1956 Series One Rebuild Project

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ANDYD
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1956 Series One Rebuild Project

#1 Post by ANDYD » Mon Sep 11, 2017 11:28 pm

Well, after being inspired by other rebuild projects done by fellow Rover-Lander members I started thinking, wouldn't it be awesome if we all took on at least one old Land Rover and brought it back to life! So when this 1956 "project" came along I thought its time, time for me to bring one back to life ... so the story begins..... (June 2017).
First job was to clear the garage (barely room to swing a cat) then rent a U-Haul trailer and to head up to Logan Lake pick up the old girl.
I wasn't really picking up a Land Rover, more a big pile of misc parts and a chassis, hence a car hauler wouldn't work, so I opted for an enclosed trailer which was just about big enough to squeeze all the random parts, boxes, panels, axels, engine (in multiple parts), gearbox, wheels, etc and slide the door shut.... then back to Richmond we went. I wanted to set my self a reasonable goal for finishing the rebuild, I thought maybe 1 year was a reasonable time, ummm, maybe a little optimistic as I have two other running Land Rovers that often shout out for my time and attention. How about 18 months? We will have to see........

Photo 1 - A trailer full of Land Rover parts!
Photo 2 - A garage full of Land Rover parts!
Attachments
IMG_20170604_194407 - Copy (2).jpg
IMG_20170604_194407 - Copy (2).jpg (44.32 KiB) Viewed 6598 times
IMG_20170604_213904.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#2 Post by ANDYD » Mon Sep 11, 2017 11:48 pm

The first step I did was to go through the pile of parts and separate them into 12 Rubbermaid storage bins, marking them up as I went along, Brakes, Steering, Suspension, Engine, Electrical, Heater, etc.. etc .... with the little amount of space I have, I had to be some what organized.
Next step was to get the chassis up on stands (two aluminum saw horses) so I could have a good look at it and decide on what parts needed repairs.

Photo 1 - Sorting and labeling parts.
Photo 2 - Chassis up on stands, ready for inspection
Attachments
IMG_20170607_182701.jpg
IMG_20170607_182701.jpg (133.37 KiB) Viewed 6594 times
IMG_20170609_114343.jpg
IMG_20170609_114343.jpg (194.46 KiB) Viewed 6594 times
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

terayon
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Re: 1956 Series One Rebuild Project

#3 Post by terayon » Tue Sep 12, 2017 12:10 am

Looks great! Can't wait to see it complete!

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'63 109 Stationwagon
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ANDYD
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Re: 1956 Series One Rebuild Project

#4 Post by ANDYD » Tue Sep 12, 2017 12:18 am

The old chassis is surprisingly solid for being 61 years old! There is only bad rust in 3 typical places, (water/mud traps) the Rear cross member, the Gearbox cross member and one of the bulkhead outriggers. These 3 parts will need replacement, the rest of the chassis just has light surface rust and can be brought back to life.
I was surprised to find out that the Series 1 chassis parts are not so easy to find in North America, (lots of places selling Series 2, 2a, 3, but not Series 1) so I decided to order these replacement chassis parts from England.

Photo 1- Too far gone, rear cross member
Photo 2 -Rusty Gearbox cross member, it's gotta go!
Attachments
IMG_20170607_182809.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#5 Post by ANDYD » Tue Sep 12, 2017 12:52 am

While I patiently await for chassis parts to arrive, attention is turned to the rest of the chassis. I signed up my son to assist me with removing all the old paint and surface rust. Also removing the old suspension bushings which really, really did not want to part with the chassis! After much swearing and sweating I found the best way to remove them was to force out the inner metal tube with a really big hammer, then using a hacksaw to cut almost through the outer metal tube. Then I used a selection of pullers (and pushers!) to get the rest of the old bushing out. Not a nice job for sure!

Photo 1 - Prepping the chassis, removing old paint and rust
Photo 2 - Using a puller / pusher then a BIG hammer!
Photo 3 - Old bushes (removed) New bushes ready for install.
Attachments
IMG_20170612_194004.jpg
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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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rayhyland
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Re: 1956 Series One Rebuild Project

#6 Post by rayhyland » Tue Sep 12, 2017 4:38 am

Awesome. Let me know if you need anything.


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I drive a 113 (a 110 and three Series 1s)

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bsa_m21
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Re: 1956 Series One Rebuild Project

#7 Post by bsa_m21 » Tue Sep 12, 2017 11:13 am

Hey Andy,

Looks like you and your son are having fun. Yup, the ONLY way to remove old bushing is as you described. Ah, memories.

FYI - I also have a number of spare parts (pistons, wheel cylinders, trannies, etc.), so let me know before you buy from overseas.

And let me know if/when you need to weld on the new parts. I just finished rebuilding a boat trailer and have run out of metal projects for the moment. (But don't let my wife know!) :bounce:
Martin
=======
Series/Disco Coiler Hybrid (build in progress)
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle
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ANDYD
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Re: 1956 Series One Rebuild Project

#8 Post by ANDYD » Tue Sep 12, 2017 3:31 pm

Hey Guys,
Thanks very much for the offers of parts and assistance. I'm sure I will take you up on that as the project progresses. I am actually a little ahead of my postings here as I started this in June/July and I will catch up to real time with my postings over the next few days.

Continuing with chassis prep I decided to remove the pedal shaft as it was looking quite worn. The only way I could get it to move was with a bottle jack! As I was cranking the jack handle I was hoping it would budge before the chassis rail on the opposite side starting moving :shock: thank fully it did. just popped out (friction fit).

Photo #1 - Bottle jack removing the pedal shaft
Photo #2 - New Chassis parts arriving from England
Attachments
Pedal Shaft removal with Bottle Jack.jpg
Pedal Shaft removal with Bottle Jack.jpg (121.18 KiB) Viewed 6546 times
Rear Cross Member and Bulkhead - Outrigger Series 1.jpg
Rear Cross Member and Bulkhead - Outrigger Series 1.jpg (62.03 KiB) Viewed 6546 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#9 Post by ANDYD » Wed Sep 13, 2017 11:21 pm

Its always a big decision to choose the chassis paint. So many to choose from! I went back and forth and did lots of research, finally decided on POR15. Partly because it has a lot of great reviews and partly because its available locally (Lordco). Its not cheap, but as the old adage goes, you get what you pay for!
I was told over and over that the secret with POR15 performance is to complete all 3 steps. Its basically a 3 step process with the painting being the third step. First is the POR15 degreaser, (then rinse with water) second is the POR15 Metal Prep, (then rinse with water) then when totally dry, the third step is the POR15 paint. I have to say when done correctly you do end up with a really nice hard & even finish. I did a full 2 coats at this stage and may do a third & final coat a bit later.
I did one half of the chassis at a time, mainly due to space around the chassis. I left the 3 chassis parts that needed removing and replacing unpainted and would come back to them after welding.
Still haven't decided on whether the steering relay will come out yet (not a nice job at all!)

Photo #1 - the 3 step POR 15 process for chassis painting.
Photo #2 - one half of the chassis getting the first coat.
Attachments
IMG_20170622_221559.jpg
IMG_20170622_221559.jpg (140.95 KiB) Viewed 6504 times
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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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bsa_m21
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Re: 1956 Series One Rebuild Project

#10 Post by bsa_m21 » Thu Sep 14, 2017 12:13 pm

Andy,

POR 15 degrades over time when exposed to sunlight. (Don't ask how I know... :( )
You may want to top coat it with a chassis paint such as POR-15 (45904) Top Coat Chassis Black or similar.
Martin
=======
Series/Disco Coiler Hybrid (build in progress)
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle
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mepham55
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Re: 1956 Series One Rebuild Project

#11 Post by mepham55 » Thu Sep 14, 2017 1:51 pm

Looks great Andy! Can't wait to see you puting around in an 86"! I used the POR15 system on my truck and I works great. The "metal prep" is just phosphoric acid, you can usually get it at a marine supply shop for quite cheap. As mentioned above ^^ any areas exposed to sunlight for an extend period of time should be top coated.

Matt
Last edited by mepham55 on Fri Sep 15, 2017 8:13 am, edited 1 time in total.

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

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mepham55
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Re: 1956 Series One Rebuild Project

#12 Post by mepham55 » Thu Sep 14, 2017 5:15 pm

Also forgot to mention, put some plastic over the por15 can before you put the lid back on or else you'll never get the lid off in one piece! Hope I'm not too late with that tip!
Have fun

Matt

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

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ANDYD
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Re: 1956 Series One Rebuild Project

#13 Post by ANDYD » Fri Sep 15, 2017 7:23 pm

Good tips, thanks Matt. Yes, I pretty much destroyed the paint lid on the 3rd time of opening.
Martin, I haven't seen that top-coat at Lordco, have you seen it for sale somewhere locally?

With the three new chassis parts in hand it was time to cut off the old rusty bits and prep the area for welding the new parts on. I had read that the chassis can move about a bit when you cut off the rear cross member so I found a long piece of threaded ready-rod and bolted it in place through the Leaf Spring hangers to try and keep everything straight and true. Also took lots of measurements so I could check everything twice before welding the new bits on.

Photo 1 - Old Rear Cross Member cut off, laying besides the new part
Photo 2 - Threaded ready-rod temporary installed in case there is any movement in the LH/RH chassis rails.
Attachments
IMG_20170725_190453.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#14 Post by ANDYD » Fri Sep 15, 2017 7:59 pm

Getting ready for chassis welding, I started clamping all the pieces together (soon found out, a man can never have enough clamps!)
Also fabricated some steel plates to over-lap and strengthen the new and old parts.
After lots of research and having once had to remove the gearbox out of an old Series 2 through the inside of the cab, one modification (upgrade?) I wanted to do was make the gearbox cross member removal from under the vehicle. This way the gearbox can be dropped out the bottom for gearbox maintenance or new clutch etc, just like my more modern Defender. I fabricated 3 different styles of "brackets" until I decided to go with the ones you see below.

Photo 1 - Clamping the new Rear Cross Member in place to confirm measurments.
Photo 2 - Fabricated over-lap plates to add strength when welded.
Photo 3 - Brackets fabricated for making the Gearbox Cross Member removable.
Attachments
IMG_20170804_122916.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#15 Post by ANDYD » Tue Sep 19, 2017 11:41 pm

With the chassis now 80% painted it was time to load the chassis onto the trailer and take a visit to a fellow Rover-Lander and good friend who luckily lives near by and has a lovely Welding machine and a good knack for making the metals flow. With all the new bits prepped and clamped in the right places it was time for welding to begin.... finally the chassis would be whole again!

Photo #1 - Chassis 80% painted, loaded and on the move.
Photo #2 - Rear Cross Member clamped and ready to weld.
Photo #3 - Welder doing his magic!
Attachments
IMG_20170805_101224C.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#16 Post by ANDYD » Wed Sep 20, 2017 12:13 am

Once back in the garage I am able to complete the chassis painting of all the newly welded on bits and I give the whole thing one more coat. I still have to treat the inside of the chassis with some Waxoyl or similar product. I did take the opportunity to paint as far as I could reach on the inside of the box frame legs on the back end while the rear cross member was removed. (also removed an big old mouse nest from inside the chassis :shock: ).
Next I installed 4 new axle bump stops (really just wanted to finally install some new bits lol).
I also dry fitted the Gearbox Cross Member which was now modified to make it removable. I made up some steel tube sleeves to slide on the fixing bolts to ensure they wouldn't crush the cross member when cranked tight.

Photo #1 - Chassis back in the garage and getting a final coat of POR15
Photo #2 - Gearbox Cross Member modification - now removable instead of fixed.
Attachments
IMG_20170808_211249.jpg
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IMG_20170812_120254.jpg
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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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rayhyland
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Re: 1956 Series One Rebuild Project

#17 Post by rayhyland » Wed Sep 20, 2017 12:15 am

Looking great!


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I drive a 113 (a 110 and three Series 1s)

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ANDYD
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Re: 1956 Series One Rebuild Project

#18 Post by ANDYD » Sun Sep 24, 2017 11:09 pm

Next I turned my focus to the Springs and Axles. The springs had been sent out to be re-arched & re-furbished by the previous owner so I thought may as well go with them rather than purchase new Parabolics.
The front and rear axle casings were treated to a really good clean up and then repainted with POR15. I decided to wait until they are installed before stripping them down as they were a bit heavy and wobbly whilst balanced on the axles stands.

Photo #1 - Axle casing getting cleaned up
Photo #2 - Axle casing with a new coat of paint
Photo #3 - Refurbished Springs ready for installation
Attachments
IMG_20170714_225525.jpg
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I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

terayon
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Re: 1956 Series One Rebuild Project

#19 Post by terayon » Sun Sep 24, 2017 11:37 pm

ANDYD wrote:Next I turned my focus to the Springs and Axles. The springs had been sent out to be re-arched & re-furbished by the previous owner so I thought may as well go with them rather than purchase new Parabolics.
The front and rear axle casings were treated to a really good clean up and then repainted with POR15. I decided to wait until they are installed before stripping them down as they were a bit heavy and wobbly whilst balanced on the axles stands.

Photo #1 - Axle casing getting cleaned up
Photo #2 - Axle casing with a new coat of paint
Photo #3 - Refurbished Springs ready for installation
Looking great! Love to see the finished product. That will be one tasty Landy.

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

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ANDYD
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Re: 1956 Series One Rebuild Project

#20 Post by ANDYD » Sun Sep 24, 2017 11:39 pm

I bolted one end of the springs to the chassis, then bolted the Axle casings to the springs and then the other end of the springs to the chassis. Using all new bushings, bolts, u-bolts made the job a lot easier.
I left all the fixings a little loose because I read its better that the springs have some load on them before torqueing them all tight.

Photos - Springs and axle casings being installed to the chassis
Attachments
IMG_20170812_120200.jpg
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IMG_20170813_193957.jpg (170.47 KiB) Viewed 5463 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#21 Post by ANDYD » Mon Sep 25, 2017 12:02 am

Now that I have the Axle casings secure I could focus on stripping them down for cleaning, inspection and to replace the seals, bearings & the distance pieces. The previous owner had purchased some Britpart seals. I know that the reputation of Britpart seals is not the best, but these looked as good as other brands of seals I have purchased and they are here and at no extra cost so I'm going to use them and see how it goes ....

Photo 1 - Rear & Front Axles - pulling out bearings, seals. Inspecting & cleaning up any reusable parts.
Photo 2 - Rear diff, inspecting bearings and replacing seals.
Attachments
IMG_20170815_205208.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#22 Post by ANDYD » Mon Sep 25, 2017 12:50 am

The Distance Pieces had some wear and were a bitch to remove and the new ones needed a shop press to get them installed. The Distance Pieces can get scored and the seals that run on them will start leaking.
There are some good arguments to leaving the axle seals out so the axle oil can run right from one end to the other. I considered the options and decided to refit as per factory install.
My rear axle had what I'm told is a popular modification with the installation of hub spacers. These are 1/2" spacers that allow for the use of Series 2/3 half shafts which are a little longer that Series 1's and still easy to get hold of. Original Series 1's half shafts are very rare and quite expensive.

Photo #1 - Distance Piece - old & new
Photo #2 - Rebuilding, reinstalling
Photo #3 - Brakes and Brake drum all reinstalled (1/2" hub spacer shown with arrow)
Attachments
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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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StuartL
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Re: 1956 Series One Rebuild Project

#23 Post by StuartL » Sat Sep 30, 2017 10:30 am

Andy, I am absolutely gob-smacked by this project and your mechanical prowess!! Here I thought you were just a figurehead and now I see you are not mortal but a Land Rover god!

Keep in coming, you'll have the beginning of a masterpiece.

Cheers,
Tata for now....

Stuart
Vancouver, BC


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ANDYD
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Re: 1956 Series One Rebuild Project

#24 Post by ANDYD » Sat Sep 30, 2017 1:58 pm

Hey Stuart,

Thanks for the words of encouragement, I've been surprised so far, everything has been fairly straight forward, just like a big Mechano Set really, just like we had when we were young ... I have a few challenges with elbow room here, but I remind myself that this little garage is still better than doing this out in the driveway or on the lawn! ha..

Starting pulling a few other parts out of the pile today and discovered those Land Rover Engineers had thought of everything! There is even a nice little toilet seat under the center front seat! Don't even have to stop to use it :shock:

Photo 1 - Center seat toilet lid closed
Photo 2 - Center Seat toilet lid open and ready for action (where is the TP holder?)
Attachments
IMG_20170918_194540.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#25 Post by ANDYD » Sat Sep 30, 2017 2:14 pm

Back to business, starting stripping down the front axle, I'm determined to have a "rolling chassis" by Halloween!

I pulled the seals and bearings out of the front diff drive and then removed and disassembled the front brakes, bearings, swivel balls etc.. spent some time cleaning out the axle casings (old smelly gear oil!) There appears to be very little play in the main differentials & they are turning very smoothly Much better than my Defender for sure!
The Chrome Swivel Balls, bearings and seals will all need to be changed for new and I will install the Railco bushings "upgrade" when reassembling.

Photo #1 - Stripping down the Front Diff drive seal & bearing
Photo #2 - Stripping down the Swivel Ball casing, seals and wheel bearings
Attachments
IMG_20170907_175536.jpg
IMG_20170907_175536.jpg (130.09 KiB) Viewed 5422 times
IMG_20170907_175527.jpg
IMG_20170907_175527.jpg (179.54 KiB) Viewed 5422 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#26 Post by ANDYD » Sat Sep 30, 2017 2:38 pm

Once all the parts were disassembled from the front axle I began inspecting & cleaning up everything to see what could be reused and what is scrap! The Swivel ball casings, brake drums, brake backing plates all are good, so just a good cleaning, then de-rust treatment and repainting. The multiple seals, bearings, bushes, chromed swivel balls are all showing some wear so will be renewed.

Photo #1 - New seals installed in the Front axle
Photo #2 - Cleaned up and repainted Swivel Ball housings
Photo #3 - Cleaned up and repainted Brake drums
Attachments
IMG_20170925_203641.jpg
IMG_20170925_203641.jpg (150.43 KiB) Viewed 5416 times
IMG_20170918_194717.jpg
IMG_20170918_194717.jpg (157.18 KiB) Viewed 5416 times
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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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rayhyland
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Re: 1956 Series One Rebuild Project

#27 Post by rayhyland » Sat Sep 30, 2017 2:50 pm

What are you using to get rid of all the rust? Vinegar bath? Or just elbow grease and wire brush?


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I drive a 113 (a 110 and three Series 1s)

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Re: 1956 Series One Rebuild Project

#28 Post by ANDYD » Sat Sep 30, 2017 3:06 pm

Today I have all the front axle parts laid out on boards on top of the chassis (no room anywhere else!!)
There are a lot of parts and I split them in groups and start the rebuilding process. The brakes are straight forward enough, I have a lot of new parts ready for assembly so I focus on that for a while.
I bagged the old swivel balls up (just stinky!) while I wait to pick new ones.
The half shafts look good, I will likely replace the U joints just because its easy at this point.
There are "Warn" wheel/Hub lockers to inspect, I don't know much about these (never had hub lockers before) so will have to do some internet searching / reading on these. There is also a spare set of "Cutlass" Hub lockers, not sure about these either!
I replaced the Distance Pieces on the Stub axles that the seals ride on like on the rear, again this was a challenge to remove them and I needed a shop press to reinstall the new ones.
I decided that all the seals, bearings and most of the nuts/bolts/ locking tabs should all be replaced.

Photo #1 - All Front Axle parts laid out and the reassemble begins..
Photo #2 - Warn Hub Lockers
Attachments
IMG_20170925_204341.jpg
IMG_20170925_204341.jpg (210.34 KiB) Viewed 5406 times
IMG_20170925_203827.jpg
IMG_20170925_203827.jpg (171.53 KiB) Viewed 5406 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#29 Post by ANDYD » Sat Sep 30, 2017 3:15 pm

Hi Ray,

The process I am using for rust is yes. lots of elbow grease, wire brush, wire brush wheel (on hand drill) then I good bath of the POR de-greaser while scrubbing with a stiff brush, good rinse then the POR metal treatment, another good rinse then when totally dry apply the POR paint (typically 2 or 3 coats)... The POR (Paint Over Rust) application can be applied over a rusty metal as long as its not loose rust or greasy.
Then I hope it will last for ever! (well, at least another 60 years)

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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Doc Tari
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Re: 1956 Series One Rebuild Project

#30 Post by Doc Tari » Sat Sep 30, 2017 10:42 pm

Hey there Andy! Just discovered your project thread, the build looks great. Is the Series I going to replace Jill's Disco?

It seems that being a retired president has left you with time to spare... Nice work, heck of a job in such a tight space.

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Re: 1956 Series One Rebuild Project

#31 Post by ANDYD » Sun Oct 01, 2017 9:10 pm

Hey Pete,
Good to hear from you and nice to see that you are still visiting us here on the forum.
I don't think the Series 1 will replace Jill's Disco (she likes the Automatic's...), but she may soon get mad that she wont be fitting the Disco in the garage when the winter snow arrives! I told her I would "have it fixed up and running around in no time" .... ha, good that I didn't put a date on it ..........
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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Bill E.
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Re: 1956 Series One Rebuild Project

#32 Post by Bill E. » Tue Oct 03, 2017 3:20 pm

Always give the month...but never the year. :wink:

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ANDYD
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Re: 1956 Series One Rebuild Project

#33 Post by ANDYD » Mon Oct 09, 2017 11:26 pm

Ok, managed to get a few hours on the SI today, focussing on the front axle. There is a lot of confusing information out there on the installation of the Railko Bush kit that is typically used on later Series Land Rovers and also recommended for a Series 1 upgrade (I'm sure there will be some die hard Series One guys out there that prefer to stay totally original, and that's ok too).
The new Railko bush gets installed on the top position of the swivel ball and the roller bearing goes in the bottom where the steering arm connects. This is great for all Series Land Rovers except the Series 1 because the steering arm connects to the top position where the new Railko bush is getting installed. I have read that its just a case of moving the steering arm on the Series 1 to the lower position. This is not the best, plus you then need an extra swivel pin that doesn't come in the Railko kit. Also moving the arm to the bottom puts the steering arm upside down (has a taper) and the ball joints connections upside down, So not ideal.
Anyhow, to save a looooong story and after lots of research I opted for leaving the steering arm on top (with the Railko bush attached to the arm and the bearing at the bottom, This still involved drilling out the little securing pin and a heavy press to remove the old splined pin and the press again to install the Railko pin. Not really the simple DIY job that I had been expecting....

Photo #1 - Swivel Balls, old vs new
Photo #2 - Close-up of years of old scars (hard for the oil seal to work with these)
Photo #3 - New parts including the Railko bush, ready to install
Attachments
IMG_20171006_142625.jpg
IMG_20171006_142625.jpg (132.64 KiB) Viewed 5760 times
IMG_20171006_142706.jpg
IMG_20171006_142706.jpg (115.11 KiB) Viewed 5760 times
IMG_20171006_145134.jpg
IMG_20171006_145134.jpg (123.4 KiB) Viewed 5760 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#34 Post by ANDYD » Mon Oct 09, 2017 11:57 pm

Swivel arms being retro fitted with the Railko bushes. Splined pin needs to first have the securing pin drilled out and then a press popped it out at around 20 tons of "push"!
Once installed (pressed into place the new Railko bush then needs to be drilled so the new securing pins can be installed.
Attachments
IMG_20171009_152431.jpg
IMG_20171009_152431.jpg (119.61 KiB) Viewed 5757 times
IMG_20171009_152511.jpg
IMG_20171009_152511.jpg (76.01 KiB) Viewed 5757 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#35 Post by ANDYD » Tue Oct 10, 2017 12:11 am

The new Swivel Ball bearings and Railko bushes were gently tapped into the new swivel balls. This part went smoothly so I was very Thankful on Thanksgiving Day!

Photo #1 - Old Splined bush compared to the new Railko bush (and pin)
Photo #2 - New bearing race's being installed
Photo #3 - New lower bearing compared to the old bearing
Attachments
IMG_20171007_153627.jpg
IMG_20171007_153627.jpg (166.3 KiB) Viewed 5755 times
IMG_20171007_153405.jpg
IMG_20171007_153405.jpg (149.4 KiB) Viewed 5755 times
IMG_20171007_153729.jpg
IMG_20171007_153729.jpg (135.47 KiB) Viewed 5755 times
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: 1956 Series One Rebuild Project

#36 Post by cbalme » Tue Oct 10, 2017 9:45 pm

My Axle from an early Series 2 had the style of swivel pin like yours. I didn't have to go through all of that since I acquired a newer axle but I suppose I would've had to do the same thing. I don't think it matters too much where the steering arms are as long as the bearing is on the bottom.

Do you know the advantage of upgrading to the Railko Bushings or is just for the availability of parts?
Colin

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

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ANDYD
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Re: 1956 Series One Rebuild Project

#37 Post by ANDYD » Wed Oct 11, 2017 11:47 am

Do you know the advantage of upgrading to the Railko Bushings or is just for the availability of parts?
From what I have learnt, the Railko Bush helps dampen the steering, less vibration and more responsive feel.
Also the old splined pin and cone parts wear faster, are getting harder to find and are more expensive to buy these days.
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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ANDYD
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Re: 1956 Series One Rebuild Project

#38 Post by ANDYD » Wed Oct 18, 2017 6:11 pm

The Swivel Ball assembly was straight forward. On initial testing I could tell I needed more spacing shims so will have to leave these until the new shims arrive.
Attachments
IMG_20171009_200115.jpg
IMG_20171009_200115.jpg (128.8 KiB) Viewed 5654 times
IMG_20171009_200126.jpg
IMG_20171009_200126.jpg (167.57 KiB) Viewed 5654 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#39 Post by ANDYD » Wed Oct 18, 2017 6:26 pm

While I wait for parts to complete the Swivel Balls I spend some time on the front half shafts. Changing the U-joints and inspecting the splines and bushings. The U-joints require the rubber dust guard to be removed as these u-joints are running inside the axle and in a bath of gear oil.
Attachments
IMG_20171007_174219.jpg
IMG_20171007_174219.jpg (152.71 KiB) Viewed 5653 times
IMG_20171007_174537.jpg
IMG_20171007_174537.jpg (178.88 KiB) Viewed 5653 times
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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ANDYD
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Re: 1956 Series One Rebuild Project

#40 Post by ANDYD » Sun Oct 22, 2017 3:34 pm

New shims arrived quickly thanks to Jeremy at Rocky Mountain, so spent some time getting the correct "drag". Lots of confusion on web about what is the right amount of resistance. Its doesn't help that its a mix of Series 1 and Series 3 parts with the Railko bush. I settled for between 6-7 kg of "drag" which feels right. I can always add / remove a shim later on if required. Then fitted the swivel ball seal and retainer. The swivel balls are ready for refitting now.

Photo #1 - adding / removing shims
Photo #2 - New seal and retainer ready to go on
Photo #3 - Seal & retainer installed.
Attachments
IMG_20171019_205237.jpg
IMG_20171019_205237.jpg (148.1 KiB) Viewed 5613 times
IMG_20171019_205804.jpg
IMG_20171019_205804.jpg (142.63 KiB) Viewed 5613 times
IMG_20171019_205952.jpg
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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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ANDYD
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Re: 1956 Series One Rebuild Project

#41 Post by ANDYD » Sun Oct 22, 2017 3:54 pm

Good progress today with getting the swivel ball housings reinstalled, then the brake back plates followed by the slave cylinders and brake shoes. Then slid the two half shafts into place.
Attachments
IMG_20171021_121446.jpg
IMG_20171021_121446.jpg (117.43 KiB) Viewed 5632 times
IMG_20171021_121433.jpg
IMG_20171021_121433.jpg (144.38 KiB) Viewed 5632 times
I======IooooI
|l __ l| __ ,\___,\___
l,---. l__ l,---._lO---Ol
(o)_) ~ ( (o)_)-o-)_)
~~~~~~~~~~~~~~~~~~~~
1991 Defender 110 / 2018 Evoque / 1956 Series 1- 86

DrRangelove
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Re: 1956 Series One Rebuild Project

#42 Post by DrRangelove » Sun Oct 22, 2017 9:56 pm

Looking good Andy!

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Re: 1956 Series One Rebuild Project

#43 Post by ANDYD » Thu Nov 02, 2017 10:20 pm

Thanks Dave, its a labour of love as you know with yours! Good days and bad days.....

Completed putting together the front brakes and hubs. All I need now is a steering bar and the wheels on and this chassis will be rolling again :bounce: First time for 7 years (previous owner dismantled this Land Rover in 2010)

After looking into the steering parts more I confirmed that there are two types of tie-rod ends (early type & the later type), the early ones need to go into the early steering bars and the later ones should go with later steering bars and they shouldn't be mixed.
The early tie rod ends have a shank on them that is designed to have the clamp tightened on the unthreaded section where as the later one is threaded all the way along and the clamp is designed to be tightened on the threaded section.
The early ones have a castle nut and split pin where as the later type have a ny-lock nut. The tapers and threads are the same.
I found that you can use the later (series 3) steering bars on a series 1 but you should then use the later tie rod ends.

Photo #1 - Front axle almost fully assembled and completed
Photo #2 - Early type of steering tie-rod end (left) compared with the later type of tie-rod end (right)
Attachments
IMG_20171029_123803.jpg
IMG_20171029_123803.jpg (135.37 KiB) Viewed 5548 times
IMG_20171029_132013.jpg
IMG_20171029_132013.jpg (151.06 KiB) Viewed 5548 times
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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bsa_m21
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Re: 1956 Series One Rebuild Project

#44 Post by bsa_m21 » Fri Nov 03, 2017 6:20 pm

Andy,

You are quite correct re the tie road ends. There are a number of reports in the UK, of owners who mixed them up and ended up with failures causing crashes, and even death. :|

M.
Martin
=======
Series/Disco Coiler Hybrid (build in progress)
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle
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Re: 1956 Series One Rebuild Project

#45 Post by Dave_F » Sun Nov 05, 2017 8:21 pm

Damn Andy...you are just ripping along with this project. Gonna give those Land Rover restoration guys in Solihull a run for their money.
1956 Series 1 86 Hardtop 173601415
1991 x-MoD 19 KK 88 Defender 110 ~ daily driver
2006 LR3 HSE HD



1955 Series 1 86 Hardtop 57130577 ~ just a heap o' parts now

1985 Series III 109 x-MoD BATUS 77 KC 63 < sold lives in Calgary
1965 x-MoD 35 ET 73 Sankey Narrow Track Trailer ~ sold

http://www.freewebs.com/83s3109/

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ANDYD
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Re: 1956 Series One Rebuild Project

#46 Post by ANDYD » Mon Nov 06, 2017 3:51 pm

Yes .... :happy7:

She rolled out of the garage on the weekend for a 3m "leg" stretch, felt how cold it was and rolled right back in again..

Now to dig out the next box of parts.
Attachments
1956 LR Rolling Chassis 003.jpg
1956 LR Rolling Chassis 003.jpg (73.18 KiB) Viewed 5790 times
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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cbalme
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Re: 1956 Series One Rebuild Project

#47 Post by cbalme » Mon Nov 06, 2017 6:24 pm

I guess it is my turn to get a move on.
Colin

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

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rayhyland
Drag Link
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Re: 1956 Series One Rebuild Project

#48 Post by rayhyland » Tue Nov 07, 2017 9:19 am

Yeah, I need to empty my garage now so I can get to work on my trucks too.


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I drive a 113 (a 110 and three Series 1s)

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Re: 1956 Series One Rebuild Project

#49 Post by mepham55 » Wed Nov 15, 2017 3:17 pm

Coming along nicely Andy. What are you using for hosting/posting your pictures on the forum? I can never get any small enough for the forum to load them?

Matt

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

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Re: 1956 Series One Rebuild Project

#50 Post by bsa_m21 » Wed Nov 15, 2017 3:56 pm

Here is a simple free tool to resize and save a copy of your photo's so you can upload them from your desktop to this forum.

http://www.rw-designer.com/picture-resize

M.
Martin
=======
Series/Disco Coiler Hybrid (build in progress)
'52 S1 - Runcle
'96 Discovery 1 - Hothead
'80 Triumph TR7v8 (Rover 4L) - Myrtle
(Roverlanders webmaster)

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