29 October 2009

31st October - Engine mount fixed......Rad panel off for galv

EXHAUST SYSTEM
Taking another look at both the possible routes and parts to use to make a usable system for the tdi I had a bit of an epiphany and thought 'why not look at the original Series petrol system?'. This one is in good condition and had only been on Trigger for 2 years before it moved on to me.

Now looking at the Disco system the internal bore is 2.1" at the downpipe and drops to 1.8" further back with two silencer boxes. The Series std system had a bore minimum of 1.5" ID. Not much difference and it has a single box - and I could use the large rear box from the Disco easily enough if it is more efficient or use nowt?

Lining up the Series downpipe with the 300tdi mounting proved that it would both miss the engine mount plus the first cross-member behind the engine. The route would then be spot-on and I could use all the original mounts! All it would need is a 3 stud flange either by modifying the existing one or aquire and weld on one from a 200/300 tdi downpipe. I have a new 300tdi downpipe here which owes me £25 so I could butcher that, but I would prefer to use a secondhand one off an old system - if I can find one? Then I can 'Bay the new unused section. So far it looks as if the flange is not available as a 'spare'. They are only suppllied fitted to the downpipe. Or make one up from a piece of 1/4" mild steel plate?

The other issue is would the system work OK with the slightly increased back pressure induced by the reduced bore?

The thread I started on this subject is here --> http://www.series2club.co.uk/forum/index.php?topic=31277.msg279106#msg279106

Decision made on the exhaust. From the discussion on the link above I will build the exhaust from parts I have to hand, starting with the the 300tdi Defender downpipe - modified slightly. At least then from that point it should be straightforward?


RAD PANEL
Well a bit of progress here. As mentioned in the last post the panel has now been stripped and after a bit of haggling I have agreed that the panel is going to be repaired by Ashtree. Price was also haggled down a little as I am local and will drop off and pick-up. So they will repair and fully galvanise it! The only issue now is to arrange a drop-off. They respond to emails after 24 hours but mobile and landlines are always on answerphone?

In the end I got hold of Lyn (he works as almost a one man operation) just before he headed to Holland for one week to deliver another batch of galv bulkheads. Front panel is now with him and should be back with me in 3-4 weeks.

ENGINE MOUNTS
After finding out the offside was lacking a certain 'slipper plate' that then went back on over the weekend. Engine now sits spot on level and there is no longer any strain on the mounts. Tidy!





Well the fuel tanks didn't get fitted and there was no progress on the exhaust over the weekend due to both time and the weather so let's see what the next one brings?

25 October 2009

25th October - Turbo assembly in and tweaked!

TURBO
Now despite the 300tdi turbo being far a better orientation for this type of install (over the 200tdi Disco type) I still fancied tweaking the turbo boost outlet a tad. Then I could get a bit more space between both it and the nearside wing. I didn't need to do it, and I could have got away with not doing it....but what the hell?

To allow the outlet port to be rotated by 45 degrees requiers the turbo internal valve vacuum unit to also be moved. Here it is after the body of the turbo was rotated and then adjusted so the shaft action is still perpendicular to the actuator body.

To rotate the turbo body either tap it around with a raw hide mallet or remove the large circlip on the body.



Once the assembly was back in position it now looks like this......



I did have a problem with one of the two top center exhaust manifold stubs. One thread started to strip and it was then discovered that the actual thread in the block was 1/4" deeper than the stud. There never was much holding it into the block. So the thread was cleaned with a 10mm plug tap then both this and the stud alongside were replaced with 10mm cap head screws. This now also means I can access them easier if nec.

So the next item to tackle is the actual exhaust - but for now I need to work on some of the other bits such as swapping the diffs and bulkhead bits and bob's.

BULKHEAD
Wipers/vent seals/fly screen/washer jets are now all back on. The curved wiper tube to the left hand end had been mullered by a PO when they installed the S3 assembly instead of the original twin motor setup. While I was at the October Bath & West LR 'show' I picked up a complete wiper assembly for £5. I then used that tube and kept the rest for spares.



AXLES
Rich (aka 'Rogue Trooper') dropped off a spare Range Rover rear diff during the week (plus a spare S2 gearbox) so the diff was cleaned up and fitted in the back axle. One of the diffs I reclaimed from the scrap Disco was also fitted in the front (10 spline too). So both axles are now 3.54:1, filled with GL4 and are ready to go.

OIL COOLER
A decision was made on the oil cooler/rad. I am going to stay with the Series rad and fit an auxiliary oil cooler. So order now placed for a 13 row/plate FPHE type plus all the necessary pipework/fittings etc. These should be here for next weekend.

ENGINE MOUNTS
While fiddling with the oil cooler connections at the filter block I noticed this.



Offside Series petrol mount is starting to split! It is under some strain but should be able to take it? Now this was new when the engine was dropped in a few weeks ago, but were 'pattern' parts from an unknown source. No marking on the packet and bought from Paddocks. May have been Br1tpart?

This will obviously need to be removed and chucked but do I replace with the same again or like the gearbox rubbers change for 2.5N/A ones which are more substantial?


Well now I know why the rubber is under stress! Delving in piles of boxes at the back of the garage I found my fruit box marked 'Chassis bits' and in the bottom under several layers of rubbish was this.



I now need to clean this up and fit it on the RH engine chassis mount where it should be!

MISC
I now need to get that front rad panel fully stripped and then decide do I pay through the nose to get it rebuilt and galv'd? (£150!) ....or go for the cheaper £50 and just get a bit welded in?

12 October 2009

3/4 & 10/11 October - Tx box back on and dipstick sorted.....

Two weekends worth of blog in one. Either I was too busy or just too damn tardy to get this all down?

Well the transfer box/gbx seal went in (Allmakes this time) and looked the same as the genuine unlike the Britpart one I had received then mullered previously. New set of Britpart gaskets, which seemed all fine despite some having problems with them, enabled the box to be rebuilt and refilled with the saved lube - once the transmission brake was refitted. The brake was in good condition when I removed it, but I rebuilt it with new shoes etc. anyway.

Painted what will be the outside of the bulkhead with Containergard in DBG. Interior will stay gloss DBG. It's easier to wipe down.

Using the old 'work out how long a drive belt you need with a piece of wire' trick I dropped by the local emporium and found that a Halfords HB1250c drive belt would fit (£4.50 with 'trade' discount). Maybe a tad thick as it rises a little out of the alternator pulley but I will see how it goes. There was a thinner option which was a bit shorter if I need to change it.




That was all last weekend and not much has happened during this one due to the weather and all the other stuff that had to be done. But I have sorted the dipstick!

With a 300tdi turbo assembly and the 200tdi inlet mani the original dipstick tube will not fit so something had to be done. After a bit of fettling it looked like this and even is secure on the original two mounting screws when fitted. Takes a bit of wiggling to get both it and the 300tdi turbo assy on/off but it is easily do-able if you know the procedure now.





Managed to get the vent flaps on (now painted in DBG) and most of the metalwork off the old bulkhead. Did start to fit the vent seals but dopey managed to put the glue on the wrong side so they are trashed and will have to be done again. Duoooogh?

Next weekend's plan is to fit the wiper motors and vent screens; both fuel tanks in; and to decide on the turbo outlet position. I planned to rotate it slightly to improve the fitting of the turbo ductwork but that is going to entail some fettlin' with the linkage to make it workable. I may give up and fit it anyway....or I may not. Come back next time ;)