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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.

#201 Post by red90 » Mon Feb 25, 2019 4:34 pm

Sounds like bad u-joints. There are only those two sizes. The smaller ones are not used on anything but Land Rovers so your dad won’t have any luck locally. The larger ones are 1310s and commoner than dirt.

I always use Hardy Spicer joints from the UK and they always fit.

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bsa_m21
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Re: Oliver and Colin's 1960 Series II rebuild.

#202 Post by bsa_m21 » Mon Feb 25, 2019 4:57 pm

I agree with Red90, except the smaller ones (Precision 344, Spicer/Dana 1300 series #5-3214x) are also used on Triumph TR2/3/5/6, Volvo 140/240/740, some Maserati models and more. :twisted:
You can buy the #5-3214x from most parts stores locally.

Here is a zip with a pdf of the hardy-spicer 1300 spec's. You can measure up what you have to see what's wrong. (Yours were probably made in China..... :oops: )
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Hardy Spicer 1300.zip
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cbalme
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Re: Oliver and Colin's 1960 Series II rebuild.

#203 Post by cbalme » Wed Feb 27, 2019 8:47 pm

Hi there, before I go out and buy new U joints I think it'll be worth taking this one apart and seeing if any pins have fallen over. I will find out either Thursday or Friday if that is my problem.

In the future I'll probably end up getting joints from the UK as the Hardy Spicer and GKN are surprisingly cheap compared to the MOOGs from the local shop.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#204 Post by cbalme » Sat Mar 02, 2019 8:57 pm

Haven't got a chance to take a look at those U-joints yet. But I have got quite a few other jobs done.

The clutch master cylinder has been replaced and as far as I can tell it works. It may need bled a bit more and the pedal height needs properly adjusted too.

I cleaned up the wiring from the Kodiak MK2 and found out that it's a two-speed motor which is nice because I don't need the resistor inside. They're now slightly wrapped in hockey tape which makes for a good disguise to match the rest of the loom compared to electrical tape.

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The Spade style dipswitch has been screwed into the footwell. I still need to drill a hole for the wires but that will come later.

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Since I wasn't able to find a Kodiak Mk 2 heater cowl, I had to find a solution so I wouldn't be sucking in engine bay fumes into the core. I got a Kodiak Mk3 heater and pulled the cowl off of it and screwed it onto the Mk 2 Heater. Here is what needs to be mashed together. A bit of a shame but this is much quicker than making the proper cowl for a Mk 2.

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Cut it out, then screwed it to the Mk 2 heater thing. Where it is screwed may interfere with the matrix so it may have to be tack welded in place I will see tomorrow.

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Also tried to make a Lucas Windtone horn work. I have stripped it and cleaned all the contacts I just think the points need properly adjusted. It does honk but only when you press the points together manually.

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Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#205 Post by cbalme » Sat Mar 09, 2019 11:06 pm

Still no luck getting those wind tone horns to work. I think I will just buy a Series 3 horn without points as much as I'd like to use a windtone.

My Kodiak MK 21/2 looks like it'll work perfectly. I bought some weatherstrip tape for the foam insert. It worked perfectly and is stuck in there good.

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Polished a few things like the wiper arms and warning lights. I will have to replace the lens on the red one but the orange one turned out good. I will have to buy a new oil warning light the one I got has faded from the sun or been painted over.

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Took apart the wiper motors today for paint. The grease looks like Kreosote and is pretty gross

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My other motor had already been taken apart and was gummed up with some gross white lithium grease.

Had to go all out and make the motors look fancy. Painted them gold which will look really nice inside the green interior.

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Hopefully I'll get the wiper motors back together tomorrow they just need some soldering and to regrease all the drive gear.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#206 Post by cbalme » Sun Mar 17, 2019 7:36 pm

Progress really slowed down this weekend, I did not get many 109 related tasks completed. Thankfully it is warm enough to paint and our compressor works, but I am just painting things the wrong colour it seems. These wheels and a set of hinges will go onto the 110 next weekend, then the booth should be green again!

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The wiper motors are back together and look really nice I'm very pleased with how they turned out. They've been regreased and just need testing but I have no doubts that they'll work. All the hardware for the wipers has been rounded up I just need to make new gaskets since I don't want to pay $20 or something like that for two.

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Also got half the u-joints back together, still pretty stiff but should bed in overtime. When they wear out again I'll be ordering a set from the UK since they're significantly cheaper than buying MOOGs locally.

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Next weekend I hope to get a lot of painting done.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#207 Post by cbalme » Thu Mar 21, 2019 10:59 pm

Pleased to report that both wiper motors work. One just needed the swtich rivet peened over to tighten it further because it wouldn't turn the motor on.

While trying to save a bit of money I opted to buy just the lenses for the warning lights on the dash. The lenses were $15 or you could buy three brand new warning lights for $60 which is very expensive for a little piece of plastic. They are not too bad to take out, there are a couple methods mine was very crude but did the job. You can boil them in some water which is what I should've done but I was too lazy to walk up to the house. I found that if you punch a hole through them either by accident or on purpose, then bend the tabs and pry the lens out with the conviently placed hole. The housing doesn't get hurt at all in the process.

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Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#208 Post by cbalme » Mon Mar 25, 2019 7:25 pm

Wasted a lot of time this weekend at Canadian Tire instead of restoring the Green Machine. I was told my tires would be ready at 2:30 only to be told that I was wrong and that they were booked in for 4:30. I assume they realized their mistake because I was out of there at 3:30 and had some new tires mounted for the 110.

I was able to sort out a couple of little tasks for the 109 like this brake light switch which is now hooked up and adjusted. I had to run a set of wires across the firewall which wasn't a big deal and they look as though they kind of belong so overall I am pleased.

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I also fixed the brake line rubbing issues on the truck. One line was up against the radiator so with assistance from my Dad we got it sorted. You may be able to see a brake line in this photo I am not sure.

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Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#209 Post by cbalme » Thu Apr 18, 2019 10:14 pm

I have been very busy over the past month and haven't had much time to work on this project, but I have been slowly getting little tasks completed. The New Lenses arrived from the UK so those went into the warning light bezels.

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Wired in the Fusebox, the whole truck is run off of one fuse as far as I can tell. I will be fusing any extra modifications I make that is for sure but at the moment the system will stay stock except for the addition of a reverse light and alternator. I had to crimp on connectors and heatshrink them but that is all part of the job.

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Also picked up some Yokohoma 742s 7.50x16 tires at Founder's Day for the project and they look perfect! They are taller and Skinnier than the other tires I was looking at. The 235/85/R16 Toyo M55. Overall I am very pleased with them considering they came on defender rims. One day I will get around to painting the rims but that can wait until the truck is on the road. Also adjusted the toe in, before it was set very far in.

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They're much better suited than the old 6.50x16s on their previously

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I also waxed the inside of the bulkhead with the same products I used inside the frame.

Now that school is done for this year I can kick this project into overdrive and get it out of the barn and roadworthy for this year's rally! It may not have a roof by then and it may not come on the drive but it will be there that's for sure.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#210 Post by cbalme » Thu May 02, 2019 8:54 am

Last week was quite busy but I was able to get a bit of work done before it. I was able to get a fair bit of painting done and left it to dry while I was at work. Last night I began reassembling everything to save time when putting the whole thing back together. I got the seat box back together except for the seat frames, which will get painted and installed in the next few days. I pushed all the captive nuts into place which was a real pain in the butt. They are very difficult to install.

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Then I put the Gearbox tunnel back together, which went well until I found out the stud was too bent to be used. I had to steal another stud off of a different tunnel to make mine work. I just drilled out the hammer rivets and installed new pop rivets in.

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Here it is completed. I still have to add some sound deadening to it but that can be done anytime. I also added a grommet to the 4wd plunger which should make the engagement nice and quiet with no metal on metal contact.

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Looks good with the floors installed, I may be getting ahead of myself

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Added the doorstops with bolts that are far too long

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Also painted all the hinges and installed a Horn. Due to not being able to find a working Windtone or Clear Hooter, I had to breakdown and buy a generic horn. Which turned out much better than expected! To my untrained ear it sounds sort of like what a windtone should sound like. One day I may upgrade to a proper English Horn, but at the moment it is installed and works. Best of all there are no points to mess around with.

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This weekend I will be repainting my doors and doortops because they turned out very bad and then it's onto prepping the box. I am still on the fence whether it is worth bedlining or just spraying with endura but I have to make my decision soon.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#211 Post by cbalme » Wed May 22, 2019 9:05 am

Haven't really got much done over the past few weeks, The farm is busiest during May so it's unlikely the truck will be driving at the rally. The biggest job is still the galvanizing and I'm not sure if I will as I have a good set of cappings in the barn.

I have got a few little jobs done but they all add up. Like the vent seals. I installed new style vent seals from '92 trucks but they work for series. I was hoping that they'd glue to the bulkhead but they seal nice and tight now with vent controls I cleaned up for the meantime until I can get a set replated.

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The seat box is ready for installation and is now in storage, it needs a few more things added like turnbuckles and seat holders once the hardura is added.

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The doors and doortops have been repainted after I messed the first paintjob up.

A local dormobile owner told me that the handbrake could be taken apart so I could paint it. I should've ignored him but I gave it a shot, and this happened.

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So I decided that since I have two others, why not try them? Now I have one handbrake, but turns out it is from a Series 1....

Here's my solution. I was able to save one button so one handbrake could be made, I just had to find something to replace the rod. I was looking all over the shop and moved this bucket to look behind a shelf. It was almost perfect, although 0.5mm shy of the original thickness it would do the job since the threaded section was thinner.

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I bent it straight, put the 90 degree bend in the end and then tapped the other end and screwed the knob on. Here it is in its glory. I also drilled the small hole on the bent end for the split pin.

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All that is left to do is test it! That'll get done tonight once the handbrake is dry.

May is coming to an end so once all our crops are dealt with I will be able to put quite a bit more time into this.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#212 Post by cbalme » Thu May 23, 2019 12:09 am

This evening I was able to reinstall the handbrake. It took a bit of fiddling to make my new piece work but now it is as good as new.

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Also did a bit of work on the electrical. I checked the mixture warning light for continuity and there was none so I took the switch apart and adjusted the rod until contact was made when the choke was pulled out.

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After that I cleaned up the headlight wiring, it's now tucked up and out of the way. The some of the wiring is far too long I wish they had left the ends uncrimped so I could cut them to length.

Image
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#213 Post by island dormy » Thu May 23, 2019 9:18 am

Hay Colin

I would not take advice from those dormobile owners they are usually half asleep on the job ( or about to pull over and have a nap.)

Victor

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

#214 Post by cbalme » Mon Jun 03, 2019 9:00 am

Finally got a bit of painting done this weekend. I chose to paint the parts that are going inside the box with rubberized gravel-guard to give it a better finish inside the box instead of showing where I haven't completely sanded the paint to bare metal. I then coated the gravel guard in bronze green so I wouldn't have to look at any black bed liner.

Here it is before painting over top. I used a self-etching primer underneath to prep the aluminum and wiped it down with acetone.

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All the bits painted, I had to redo the doortops for the third time and this will be the last no matter the condition, it is getting out of hand how difficult they are to paint.

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Other than all these bits the tub is the last thing to paint green and then the truck cab. I am not sure how I want to paint that it'll either be completely white or only white on top with a green back. I really can't decide.

Won't be ready for the rally, maybe Brits on the Beach?
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#215 Post by cbalme » Tue Jun 04, 2019 1:14 pm

Installed some new headlights to replace the old lights I found in the barn. They're a lot brighter that's for sure!

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Last night I turned my attention to the dashboard, I started by installing the warning lights, for the most part they fit pretty good but are slightly loose.

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Then I got the inspection lamp socket installed. Bit of a pain because they are hard to grab onto and turn at the same time while holding the dash.

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Didn't get a chance to take many photos of the install but here is the finished product, just needs to be wired and then it can go on the bulkhead! Very pleased with how it looks.

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I also mounted the dual gauge which was a bit of a pain with the capillary tube, I was very stressed about kinking it but it turned out fine.

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I also need to find one bulb for the dash. The rest I tested and work fine. Are they available locally or do I need to order a few spares in?
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#216 Post by ANDYD » Mon Jun 10, 2019 6:55 pm

Hi Colin,

A very valiant attempt to have her ready for the Rally in the Valley! So close ... but yet so far!
No worries, all good things are worth waiting for.

She's looking great, almost there!

Cheers
Andy
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

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

#217 Post by cbalme » Thu Jun 20, 2019 11:55 pm

So close yet so far! The little jobs seem to be neverending on this project. I have been chipping away at a few of them over the past weeks.

I got the rear tub ready for the top coat of bronze green, the bed has been primed and then coated with rubberized rocker guard. It took exactly three big cans to do the whole lot. I have about a gallon of paint left so that should be plenty.

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Check rods have been recoated and reinstalled.

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Also adjusted the steering box and the self-cancelling turn signals, which work perfectly although one day I'd like to replace the dry and cracked rubber wheel.

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The capillary gauge got tested in a mug full of hot water and works as it should.

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To finish off this evening I knocked off the galvanizing I'll be using on this tub, it is in alright shape but not perfect. Considering the quality of the paint job and the fact that this truck will be used for what it was originally meant for I am not too terribly concerned about the galvanizing being faultless. Eventually, If I want I can always get a spare set regalvanised and install that down the road. But to be honest, once it's installed it will most likely never come off again. I just need some good pieces that go down the sides at the back and protect the corners and a windsheild frame I have yet to source those.

Image
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#218 Post by cbalme » Sun Jun 23, 2019 11:49 pm

One more thing knocked off the list to paint. Very annoying to paint but I don't think I missed any spots. In the next few weeks that will get the cappings put back on and then it'll get mounted to the chassis. After that, everything should come together very quickly.

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Also got the 109 out into the farmyard to see the progress in the sunlight. Really puts into perspective how small this Land Rover is compared to modern trucks.

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Still debating what colour to paint the truck cab, does anyone know what it would've been originally? I am thinking either full green or full white or white top and green back. I can't seem to find a trace of green on the whole thing so I am not sure.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#219 Post by oldgravy » Mon Jun 24, 2019 9:17 am

That's looking really awesome, man. Nice work.

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

#220 Post by cbalme » Sun Jul 07, 2019 11:05 pm

Lately, I've had quite a lot of time off so the 109 has slowly been coming together, not long now until I'll be cruising around.

I got the frame fully welded up and ready to mount a 3 door tub instead of a station wagon tub, then I gave everything that hadn't been painted a coat of gloss black, then I gave the top frame rails a good coating of waxoyl, very easy to apply with a brush and I'm pleased with how it turned out. I'll do the rest of the truck before it goes back together.

I also coated the seatbox, floors and gearbox tunnel with sound deadening asphalt stuff, time will tell how well it works. Should at least keep some of the vibration down.

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Began installing bits onto the tub a few days ago, it looks really good and I'm really pleased with how it turned out.

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Today I visited Matt down in Victoria and he gave me a crash course on hammer rivets. It's amazing how easy it is compared to pop rivets or screws. Here's the tailgate which we used for practice I'm very pleased with how it turned out and look forward to doing the tub.

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Almost there!
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#221 Post by cbalme » Wed Jul 10, 2019 11:07 pm

Had a riveting experience putting the tub cappings back onto the tub. It took most of the day but the end result was well worth it, I would've been there much longer if I was pop riveting the whole tub.

I started with the front bar which took the longest since it needed so many pop rivets and required a fair bit of drilling to fit.

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Then added the siderails which went very quick with the air riveter. It's much more relaxing and comfortable not to be cranking on a hand riveter all day.

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Here's a picture of the clecos in action they are very handy when you don't have a helper and keep everything nice and tight.

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I chose to install pop rivets on the gas filler but I may swap them to pop rivets someday. The pop rivets are original so should add a few points at the car shows to offset the mud splatters.

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All back together, just need to pop rivet the bed strips in but it can go onto the truck anytime now.

Image
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#222 Post by red90 » Thu Jul 11, 2019 4:28 am

You need an air pop rivet gun.

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

#223 Post by cbalme » Sat Jul 13, 2019 9:52 pm

Hi Red, yes I should've got one a while ago, but I am close to finishing so there's no point. I haven't got much else riveted because of crops and my hands are pretty tired.

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So I took a break and put the doortops back together since they were getting in the way in the old tub. Here's my sophisticated doortop stand for the time being.

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They look much better with the glass installed.

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Really pleased with the finished product although they have a few imperfections

Image
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#224 Post by cbalme » Fri Jul 19, 2019 6:34 pm

Finally got the heater installed and plumbed in, just need to wire it and then attach the cables which shouldn't be too hard. It was a bit of a struggle to make it look tidy but I managed to make it look alright in there.

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Other than that I got the headlights wired in, I had to go buy a new dipswitch because the orignal that I thought was good turned out to be a dud but everything is installed. I've been slowly cleaning up the wiring and clamping it down so it doesn't get chaffed.

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This afternoon with a bit of help I got the tub installed, the paint isn't perfect but that means I won't be as worried while offroad.

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Hopefully in the next few days I'll be taking it for a test drive!
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#225 Post by ANDYD » Mon Jul 22, 2019 7:08 pm

Looking great Colin .... so close ... so close ....
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

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

#226 Post by cbalme » Sat Jul 27, 2019 12:32 am

Hi Andy, yes it's so close I can feel the end getting near!

Hooked up all the rear lights, had a short that I couldn't find in the parking lights, turns out I had hooked the number plate light up backwards :oops:

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Also installed the dual gauge today.

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So to test it out I took it for a drive around the farmyard! Runs very well apart from a few hiccups like a leaking float in the solex and a few water leaks here and there but it purrs nice and smooth and has plenty of power.

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Here are some videos, if you click on them you should be able to watch them.

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Soon I'll be hitting the road!
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#227 Post by cbalme » Mon Aug 12, 2019 11:55 pm

Haven't got much done these past few weeks, but tonight I got the dash installed. All wired in now and everything works as it should! Really pleased with how it turned out.

Image

Looking forward to the dim lights at night, any tips on how to brighten them up?

Image
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

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

#228 Post by John » Tue Aug 13, 2019 8:32 am

Colin,

Looking good. It's nice to see the correct dash hardware used - well done.

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

#229 Post by mepham55 » Mon Aug 19, 2019 10:00 am

Looking awesome! Your red and yellow dash warning lights should be swapped to be in the “correct” positions. ;)

Matt

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

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

#230 Post by cbalme » Tue Aug 20, 2019 9:46 pm

Thanks John, I had to scrounge up a few flathead screws from various stashes of other Series owners.

Matt, I will fix that next time the dash comes off which will be when I add those fancy defroster hoses.

Been a busy few evenings lining everything up. Never thought it could be such a pain making sure everything fits rights. The right-hand side of the bulkhead has about a 3/4 spacer. I will need to get a longer bulkhead bolt because the nut does not thread all the way on. I guess the years of military use bent the bulkhead outrigger back.

It's very stressful installing all these freshly painted panels, I'll have to invest in some touch-up paint because I made a few mistakes here and there...

With the help of my Dad we have been installing the interior, everything is fitting nicely and I only had to drill one hole into the frame where the seatbox bolts on. Here is the seatbox in. I added some closed cell foam tape to hopefully prevent some of the drafts.

Image

Here is the whole floor installed, really pleased with how it turned out.

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Next on the list is door alignment and cleaning up the engine bay.
Colin

1960 Series II 109 Pickup
1977 Series III Lightweight
1987 110 Station Wagon

Bill E.
Solihull Foreman
Posts: 895
Joined: Wed Mar 03, 2004 12:30 pm
Location: Tsawwassen BC

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

#231 Post by Bill E. » Wed Aug 21, 2019 7:41 am

Hi Colin,
I've watched with interest your many posts on this thread. You are doing a tremendous job on your 109. So close now, we're getting excited for you. Keep up the good work and thanks to your family and your friends for their help and encouragement.
Bill

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