15th November - Clutch working....and that's about it?

Well two more weeks have gone by without a post.....again, and it would appear to the outside observer that not a lot has been done? In reality I have been in 'the bunker' working on all those fiddly bits that always slow down a project but have to be done. You know, clean this and that, paint this and that, then redo it all again after dropping the newly painted item in the dust on the floor when hanging it up to dry?!

So what can I tick off the list?

Oil cooler has arrived and the mounts are now drilled/tapped/fitted in the original military oil cooler mounting position (Same width and far more efficient with 1/3rd of the height). Hose and fittings all ready to connect. But the final pipe positions and lengths will need to be determined once the radiator panel is back and fitted. On that subject Lyn at Ashtree informs me that the rad panel went off for initial sandblasting towards the end of last week so expect that to be ready in a couple of weeks.

Clutch pedal bolted in (with S3 master cylinder) and hoses connected. Filled with DOT4 and bled without any problems. Just need to set the clutch free play and height...and stick a rubber pad on it.

I  had planned to fit both fuel tanks in position and had already applied underbody Waxoyl to the chassis area enclosed when the tanks are installed and the neighbouring part of each fuel tank. That is where the crud gets trapped after all? But thinking about it again I decided that installing them will restrict access for the brake pipe install etc. So they have gone back into storage for now.

Biodiesel proof fuel lines and tank filters have arrived and are ready to fit but first I need to organise the placement of the main fuel filter. This needs to be bolted through the blind box section in the bulkhead. To mount the filter (and later a flat plate heat ex for WVO viscocity reduction) I have decided to fab a plate with 8-10mm studs to hold the filter and secure this to the b/h with six 6mm sheet-nuts/rivnuts. I hope to sort this next weekend.

The main fuel filter is now complete and is basically the original Discovery filter with an additional 8mm banjo connection for the fuel return from the Bosch injection pump. Plus I have slipped some pipe lagging over the whole assembly. So if the FPHE is installed the heat can be held in there. It costs peanuts after all?

Under floodlights on Sunday I started to tackle the exhaust system. Not a good time to do it but thought I would give it a go. So with the 300tdi Defender downpipe to hand I cut and tacked to form a suitable bend to clear the LH engine mount and the bolts to the rear of the front leaf spring. After a few hours it was starting to look good with the pipework running 1/4" below the gearbox cross member. But that is where I had to leave it.....run out of time.

I am travelling again this week so I will have to revisit the exhaust next Saturday ;)