30 July 2010

30th July - Started paint and wheel well finished

After the last post and moving the 109 turned around this now enabled easier access to the rear end  for painting (bonnet/wings/cab to follow when I get to them). BUt, before that could be done a few other tasks had to be completed....

CAVITY WAX
In the middle of the week the 'new to me' compressor arrived which means I can now inject the Dinitrol 3125 into the bulkhead; chassis outriggers; rear x-mem; door bottoms. Out of the three 1 litre cartridges I had bought I only used one. That was a struggle but reading that this stuff goes a lot further than Waxoyl maybe that is enough? After all one 5 litre cart of Waxoyl is enough for a whole chassis - and I am only doing the x-mem etc. as the chassis is galv'd already?

SPARE WHEEL WELL
I have had this sitting around for a while ('Rogue Trooper' donation - cheers Rich) I decided to fit this in the rear tub on the passenger side. After all a bonnet mounted 750 tyre makes lifting the hood a PITA - plus getting it off can do you an injury. So the rear tub location it is.

The well and wheel securing bracket came off a 88" and were originally mounted behind the bulkhead on the SWB - but the same parts fit almost spot on at the side of the tub in the 109. So with a bit of fettlin' they went in and the spare is now enscounced in here.

ANTENNA MOUNTS
The two rear mounting points for the antenna brackets needed a bit of tidying but all the reinforcing/strengthening brackets had already been painted with POR15 sometime in the past, so only needed a top coat and could then be riveted in place.

Once all this was done all bare parts could be etch primed after rubbing it all back with some 80 grade paper on the rotary sander.

Ideally I would fit the 'correct for year' Larkspur mounts but they either cost an arm and a lower limb or are unobtainable.....so I will fit the pair of 'Clansman' bases I have to hand.

PAINT
Once all the items above had been ticked off and the primer left for 4-5 hours (warm weather anyway) I could thin some Containergard, grab a brush and a mini roller and tackle the tub and sills (the latter were painted off the vehicle).

So in the pic below we have one coat on there, but it looks tidy so far. Weather permitting I will get a final coat on tomorrow and it can then be left to harden for a few days.

After one coat.....




Next task is to finish the paintwork (as above) then get the fuel return selector/tap seal replaced - I still haven't done that after over a month of talking about it. Mmmmm

27 July 2010

24th July - tailgate on and turn the 109 around

Have a week off so I can get a few things done on the 109.

TUB
Tailgate now on and treated to a coat of paint along with the backend of the tub. All sockets fitted too, so it all looks complete from the ar5e end? 3 hours with the wacky wheel saw all the tub capping stripped of paint and lightly polished. This is not going to be painted.


DOORS
Cut out the rotten bottom sections of each door (see pic) and welded in some pre-made sections of good stuff. The broken lock surround was repaired last week. All the steel frame was then treated to a coat of hammerite anti-rust primer then two coats of Paddocks enamel. Also drilled a couple of holes at either end of the bottom section so water can get out and I can get a load of Dinitrol in (compressor arrives next week so I can get Dinitrol crazy!)


Doors hung on both sides and it needed a bit of tweaking on the bulkhead stay to get them to line up after a fashion. Still cannot get the passenger side one to go level with the top of the capping. It's about 1/8" high.

16 July 2010

10th July - Trigger moves again....and steers

As promised Trigger's steering was completed on Saturday afternoon which meant he could be driven out of the drive without the need for 'manual' steering (i.e. bloke on each front wheel). Once out we could do a pick-up of all the past 18 months 'droppages' while stripping/assembling the 109 (plus the dessicated cat droppings).

Here we go driving him back into the drive. Smokes nicely with a blip of throttle. This should stop once it gets a bit more use.


Sunday the tailgate came off to be cleaned up/primed and external surfaces painted. Left in the garage for the rest of the week to harden off whilst I spend most evenings revising for my IET 17th Edition Wiring Regulations assessment (BS7671).

Next weekend I plan to repair the bottom of both doors and fit the newly repainted rear tailgate and items such as the No. plate etc......after the rear end is treated to a fresh coat of Containergard.

08 July 2010

6th July - steering

STEERING BOX etc.
Box is now in and spaced off the bulkhead to suit the door clearance. Yep, one door is also on!

In the end I will live with a bit of roughness from the box as the inner shaft and recipricating ball race were not replaced. Maybe I will find a better one or an alternative in the future and do it but for now this one is far better than it was and works well - even if it is a bit coarse?

Re-assembly looked a nightmare if I tried to follow the green bible. So I did it my way and it went together quite easily. Packed all the bearings with Lithium grease and filled with GL4/5 once the box was on and torqued up.

The rest of the steering linkage will have to wait until I re-route the oil cooler pipes to free space for the relay linkage. That could happen by this coming weekend and if that's done I can drive the 109 around in the yard!

SEAT BOX/BATTERY TRAY
The S3 military battery tray has now been cleaned up/enameled and fitted in the now repainted and modded seat box. I had to fettle the center seat area to accomodate the battery tray.

I had also planned to install the LR Disco battery I was occassionally using to start the 109 - but it was too tall. The alternative was a spare Bosch S4 I had around, and that fits in snug plus there is space behind for an additional batt for future auxiliary supplies. For now the Bosch will sit there on it's lonesome.


Lid now fitted with the sprung clips and cable routed.


DOORS
To set the bulkhead position more accurately when setting the steering box position I had to fit one door. After all this would show up the gap size; how parallel they were; and if everything actually fitted.

Until now the doors have been behind the woodpile for the past year. Dusting them down and giving them the once over I found both will need the bottom section of the steel frame replacing due to rust. Not a big issue. Also the passenger side lock assy mounting has cracked. Welding needed meethinks?



DOOR SILLS
On checking the door sill alignment I found a few problems due to damaged door seal rubbers pushing out the aluminium lower panel/valance. These have been stripped off and new rubbers will have to be fitted.

Next stage......
  • Door sills and valances fitted and aligned
  • Repair both doors
  • Re-route oil cooler pipework
  • Complete steering linkage