1970 2a Upgrades

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deanc5
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1970 2a Upgrades

#1 Post by deanc5 » Thu Jan 18, 2018 8:47 pm

I have started a makeover of a 1970 Series 2a. The truck was previously owned by a friend of mine who had owned for the last 30 years. Originally a BC Hydro truck, it has 58000km on it. Here it is on the day I bought it home. He also included all the missing door parts. My plans include a full rebuild along with a discovery 1 coil suspension and axles, a 2.5L NA diesel swap, and I thought I may as well do a power steering upgrade while I'm at it.
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deanc5
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Re: 1970 2a Upgrades

#2 Post by deanc5 » Thu Jan 18, 2018 8:58 pm

Here are some of the parts I've collected for the project so far.
Full set of deluxe seats, and the new axles.
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deanc5
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Re: 1970 2a Upgrades

#3 Post by deanc5 » Thu Jan 18, 2018 9:02 pm

The Koenig PTO winch will also be getting a cleanup and new cable.
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terayon
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Re: 1970 2a Upgrades

#4 Post by terayon » Thu Jan 18, 2018 9:07 pm

Looks great! Tis they season to get inspired and get something done!

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Re: 1970 2a Upgrades

#5 Post by deanc5 » Thu Jan 18, 2018 9:10 pm

At home, I got a better look after a thorough steam cleaning.
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Re: 1970 2a Upgrades

#6 Post by deanc5 » Thu Jan 18, 2018 9:53 pm

Teardown started. First order of business is to strip down to the frame and transmission so I can dry fit the diesel and get to work sorting out the far side motor mount. This frame is in fantastic shape. It apparently received new paint in the late 80's before my buddy bought it. Then it never left his acreage after that.
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deanc5
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Re: 1970 2a Upgrades

#7 Post by deanc5 » Thu Jan 18, 2018 9:58 pm

Bulkhead is pretty much intact. One small hole on the lower drivers door post. Being a late 2a, it also came with the power brake booster.
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Re: 1970 2a Upgrades

#8 Post by deanc5 » Thu Jan 18, 2018 10:06 pm

More parts from my brothers neighbor. He's been collecting and rebuilding series and defenders for 30 years. He's got a great selection of parts to pick through. So this defender roof and '59 tub will eventually become a trailer.
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Re: 1970 2a Upgrades

#9 Post by deanc5 » Thu Jan 18, 2018 10:25 pm

Diesel fit up time. Today I pushed the frame outside and ground off the front shock mounts, right side motor mount, battery box, and anything else that doesn't belong on a coil chassis. Then I temporarily stuck the diesel in place so I could get a look at the motor mount situation.

Instead of moving the battery inside the cab, I am thinking I will build a new removable battery box to keep the battery under the hood. I want to use the space under the driver's seat for a second fuel tank.
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The driver's side fit pretty good using the 2.25 petrol mount.
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This diesel has an extended mount on the passenger side to clear the injection pump.
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ANDYD
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Re: 1970 2a Upgrades

#10 Post by ANDYD » Thu Jan 18, 2018 10:48 pm

Looking great, nice find!

Thanks for sharing your progress, keep it coming 8)
I======IooooI
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Re: 1970 2a Upgrades

#11 Post by deanc5 » Sun Jan 21, 2018 9:01 pm

Got the motor mount built today.
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Re: 1970 2a Upgrades

#12 Post by deanc5 » Thu Jan 25, 2018 4:19 pm

I had a distraction lately when I took a road trip to pick up this Lister Petter TX2 twin cylinder diesel for my new 10kw generator project. This will allow me to use my plasma cutter and mig welder up at the storage building as I cannot use them in the house. Yes the rover is actually downstairs in the house. Some of you may have seen this advertised in Lillooet for the past month. Made an offer and it was well worth the drive. I brought it home, bled the fuel lines, and she fired right up. Plenty loud too with no muffler on the broken exhaust manifold. I have a manifold on order.
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Re: 1970 2a Upgrades

#13 Post by deanc5 » Thu Jan 25, 2018 4:30 pm

I am actually not happy with the way my right side motor mount turned out for the NA2.5 swap. The frame mount, which fits the stock na2.5 motor mount perfectly is sloped at a sharper angle than the left side stock 2.25 petrol mount. This has the effect of pushing the motor to the left as it strains the rubber isolators. The motor looks like it may foul my front pto driveshaft. It may not matter now anyway as I might be getting a brand new 2.4L turbo diesel! Seriously, I may have found a brand new crate motor at a price I cannot refuse. More about that later.
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Re: 1970 2a Upgrades

#14 Post by deanc5 » Thu Jan 25, 2018 4:36 pm

Look what else showed up today. Its 7 boxes from Paddock Spares. I thought if I compiled one large order instead of several small orders, I might save on shipping. Nope. That didn't happen. Anyway, I have a lot to do now.
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BlkP38
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Re: 1970 2a Upgrades

#15 Post by BlkP38 » Thu Jan 25, 2018 8:01 pm

What do you plan for the body?
Have been hesitating as it’s open to opinion but to me the body looks perfect as-is. Just protect the steel parts.
Eric.

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Re: 1970 2a Upgrades

#16 Post by deanc5 » Fri Jan 26, 2018 12:57 am

BuckBlue90 wrote:What do you plan for the body?
Have been hesitating as it’s open to opinion but to me the body looks perfect as-is. Just protect the steel parts.
Eric.
Agreed. At first, I thought that it was a bit too rough to leave as is even though I do really like patina. The rear quarters are quite badly dented and pockmarked although they don't really show it in the photos. The wings are pushed back and creased from years of work in the woods on Vancouver Island. But I recently came around to the fact that, if just for the time being, it looks great the way it is. I will paint the bulkhead and rad support. I'll also remove the paint from all the galvanized trim. But leave the rest as is. I did order some front wing panels, but I'll just save them for later and see what I can do with a dolly and hammer.

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Re: 1970 2a Upgrades

#17 Post by bsa_m21 » Fri Jan 26, 2018 7:59 am

My advice re condition of LR bodies is, "She earned the dents, she can keep them." Clean it up as best you can and paint it. :bounce:
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Re: 1970 2a Upgrades

#18 Post by deanc5 » Sat Jan 27, 2018 6:11 pm

So what do you do when you are ready to install your new coil axles but they are stored in a building a half kilometer away in a blizzard, and you have no hoist and no one to help you? Easy. You tie them to a tire, drag them down the mountain, then you winch them the rest of the way into the garage with your 1500 pound winch that you've had on the shelf for years, and that you've attached to your series chassis with a giant c-clamp. Pretty simple really.
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Re: 1970 2a Upgrades

#19 Post by HeadDamage » Sat Jan 27, 2018 6:15 pm

Nice trailer grooming drag, might be able to make a few bucks selling those to Whistler ;)

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Re: 1970 2a Upgrades

#20 Post by deanc5 » Sun Feb 11, 2018 1:56 pm

I'm just getting the frame stripped a little further. The Relay removal was relatively painless and only took about 5 minutes. I picked up a 6-ton bottle jack at princess auto on sale and I had a piece of chain laying around. So with those and a scrap piece of 2x2 square tubing it popped right out. It definitely needed some force, but the 6-ton was more than enough. Actually, the hardest parts to remove from the frame were the front springs. The bolts were firmly seized in the bushings and needed to be cut off with a grinder.
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Re: 1970 2a Upgrades

#21 Post by deanc5 » Sun Feb 18, 2018 9:04 pm

I did a lot of research before attempting this build. Economics dictated that the low mileage Discovery 1 axles and suspension would be a MUCH cheaper option than rebuilding the series axles and purchasing parabolic springs. In fact, the disco suspension was a fraction of the price and provides many advantages over the stock suspension. As well, my attitude has always been that a land rover engineer at the Solihull plant in 1970 would have preferred coils to leaves if he/she had had the choice. Unfortunately, I was unable to find any specific information regarding the frame modifications required in order to mount a coil suspension on a series chassis. So I did the best I could deciphering the few photos that my research did turn up and went ahead and ordered defender radius arm brackets and spring seats. These photos show the frame mods that I had to do to get the radius arm brackets installed.
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Re: 1970 2a Upgrades

#22 Post by deanc5 » Sun Feb 18, 2018 9:11 pm

Alignment and squaring of the axles wasn't too difficult. I started with mounting the front radius arm brackets in the only spot they can go which is snug up against the bulkhead outriggers. Then I mounted the front axle. It was then a simple matter to measure out an exact 88-inch wheelbase to locate the rear axle. A quick test fit of the tub and it looks like the rear axle location is a perfect fit beneath the wheel arches. I did not try to mount the rear axle exactly where the original rear axle was because for whatever reason that would have resulted in an 86.5" wheelbase.
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Re: 1970 2a Upgrades

#23 Post by deanc5 » Sun Feb 18, 2018 9:16 pm

Shown below is a Defender cross member that I am "trying on for size". It will be heavily modified and reinforced to become an A-arm cross member on the series frame. I know the frame looks dirty but I ground it down to bare metal wherever I needed to weld. The whole thing will be sandblasted after the mods and repairs are complete.
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red90
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Re: 1970 2a Upgrades

#24 Post by red90 » Mon Feb 19, 2018 9:19 am

Normally people keep the disco frame and modify it to fit the series body. It is a lot less work and you can buy the body mounts cheap.

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Re: 1970 2a Upgrades

#25 Post by cbalme » Mon Feb 19, 2018 9:49 pm

Have you got a plan for a fuel tank? It looks as though the original Series tank won't fit due to the arms getting in the way.
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Re: 1970 2a Upgrades

#26 Post by deanc5 » Mon Feb 19, 2018 11:55 pm

red90 wrote:Normally people keep the disco frame and modify it to fit the series body. It is a lot less work and you can buy the body mounts cheap.
Yes, I had no other frame. Besides, then I wouldn't be having all this fun.

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Re: 1970 2a Upgrades

#27 Post by deanc5 » Tue Feb 20, 2018 12:01 am

cbalme wrote:Have you got a plan for a fuel tank? It looks as though the original Series tank won't fit due to the arms getting in the way.
My plan is to modify 1 or 2 series tanks. I found these tanks at http://www.allisport.com but they are a bit $$$.
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Re: 1970 2a Upgrades

#28 Post by bsa_m21 » Tue Feb 20, 2018 1:18 pm

Well one thing is for sure ..... that frame isn't going to flex!! :bounce:

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Re: 1970 2a Upgrades

#29 Post by Bill E. » Tue Feb 20, 2018 1:49 pm

Thanks for sharing all the photos. You are doing some very nice fabrication work there!

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Re: 1970 2a Upgrades

#30 Post by deanc5 » Tue Feb 20, 2018 5:46 pm

Thanks, I hope this can help others. As I said, I'm just making this up as I go along. There isn't much online regarding a coil/power steering conversion. The steering box wants to foul the coil spring bracket, and then there is the panhard rod mount to consider. Spacing in this area is critical. I spent some time today planning the power steering box/panhard rod mount bracket. I'm using a standard ANR5321 steering box (range rover/p38). These pics show what I have so far. The design is not finished yet but it should look something pretty close to this. I'll get the drawings done and off the laser cutters tomorrow.
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Re: 1970 2a Upgrades

#31 Post by deanc5 » Thu Apr 19, 2018 7:16 am

I had a back problem and couldn't work on the project for a while. But I have made some progress recently that I can share.

Here is how the final power steering mount turned out. As I mentioned in an earlier post, I could not find much info online regarding a coil spring conversion combined with a power steering conversion. I had seen a pic or two of finished vehicles with these mods done so I knew it was possible, but I could not find any technical information on how it was done. So I was in uncharted waters, and there was quite a bit of design work and test fitting of the steering box to get it right. The box had to clear the front spring seat, but not be so far forward that it fouled the grill. Then there was the issue of adding a panhard mount as well. It turns out that in this application, the front springs had to be moved back about 3/4 inch. Not just the top spring seats, but the spring plates on the axle were also moved back and their angle shifted slightly. In the end, it turned out great.
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The panhard bar bracket was then added. Attention was paid to be sure that the panhard bar angle matched the drag link angle.
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Re: 1970 2a Upgrades

#32 Post by deanc5 » Thu Apr 19, 2018 7:28 am

After the steering parts were finished, I moved on to the rear A-arm crossmember. A defender crossmember was modified and installed. Then it was time for paint. The frame was sandblasted and got 2 coats of por15.
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Re: 1970 2a Upgrades

#33 Post by deanc5 » Thu Apr 19, 2018 7:36 am

Here is the finished power steering /panhard bar mount. It is made of 3/8" plate and is plenty strong. Clearances were integrated for both the pitman arm, and the pto winch driveshaft.
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Re: 1970 2a Upgrades

#34 Post by deanc5 » Thu Apr 19, 2018 7:44 am

With all the mods complete it was time to mount the axles.
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Re: 1970 2a Upgrades

#35 Post by deanc5 » Thu Apr 19, 2018 7:49 am

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Re: 1970 2a Upgrades

#36 Post by deanc5 » Sun Jun 30, 2019 11:12 am

Thought I would catch up on the progress of the upgrades. The bulkhead and rad support epoxy primered and painted.
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Re: 1970 2a Upgrades

#37 Post by deanc5 » Sun Jun 30, 2019 11:38 am

I originally planned on re-building a 2.5 na diesel for this project but plans changed when I came across this brand new 2.0L VM Motori turbodiesel crate motor in Kelowna. Originally rated at 90hp, I figured I would tweak it up a bit and add an intercooler to get a bit more out of it. I heard good things about the fuel economy of these motors. They were used in the '80s in British cabs, Alpha Romeos, and a 2.4l version was used in the '86-'89 Range Rover.
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Re: 1970 2a Upgrades

#38 Post by deanc5 » Sun Jun 30, 2019 11:44 am

Here is the transmission adapter blank drilled for the VM diesel. I am marking the locations for the Series hole pattern.
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Re: 1970 2a Upgrades

#39 Post by deanc5 » Sun Jun 30, 2019 11:51 am

With the holes drilled and countersunk, it was time to machine the VM starter motor mount opening and stud holes.
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Re: 1970 2a Upgrades

#40 Post by deanc5 » Sun Jun 30, 2019 11:55 am

Placing the inserts for the starter motor in the correct positions.
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Re: 1970 2a Upgrades

#41 Post by deanc5 » Sun Jun 30, 2019 11:58 am

Here is the cover I made for the starter opening. I also added a delete plate where the original series starter would have been.
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Re: 1970 2a Upgrades

#42 Post by deanc5 » Sun Jun 30, 2019 12:18 pm

Lastly in the adapter build was a pilot bearing spacer and clutch installation. Because the VM diesels were used in so many applications from marine engines to industrial and automotive, the flywheels came pre-drilled with several hole patterns. Luckily the land rover pressure plate was a direct bolt-on.
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Re: 1970 2a Upgrades

#43 Post by deanc5 » Sun Jun 30, 2019 12:34 pm

Positioning the VM diesel for motor mount design.
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Re: 1970 2a Upgrades

#44 Post by deanc5 » Sun Jun 30, 2019 12:51 pm

VM diesel installation complete.
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deanc5
Little Wheel
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Re: 1970 2a Upgrades

#45 Post by deanc5 » Sun Jun 30, 2019 1:01 pm

By this point, I had installed new brake lines and was installing a bracket for the Wilwood brake balance valve.
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deanc5
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Re: 1970 2a Upgrades

#46 Post by deanc5 » Sun Jun 30, 2019 1:22 pm

Finished brake booster.
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deanc5
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Re: 1970 2a Upgrades

#47 Post by deanc5 » Sun Jun 30, 2019 1:30 pm

Nice new springs on the pedals.
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deanc5
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Re: 1970 2a Upgrades

#48 Post by deanc5 » Sun Jun 30, 2019 2:13 pm

Castor Correction -

When I designed the suspension installation, I made sure that I would have about 4" of lift over the stock series suspension. This meant that I would have some serious castor correction to do. I had seen the castor corrected radius arms online but after looking at the price, I decided to look at other alternatives. Eventually, I thought I would try to correct the stock radius arms myself. The process of adding 6 degrees of castor wasn't that difficult and they actually turned out great. The hole spacing was appropriately adjusted, and the frame attachment stud was also cut and rewelded at an angle to better align with the frame brackets.
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deanc5
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Re: 1970 2a Upgrades

#49 Post by deanc5 » Sun Jun 30, 2019 2:22 pm

Picked up a couple of Volvo electric vacuum pumps at the wreckers since the VM diesel didn't have the pump option installed. I actually got the mechanical pump along with the motor but it requires a drive gear that I don't have.
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deanc5
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Re: 1970 2a Upgrades

#50 Post by deanc5 » Sun Jun 30, 2019 2:23 pm

While in Kelowna I also had hoses made for the ex-mod 2.5l oil cooler.
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