 times
IMG_20171202_105350.jpg
IMG_20171202_105350.jpg (152.69 KiB) Viewed 806 times
IMG_20171201_201519.jpg
IMG_20171201_201519.jpg (149.18 KiB) Viewed 806 times
IMG_20171202_125542.jpg
IMG_20171202_125542.jpg (162.4 KiB) Viewed 806 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

Re: 1956 Series One Rebuild Project

#56 Post by rayhyland » Fri Dec 08, 2017 6:57 pm

Wow looks great!


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#57 Post by ANDYD » Sat Dec 23, 2017 11:24 pm

Its been a productive couple of weeks, I finished the restoration of the fuel tank and installed it along with the intake, sender and fill spout....
Attachments
IMG_20171217_152449.jpg
IMG_20171217_152449.jpg (103.79 KiB) Viewed 694 times
IMG_5731 FT.JPG
IMG_5731 FT.JPG (160.88 KiB) Viewed 694 times
IMG_5735 FT.JPG
IMG_5735 FT.JPG (176.51 KiB) Viewed 694 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#58 Post by ANDYD » Sat Dec 23, 2017 11:46 pm

The old brake lines had been removed and disposed of by the previous owner so I didn't have any old "templates" to follow, so I had to start from scratch, using information from club members, manuals and the internet. I borrowed a brake flaring kit and got to work.... I learnt a lot along the way about "double flares" and "bubble flares" and male fittings and female fittings etc.. but it is very important that you identify the type of flare you need for each connection. With the newer Series 2 & 3 parts that you have to buy for the older Series 1 Land Rovers its quite likely you will require a "double flare" at one end of the brake pipe and a "bubble flare" at the other end.. :shock:
Attachments
IMG_20171211_165431.jpg
IMG_20171211_165431.jpg (186.8 KiB) Viewed 690 times
IMG_20171212_162354.jpg
IMG_20171212_162354.jpg (114.25 KiB) Viewed 690 times
IMG_20171212_162434.jpg
IMG_20171212_162434.jpg (162.51 KiB) Viewed 690 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#59 Post by ANDYD » Sun Dec 24, 2017 12:08 am

Its a good feeling to start emptying boxes of random parts and bolting them into place. I cleaned up, painted and installed the hand brake assembly. Its awesome to see the old 1950's engineering that went into making the handbrake work on the LHD.
After getting the hand brake installed I turned my attention to the Master Brake Cylinder. A lot of people modify a Series 2 Master Cylinder to work on a Series 1, mainly because its a bout 1/10th of the price and more readily available. After inspection of mine, it looks it really good condition (internally) so I have decided to order a new seal kit and try that first. Only time will tell if that was a good idea .... I've not had a lot of success with new MC seal kits in the past and once vowed never to use one again ... we will see!
Attachments
IMG_5730 FT and HB.JPG
IMG_5730 FT and HB.JPG (160.59 KiB) Viewed 686 times
IMG_20171211_221329.jpg
IMG_20171211_221329.jpg (134.93 KiB) Viewed 688 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
bsa_m21
Junkyard Master
Posts: 169
Joined: Mon Mar 02, 2015 1:30 pm
Location: Surrey, BC

Re: 1956 Series One Rebuild Project

#60 Post by bsa_m21 » Mon Dec 25, 2017 11:17 am

Merry Christmas Andy,

I used a brake hone to clean up the master cylinder on my 80" (same one as your's) when I first rebuilt it. But she started leaking after several years. Well after fighting with multiple rebuilds over the years, I gave up. I was going to get the master cylinder sleeved with a stainless steel insert, but it was way cheaper and better (IMHO) to replace the unit with one from Wilwood. (http://www.wilwood.com/MasterCylinders/ ... 20Cylinder)

Unless you are going for a concours resto, the change is invisible and he benefit of incorporating dual circuit brakes instead of the original single circuit swayed me. I also added 2psi Residual Pressure Valves to improve the feel of the brakes. Works like a charm.

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

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#61 Post by ANDYD » Fri Dec 29, 2017 3:45 pm

Hi Martin,

Thanks for the tips. With the new MC fitted did you keep the original brake fluid reservoir? Also did you re-run the brake lines to separate the front and rear into two circuits?

cheers,
Andy
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

Re: 1956 Series One Rebuild Project

#62 Post by rayhyland » Fri Dec 29, 2017 9:43 pm

I love the brake fluid reservoir in my Series 1. It’s like an old pre-war can for truffle oil, or something equally obscure.


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
bsa_m21
Junkyard Master
Posts: 169
Joined: Mon Mar 02, 2015 1:30 pm
Location: Surrey, BC

Re: 1956 Series One Rebuild Project

#63 Post by bsa_m21 » Sat Dec 30, 2017 9:53 am

Hi Andy,

Actually, I replaced the remote reservoir with a plastic one as mine was rotting out. A simple brake-safe hose connects from the reservoir to the existing pipe.

On my 80", the brake lines already split (front/rear) at the MC with a T-junction, so I just removed the T, added two connectors and short pipe sections to connect them to the MC. No proportioning valve mind you. I really only separated them for safety if one line is compromised.

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

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#64 Post by ANDYD » Tue Jan 23, 2018 7:22 pm

OK, it's time to address the dreaded Steering Relay.
It actually turns smoothly and has no play or obvious wear & tear. Originally I was considering just leaving it well alone.

On closer inspection I could see that where the upper and lower oil seal sit there is grooves worn into the shaft and its unlikely that new seals will ever keep the oil in. In addition to this I cant get any new oil in or out of the steering unit. I have come to the conclusion that sometime in the past a previous owner has given up trying to seal the oil leaks so has just filled the unit with thick grease.
So with no idea if its full of good grease / old grease / no grease the only option is to change the whole unit or change the inner parts.
After a few days of trying to remove the complete unit, including a 20 ton hydraulic jack, a full can of penetrating oil and various large hammers.... I come to the conclusion that I will go with just removing the inner parts.
I recently discovered that the previous owner had already removed the upper and lower oil seals and the retainer, the famous large spring has apparently be free to come shooting out at any time but it had chosen not to .... not yet anyway!
Attachments
IMG_20171206_202528.jpg
IMG_20171206_202528.jpg (169.42 KiB) Viewed 767 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

1956 Series One Rebuild Project

#65 Post by rayhyland » Wed Jan 24, 2018 10:37 am

Can you clean it out by spraying brake cleaner into it and then injecting fresh grease?


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
bsa_m21
Junkyard Master
Posts: 169
Joined: Mon Mar 02, 2015 1:30 pm
Location: Surrey, BC

Re: 1956 Series One Rebuild Project

#66 Post by bsa_m21 » Wed Jan 24, 2018 4:02 pm

rayhyland wrote:Can you clean it out by spraying brake cleaner into it and then injecting fresh grease?
That's what I did. Worked great.
Martin
=======
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#67 Post by ANDYD » Wed Jan 24, 2018 8:44 pm

Ray / Martin, Thanks for the tips.. So to clarify, you mean to and spray brake cleaner into the little hole in the top with the hope the old thick grease breaks down and all drains out the little screw hole in the bottom? Would brake cleaner break it down that thin?
How would I know how much of the old grease has been removed?

Hummmmm ..... I can see that as an option if the vehicle was all complete and the relay was hard to access, but right now as a rolling chassis it would probably make sense to fully service the unit.

I'm going to ponder it some more with my mug of tea and a cookie or two or three .....
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

1956 Series One Rebuild Project

#68 Post by rayhyland » Wed Jan 24, 2018 10:49 pm

If you can’t get it out, and you said it’s nice and smooth, I’d go this route. If it’s stiff then you need to do what you need to do. I’ve heard of people having to cut them out with a torch...

Mine was really really bad. Drove it like that till we reached the UAE when I came across a spare.


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#69 Post by ANDYD » Thu Jan 25, 2018 11:47 pm

As the Steering Relay body doesn't want to move I decided to see if the Steering Relay inner parts would come out.
With bucket positioned underneath I gave it a few good taps downwards and the shaft has started to move down. It moved down about 1 inch before getting stuck again. It did open up at the top enough to let me get a bunch of penetrating oil into the relay body. I will leave it soaking for a day or two before giving it another good bang downwards. Apparently the BIG spring is in no hurry to leave its home!

Photo - Steering Relay Shaft moved down about 1 inch before getting stuck again.
Attachments
IMG_0170 Steering Relay.jpg
IMG_0170 Steering Relay.jpg (110.54 KiB) Viewed 670 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#70 Post by ANDYD » Mon Jan 29, 2018 2:47 pm

After another day of good soaking time in penetrating oil and grabbing a bigger hammer I was able persuade the Steering Relay "guts" to fall out the bottom into my rag filled bucket, a lot less drama with the big spring than I was expecting, partially I expect due to the amount of rusty, corrosion that had built up inside the relay body.
It looks like at some time in its life, water was able to find its way into the housing and everything is pretty rusty.

1st Photo - is looking through the Steering Relay body from the top
2nd Photo - is all the "guts" spread out after retrieving them from the bucket
Attachments
Steering Relay IMG_0210.JPG
Steering Relay IMG_0210.JPG (127.34 KiB) Viewed 645 times
Steering Relay IMG_0200.JPG
Steering Relay IMG_0200.JPG (71.57 KiB) Viewed 645 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

Re: 1956 Series One Rebuild Project

#71 Post by rayhyland » Mon Jan 29, 2018 5:07 pm

Can you reuse anything or are you getting all new parts?


Sent from my iPhone using Tapatalk
Ray Hyland
BCOverlandRally.com, NWOverlandRally.com
I drive a 113 (a 110 and three Series 1s)

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#72 Post by ANDYD » Mon Feb 05, 2018 10:58 pm

Nothing really worth re-using, all very rusty and corroded. The internal replacement parts are not expensive and Jeremy has them all in stock.
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#73 Post by ANDYD » Mon Feb 05, 2018 11:14 pm

Well, after feeling a new burst of energy from removing the Steering Relay inner parts I decided to have another go at getting the old steering relay body off. With the guts removed I could see that a simple pulling jig could be made with a piece of 3/4" ready-rod through the center of the body and a couple of spacers and washers, all I had to do was crank the nut down the ready rod and it should pull and pop the relay body right out of the chassis...... ummmm ... sounds so simple, what could possible go wrong....

Photo 1 - Pulling Jig in place, start cranking on the nut to pull the steering relay body out of the chassis
Photo 2 - Movement! The steering Relay body starts to move upwards... Success?
Attachments
IMG_0211.JPG
IMG_0211.JPG (115.32 KiB) Viewed 558 times
IMG_0213.JPG
IMG_0213.JPG (121.48 KiB) Viewed 558 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#74 Post by ANDYD » Mon Feb 05, 2018 11:32 pm

The upwards movement continued, this was going way too easily?
Then I realised that the "pop" I heard wasn't the Steering Relay body coming loose but it was actually the welds breaking on the metal tube that the relay sits inside. The top and bottom welds had sheared right off and the sleeve had come out still firmly attached to the relay body...
Once off the chassis, it still took a lot of work to remove the metal sleeve from the relay body, 61 years of crud in the gap had done an amazing job of welding to two parts together.

Now I will have to get this piece welded back in place (still seems very solid) then I can finally install the brand new Steering Relay.
I think I will rebuild the old one and keep it as a spare, I hate throwing out any original Series 1 parts :roll:

Photo 1- The welded sleeve popped right out of the chassis before the corroded parts would let go of each other
Photo 2- Hopefully this sleeve will pop right back in and I can get it re-welded back in place.
Attachments
IMG_0217.JPG
IMG_0217.JPG (152.88 KiB) Viewed 553 times
IMG_0231.JPG
IMG_0231.JPG (138.74 KiB) Viewed 553 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#75 Post by ANDYD » Mon Feb 05, 2018 11:46 pm

A quick call to "Rothman's Mobile Welding Unit".. (a very friendly, helpful Rover-Landers Member) and we had the welding on the go!

It didn't take long to get the metal sleeve back in place and we also took the opportunity to replace the 3 tabs that support the Front "Breakfast" piece, they had been chopped off :shock: by a previous owner for some strange reason.

Photos 1 & 2 - The young :wink: welder in action.....
Attachments
IMG_0262.JPG
IMG_0262.JPG (208.29 KiB) Viewed 552 times
IMG_0264.JPG
IMG_0264.JPG (186.58 KiB) Viewed 552 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

mepham55
Drag Link
Posts: 617
Joined: Fri Mar 26, 2004 8:38 pm
Location: Victoria, BC, Canada

Re: 1956 Series One Rebuild Project

#76 Post by mepham55 » Tue Feb 06, 2018 12:30 am

That’s exactly what happened to my chassis when I removed the old relay. I had a muffler shop stretch a new piece of pipe to fit the hole, then I welded it in. Make sure you slop a bunch of anti-seize on the new relay for the next owner that will have to deal with this in 60yrs!

Matt

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

User avatar
rayhyland
Greasy Fingers
Posts: 781
Joined: Mon Feb 23, 2009 5:28 pm

Re: 1956 Series One Rebuild Project

#77 Post by rayhyland » Mon May 07, 2018 11:21 pm

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

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#78 Post by ANDYD » Thu May 10, 2018 11:15 pm

Hi Ray,

Yes the project is still ticking along, good progress made over the last couple of weeks.

Once the welding repairs were complete, a clean up with the grinder then a few coats of paint and the new Steering Relay slipped right into place and was bolted in tight.
Attachments
IMG_0288.JPG
IMG_0288.JPG (92.29 KiB) Viewed 241 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#79 Post by ANDYD » Thu May 10, 2018 11:45 pm

With the dreaded Steering Relay now sorted I turned my attention to the Steering box and column. After a quick inspection it was obvious that it would need some repairs. There was a broken corner flange on the aluminum steering box and also a chunk of metal missing from the end of the steering column. I happened to have a spare aluminium Steering box on hand and luckily Matt on the Island hand a spare inner steering column. I picked up all the new seals, shims, ball bearings from Jeremy at Rocky Mountain and started stripping apart the old Steering box.

Photos showing the damaged aluminum steering box (and the new box)
Attachments
IMG_0292.JPG
IMG_0292.JPG (85.11 KiB) Viewed 236 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#80 Post by ANDYD » Fri May 11, 2018 12:01 am

The Inner Steering column missing an edge from the channel that the ball bearing run along;
Attachments
IMG_0310.JPG
IMG_0310.JPG (88.04 KiB) Viewed 234 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#81 Post by ANDYD » Fri May 11, 2018 12:27 am

Onto rebuilding the Steering Box with the new parts. The new ball bearings were a little tricky getting them all in place at the same time while tightening everything up. After a few failed attempts I found the best way is to clamp the column upright in the vice and use a light grease to "stick" them in place one at a time until it was time to lock them all into position.
Attachments
IMG_0880.JPG
IMG_0880.JPG (101.7 KiB) Viewed 258 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#82 Post by ANDYD » Fri May 11, 2018 12:40 am

I had to re-take the end cap off the steering box a couple of times to add/remove shims and get a nice smooth movement without any end float and without any stiffness. Really just a case of trial and error until it feels right. I believe the outer column is from a Series 2a as it had the bearing at the top end instead of the Tuffenel Bush that the Series 1 has. I changed the bearing in the column as its easy to do at this stage and considered this as an "upgrade".
Once it was all back together, a good clean up and some POR15 on the steel parts. Then a dry-fit onto the chassis as shown below.
Attachments
IMG_0908.JPG
IMG_0908.JPG (80.85 KiB) Viewed 257 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
bsa_m21
Junkyard Master
Posts: 169
Joined: Mon Mar 02, 2015 1:30 pm
Location: Surrey, BC

Re: 1956 Series One Rebuild Project

#83 Post by bsa_m21 » Fri May 11, 2018 9:57 am

Great progress Andy. Is she going to be on the road in time for the show next weekend? :P

Actually, when you finally get her all connected, and put load on the wheels, you may find that you need to re-shim some more.

FYI - I modified my steering box by adding a tensioning bolt to the cover plate, like the later boxes have, to allow you adjust the play without shims. I drilled a hole and welded a nut to the plate, then used a grade 8 bolt and lock nut. Seems to work well.
58-column.jpg
58-column.jpg (43.87 KiB) Viewed 246 times
Martin
=======
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#84 Post by ANDYD » Wed May 16, 2018 7:11 pm

Hi Martin,
Thanks for the tip. The later Series 1's do have that that steering box adjusting screw, mine has one too.

I recently turned my attention to the Gearbox. Before stripping it down for inspection I had the task of removing 60 years of a thick crust that resembled a Grease & Dirt cement.
Once I began chipping and scraping I was happy to see that shiny aluminum emerging .......
Attachments
1956 Series 1 - Gearbox 062.JPG
1956 Series 1 - Gearbox 062.JPG (102.54 KiB) Viewed 202 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
cbalme
Bumper Sticker
Posts: 145
Joined: Fri Apr 14, 2017 2:05 pm
Location: Cobble Hill

Re: 1956 Series One Rebuild Project

#85 Post by cbalme » Wed May 16, 2018 10:20 pm

Good to see some progress on the box, if you clean it very well now you'll thank yourself later. I didn't do enough cleaning so I spent a lot more time cleaning each individual casing and piece. Rinsing the inside of the box with diesel also makes life easier after you drain all the oil.

What is the PTO for? Winch or for running farm machinery off the back?

Have fun
Colin

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#86 Post by ANDYD » Sat May 19, 2018 8:16 pm

Hi Colin,

Good advice, yes I will be scrubbing away as I take it apart. I was wondering what to flush / rinse the internals out with when I'm done, is diesel the recommended "flush" treatment?

Its looking a little cleaner now and parts are coming off which makes it easier (lighter) to move around. Taking it all apart to have a good look at the seals, bearings, gear teeth etc
Attachments
IMG_0521.JPG
IMG_0521.JPG (69.41 KiB) Viewed 75 times
IMG_0526.JPG
IMG_0526.JPG (86.26 KiB) Viewed 75 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#87 Post by ANDYD » Sun May 20, 2018 10:48 am

Spent some time on the front end of the gearbox, stripping parts and scraping and cleaning and more cleaning ....
I convinced myself to change the clutch withdrawal bearing, seals and bush, even though the original components weren't showing any obvious signs of excess wear and tear. Better now than later I guess.
In the back of the bell housing is the smaller Layshaft bearing, this is a notorious bearing for failing and was on my "must change" list. Sure enough, once removed I found lots of wear in this bearing.
Attachments
IMG_0849.JPG
IMG_0849.JPG (73.19 KiB) Viewed 65 times
IMG_0856.JPG
IMG_0856.JPG (57.97 KiB) Viewed 65 times
IMG_0857.JPG
IMG_0857.JPG (64.27 KiB) Viewed 65 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#88 Post by ANDYD » Sun May 20, 2018 11:25 am

While waiting for some new parts to arrive I switched over my attention to the four wheel drive selectors and transfer gear levers. After close inspection there was no obvious signs of wear or damage. I did find a stud sheared off the exterior of the housing cover which was easily extracted and a new stud installed. Not seeing anything else of concern and knowing the set up of all these levers can be tricky once taken apart, I opted for just cleaning everything up, new seals and gaskets, and putting it back together.
Attachments
IMG_0896.JPG
IMG_0896.JPG (67.36 KiB) Viewed 61 times
IMG_0895.JPG
IMG_0895.JPG (59.35 KiB) Viewed 61 times
IMG_0894.JPG
IMG_0894.JPG (60.85 KiB) Viewed 61 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

User avatar
ANDYD
Defender of the World
Posts: 2181
Joined: Tue Mar 09, 2004 10:45 pm
Location: Sunny Steveston BC

Re: 1956 Series One Rebuild Project

#89 Post by ANDYD » Sun May 20, 2018 11:46 am

One tip that I found worked out well, particularly if you have limited space, is to set up a work bench on the back end of the rolling chassis using some 2x8 planks. This way it can be mobile, moved back and fort to create more space and also allow you to get on all sides of your "mobile bench".
Attachments
IMG_0869.JPG
IMG_0869.JPG (57.77 KiB) Viewed 59 times
IMG_0874.JPG
IMG_0874.JPG (68.06 KiB) Viewed 59 times
1991 Defender 110 / 2003 Discovery / 1956 Series 1- 86

Post Reply