Oliver and Colin's 1960 Series II rebuild.

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red90
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Re: Oliver and Colin's 1960 Series II rebuild.

#101 Post by red90 » Sun Apr 01, 2018 5:56 pm

Or...the shaft may be installed back to front.

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

#102 Post by cbalme » Sun Apr 01, 2018 8:13 pm

The locating Pin is installed in the second hole from the front of the engine. There is no hole in the rocker shaft for the locating pin to thread into at the front but the locating pin at the back was already threaded in and lined up. This pin is in between cylinder 3 and 4. So I suppose this means the shaft is installed backwards. It should work either way, shouldn't it?
Colin

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

#103 Post by red90 » Sun Apr 01, 2018 8:48 pm

cbalme wrote:It should work either way, shouldn't it?
I'm not sure. If it is completely symmetrical, it should not matter. It looks like it, but I can't guarantee it.

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

#104 Post by cbalme » Mon Apr 02, 2018 9:23 pm

It seems as though there is an oil return and entry gallery from that video so it should work either way. I think I will use it the way it is and take my chances.
Colin

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

#105 Post by cbalme » Tue Apr 03, 2018 10:46 pm

Well I did another valve set and found one adjuster to be of concern. Is this a sign of bad things or is it normal? It is screwed in very far compared to the others. I checked the pushrod and it is straight and compared to another push rod they're the same length.

The photo is of #6 adjuster, which was adjusted when #3 valve was open.

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The push rods from the old motor are slightly longer compared to the ones from this motor.
Colin

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

#106 Post by red90 » Wed Apr 04, 2018 6:58 am

Are the valve heights the same? Rocker bent?

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

#107 Post by The_Anachronist » Thu Apr 05, 2018 6:42 am

Yeah with an engine that old I’d bet on valve height. All mine were about .25” short - and with not much zip left in the spring.
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Re: Oliver and Colin's 1960 Series II rebuild.

#108 Post by cbalme » Thu Apr 05, 2018 10:26 pm

The valve heights seem about the same compared to valves near #6

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The next thing I'd suspect would be something to do with the cam and followers. The plan is to rebuild the Solex 40 PA in the next few days and see if the engine will run. Then I'll decide from there what to do.

I have been making progress in other places like the steering and Air filter. It's a lot of painting to make things look nice and tidy. The steering box is in very good shape it just needs a new gasket to solve a leak.

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Air Filter installed

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Colin

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

#109 Post by cbalme » Sun Apr 08, 2018 11:02 pm

Got a bit of work done today on the old Series, refurbished the Solex Carb and got it back on the Motor. Very close to firing it up and seeing if it actually runs!

My Grandfather and I tore the carb apart and cleaned it up and reassembled it with a kit. It was missing some parts so we just cleaned and reused the old ones.

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Then without anything else left to do I decided to bend up the brake lines for the rear axle. I used my hand to bend the lines so it's not very pretty. The lines are longer than they need to be which is annoying.

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Colin

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

#110 Post by cbalme » Thu Apr 19, 2018 10:17 pm

We've finally got around to putting the gearbox back together. Victor came over last afternoon to give us a hand.

Here we are pressing first gear on to the layshaft. They had to remove it and take all the wax off. I'd left it on which turned out to be a bad idea.
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Pressing the bearing on to the primary pinion. We made sure to the washer on the other side as per the manual. The previous time it was apart someone put the washer on the wrong side.
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We then put the primary pinion into the bellhousing. We had a hell of a time trying to pound the bearing in so we used a heat gun to warm the bellhousing for 5 minutes then it just fell in. It was quite comical how easy it was compared to before. We used the same trick for the layshaft bearing and tightened up all the studs and bolts that held them in.
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Getting the gears ready to go in. at the time we had the layshaft assembled in the wrong order but we figured that out later when the Syncro wouldn't fit beside the gears
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Didn't take many photos of the assembly since it required many hands but it went together without too much trouble. The biggest issue was lining up the layshaft with the main shaft but after a bit of fiddling, we got it to go. The gear that matches the primary pinion was put on at the same time as the bellhousing and primary pinion since it was the only way we could get things to align.
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We called it a night after we got the gear selectors aligned. We ran it through all the gears and none of them grind so it is ready for the transfer case and final reassembly.
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Re: Oliver and Colin's 1960 Series II rebuild.

#111 Post by cbalme » Fri Apr 20, 2018 11:14 pm

Did a bit of fiddling with the gearbox tonight. Hopefully I'll have it done by next week.

I only got the reverse springs installed tonight. It was missing one so I just changed them both while it was apart.

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

#112 Post by cbalme » Sun Apr 22, 2018 1:05 pm

I got bored Saturday night and decided to put the box back together. I finished it up this morning and just need to put the slave cylinder back on then it's done.

I adjusted the clutch release pin with the 7/16 drill bit and bolted it back on. I also put the top back on with some grease to hopefully seal it.
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Then shimmed up the transfer case, it didn't need any extras it was already perfect.
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After that I mated it all together. I put the intermediate shaft in before the gearbox output gear which was a mistake so I had to take all of that apart again.
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Put the springs in for the gears and setting the clearances with the adjusters
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Just a few more things then it's ready to go back in!
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Colin

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

#113 Post by cbalme » Sun Apr 22, 2018 11:35 pm

I was expecting to be able to put the box back in the truck this afternoon but found a crack in the pipe that connects the slave cylinder to the throwout assembly.

You can just make out a hairline crack beside the hole for the pin. Above is the galvanized pipe we used to make a new one.
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Our reamer was broken so I had to file it out by hand which took quite a while. Eventually, I got it to fit as it should with a new grommet in place.
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Put a shiny new slave cylinder into the housing I found in my parts pile that was nice and clean. I will adjust it later one I get the hydraulics installed.
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I also cleaned and degreased all the mounts so I can paint them.
Colin

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

#114 Post by ANDYD » Mon Apr 23, 2018 10:37 am

Great progress Colin, I'm feeling a bit guilty having left my project for a few weeks and watching all your good progress.

So regarding the gearbox, now that you put it all back together, did you find a lot of wear and tear on gears or bearings or were the replacement parts more just to change them while you had it on the bench? I'm at that point where I am going to change all my seals, but not really seeing any wear or excess movement in the bearings or gears.
Reluctant (or lazy) to just change bearings for the sake of it .... hummmm...
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Re: Oliver and Colin's 1960 Series II rebuild.

#115 Post by cbalme » Mon Apr 23, 2018 8:11 pm

Hi Andy, good to hear it is still being worked on. With this gearbox my original plan was to just change all the gaskets and seals but I crushed that rear layshaft bearing by accident so I had to take it all apart. After disassembly 1st gear was found to be in bad shape so we changed it out. Other than that all the gears were in good shape. It's very easy to change the bearings if you have a heat gun and a freezer or access to a shop press. We changed 3 out of the 5 bearings inside the gearbox because they were easy to deal with even though they were in good shape. We left the rear mainshaft bearing because it was in perfect condition and reused the old bearing that goes between the mainshaft and the primary pinion because the new britpart bearing had more play.

I didn't change any transfer case bearings I just took it apart and cleaned it. When you go to put everything back together just shim it all and make sure it's set to the correct preloads and that sort of thing.

Overall I would just give the whole box a good look over and change anything that looks overly worn. I'd also talk to Victor or Matt who are quite good at this sort of thing.
Colin

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

#116 Post by cbalme » Wed Apr 25, 2018 12:13 am

This afternoon we got the gearbox installed. It was very fiddly and took a while to line everything up but then it all just slid into place.
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I was having troulble aligning the mounts and it turns out I put the removable cross memeber on the wrong way round. Once I got that sorted out it went into place quite well
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Then I put the handbrake on with a bit of siliconce on the mudshield. The shoes were easy to put on on the bench with older springs
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Then I torqued up the flange, put the drum on and adjusted the handbrake to how it should be.
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Also made a new cork gasket for the filler hole on top. It took two tries and turned out okay.
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Next job is putting the propshafts on and then onto welding the bulkead!
Colin

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

#117 Post by cbalme » Sun May 06, 2018 10:19 pm

It's been a busy week without much progress on the Land Rover.

Propshafts got installed last weekend with new bolts.
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Bought a battery that was an inch too long so I had to trade it for another. Getting closer and closer to firing it up!
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Found out that Land Rover makes two carburettor elbows, one is for the Solex on the left and the other is for a Weber or Zenith on the right. You can slightly see that the one on the right is slightly bigger. So I had to paint the other and not use the nicely painted one I already had. Now it's all connected and the old vacuum advance I found in the parts bin is hooked up.
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I also got a vintage Jack-All from my grandpa which will suit the 109 quite nicely.
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Colin

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

#118 Post by cbalme » Sun May 27, 2018 8:51 pm

After taking a break from working on the Land Rover to focus on school I found some time to get some work in.

I exchanged my other battery for one with the reversed terminals so it'll work with my Land Rover.

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Gave the inside of the frame a thick coat of Wax, hopefully it'll be good but I may need to recoat it because this stuff doesn't harden.
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Two Cans barely did the whole frame and I had to buy the applicator separately. It came with 3 lengths but I only used the long one.

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I also replaced the original breather hoses for the Axles since they were only stubs. Hopefully these will be long enough and not get snagged on anything. I don't think I will need breather hoses that go all the way up to the top of the bulkhead since I don't plan on doing any deep wading.

Back Axle

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Front Axle. There was no where to route the hose on the other side of the frame so I had to route the hose over the diff.

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Colin

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

#119 Post by cbalme » Mon Jun 04, 2018 12:20 pm

A few little things got done yesterday. I painted the radiator and shroud and screwed them back together. I had the radiator tested by Gerwin Solutions. It was tested up to 10 pounds and held up fine So I may get a few more years out of it. It only needed a new cap and tap. I have yet to find a cap because it is the rare kind off of a Series 1.

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I drained the old gear oil out of the steering box and filled it up to the brim with thin one shot grease. This should stop any leaks and keep it lubricated up for many years to come.

I then turned my attention to the steering wheel. I spend a good hour wire wheeling the main aluminium part and then degreased the handle and everything. I then taped off the chrome parts. After it was all masked off I took some JB weld and forced it into the cracks in the plastic so it would be strong again. I then gave one more good degreasing with scotchbrite and then primed everything with self-etching primer. Tonight I'll sand it back a bit and then give it a few coats of gloss black.

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

#120 Post by cbalme » Mon Jun 04, 2018 9:44 pm

Put two coats of gloss black on the wheel this afternoon. It's looking very good and I'm quite pleased with how it turned out.

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I also painted the part that does the electrics for the horn and the self-cancelling turn signals.

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Now I need to find something to coat the horn and surround. It is supposed to look wrinkly but has a pattern. I am going to look into finding a wrinkle paint.
Colin

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

#121 Post by bsa_m21 » Mon Jun 04, 2018 10:24 pm

You can get Eastwood black wrinkle paint from KMS. They usually have it in stock.

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

#122 Post by cbalme » Tue Jun 12, 2018 10:51 pm

Thanks for the tip Martin, the only KMS we have on the island is in Victoria so I'll look around locally before heading down. How do I separate the button from the surround that needs to be painted?

Tonight we turned the engine over on the starter, just to make sure the oil pump was working and to make sure the rocker shaft was getting oil. It was a rough start because I forgot to add the oil pressure gauge so I emptied a litre of oil onto the floor before I noticed my mistake. After plugging in the gauge we turned it over again and got 30lbs of pressure and the rocker shaft began emptying oil out of the holes so it turns out the way the shaft is facing doesn't matter.

Click on the photo and it will take you to a video.

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The original gauge showed 30lbs. I ordered a brand new one off of Craddock which will be cheaper than getting it rebuilt.

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Just need to sort out the electrical and fuel then it'll be ready to run by itself!
Colin

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

#123 Post by cbalme » Sun Jun 17, 2018 3:16 pm

Haven't got around to firing up the motor just yet, but it is almost all wired in and ready to go. In the meantime I got the centre horn button painted.

First of all, I disassembled it everything. You just need a small chisel to pry the tab over and then some water pump pliers to twist the centrepiece out. Here it is all in bits after bending the tab over.

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I then took the horn button and wet sanded the deep scratches and imperfections out with 400 grit sandpaper, it gave a super smooth finish and turned out quite nice with a coat of gloss black but I don't have any photos.

Matt told me to make sure the metal wasn't cold so I put it in the sun for an hour before I painted the horn surround.

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I took a can of VHT Wrinkle Plus to it. It sort of looked wavy and disappointing but the can said to expect that so I left for a bit.

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Then came back to this.

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The metal was almost too hot to hold at the time I painted it which I think made the wrinkles tighter than they should be but I am still very impressed!

My photos don't really show all the details but it looks the part.
Colin

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

#124 Post by cbalme » Tue Jun 19, 2018 10:36 pm

Put the horn button and centrepiece back together and it looks great!

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I got the rest of the steering wheel back together, I just need to figure out a way to take all the tape off as it's stuck on there really well.

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My parts for the handbrake from Roversnorth finally arrived, even in a green bag!

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I finished installing the handbrake this afternoon and it goes on tight after about 4 clicks. I also installed a spring but I am not sure if that is where it is actually supposed to go.

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A close up of the return spring. I'm not sure it's in the right place.

Image
Colin

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

#125 Post by oldgravy » Thu Jun 21, 2018 1:56 pm

On my S2 the return spring affixed to the backing plate. I have a poor quality photo somewhere if you need it...

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

#126 Post by cbalme » Tue Jun 26, 2018 11:13 pm

Hi oldgravy, I'd love a photo I'm not sure I set mine up right but it seems to be working.

I got a bunch of stuff from craddocks this afternoon.

A new gauge to replace the one that was missing the temperature sender.

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A new radiator cap which is very tight to put on. Time will tell whether it works or not.

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Brake line brackets for a Series III axle were installed as well. I may need to get a different type of flex hose with a long part on both ends.

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Colin

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

#127 Post by oldgravy » Fri Jun 29, 2018 3:45 pm

Here's what I got.
Attachments
2016-03-15 14.07.56_preview.jpeg
2016-03-15 14.07.56_preview.jpeg (209.01 KiB) Viewed 374 times
2016-03-15 14.08.11_preview.jpeg
2016-03-15 14.08.11_preview.jpeg (126.76 KiB) Viewed 374 times

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

#128 Post by cbalme » Sun Jul 01, 2018 9:06 am

I must have a different handbrake backing plate than you, mine doesn’t have a hook like yours.
Colin

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

#129 Post by cbalme » Tue Jul 03, 2018 12:08 am

Just been chipping away at little jobs like cleaning parts and getting them ready for paint.

Finally got a Power Brake Tower thanks to Matt, now I can do a proper job on the brake system. When I got the brake tower it was seized solid, so straight into a bucket of diesel it went. Then I pulled it out and took the impact driver to all the nuts and pulled the servo off which went straight into the bin.

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Took a bit of persuading with a brass mallet to get the pedal to move back and forth smoothly but now I can move it around by hand so I will wire wheel and paint it with POR 15 after I find a suitable clutch pedal in my parts loft.

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Very very close to firing up the old 2.25. It is all wired in properly as far as I know. The white wire goes to the + Terminal on the battery and the red one goes to the distributor.
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I had to take the fuel pump off the old seized motor after messing around with the one I was trying to use for over an hour, Something is wrong with the diaphragm it won't build pressure. The original AC pump was pulled off the seized block and pumped fuel like crazy. I bet it's been rebuilt at some point because it has a few stripped screws.

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Once I run a fuel line to the carb it should be ready to fire up!
Colin

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

#130 Post by ANDYD » Tue Jul 03, 2018 11:28 pm

Exciting times.... good luck with the start up, hope it roars like a lion (or purrs like a cat!)

The steering wheel came out well, good work.
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Re: Oliver and Colin's 1960 Series II rebuild.

#131 Post by cbalme » Wed Jul 04, 2018 12:01 am

Thanks Andy, very pleased with how the wheel turned out.

I started this evening with plumbing in the fuel lines from the pump.

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Then pushed it into the yard to fire it up.

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After doing a bit of fiddling we ran some jumper cables to the starter and tried turning it over. It turned over quite a few times and barely coughed into life and then stalled on us. Disappointing results but that means it can run, and I will make it run!

It gets spark, it's getting fuel, and it has air, I think it is lacking the pull from the starter motor or crank handle. The starter weakly turns it over and I wasn't able to crank it over by hand fast enough. Tomorrow I will get it to go somehow. If anyone has any advice it would be greatly appreciated because I don't really know what I'm doing.
Colin

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

#132 Post by John » Wed Jul 04, 2018 8:06 am

Hand cranking does not require speed and you'll never get any unless you have little to no compression. You'll only get one hit past compression at a time however I don't think I would expect to get a rebuild to start first time on the crank unless you know that everything else is spot on. Put a known good battery in it and take it from there.

Good luck.

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

#133 Post by cbalme » Wed Jul 04, 2018 10:57 pm

I thought it was all in the speed of the pull? I understand I can only hit it once and then I have to hook the crank handle back into the pulley. The battery is brand new and reading 13.3 volts when I began turning it over and has been recharged.


Which way is full choke on the Solex? I'm pretty sure it's pulled all the way back towards the bulkhead.

It did cough and sputter for a second so the timing is sort of set.
Colin

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

#134 Post by cbalme » Thu Jul 05, 2018 11:59 pm

After messing around with it this afternoon I decided to set the plug gap properly, I think that did the trick it fired up and roared like a lion before stalling because it ran out of gas.

"There you go, it runs" sums up this video https://youtu.be/z8qcYrwXSro pretty well.
Colin

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

#135 Post by franko » Fri Jul 06, 2018 6:56 am

Amazing, that’s got to be the best feeling ever 🙌🏼.

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