THROTTLE
Pedal now modified so it will allow sufficient stroke to open the injection pump fully. Now waiting for either a Disco throttle cable, or complete the one I already have half done.
RAD PANEL
Now fully painted headlight bowls and rad fitted. So the galv finish was etched/etch primed/light coat of Containergard/2xprimer filler/final 2 coats of Containergard (sanded between each coat). Hopefully nothing will get through all that?
I had a problem with the rubber seals that go between the military lamp bowls and the front of the rad panel. Old ones were, of course, knackered. The originals are no longer available (NLA) so alternatives had to be found. Initially Land Rover part No. STC3022 looked suitable but was also hard to source so in the end I bought a pair of new Wipac 7" plastic headlight bowls with seals from Paddocks (No. LGTS5400/DA3010). £6.50 per unit and even the correct Defender seals are around £13 each from LR dealers - and I can pass the plastic bowls on to someone who needs them for the £6!
Pic shows orginal seal on right and replacement fitted on left. Only mods required were to punch an additional hole for the 3rd adjuster.
Panel now assembled and resting in the lounge. Note that the colou always changes under flash conditions and in daylight BS381:224 is far darker ;)
Now I also made a decison re. the intercooler. For now it is not going to have one!
The reason being that the Disco 200tdi I/C assy will not fit comfortably in the available space in the rad panel, plus I need to move this project on and I can always come back to this later and retro fit? Options being an alternative unit from something else or build a basic custom unit from parts lying about?
FUEL SYSTEM
Both tanks bolted in and fuel lines started. Each tank will have a local disposable biodiesel grade coarse filter then through the tank selector and onto the original Disco fuel filter.
Fuel lines are made from a combination of 3/16" bio grade reinforced rubber fuel hose and clear pneumatic hose (Festo). Before I used this I placed a sample in 50:50 diesel:WVO for 3 months. No problems it seems, so I will go with this unless - something does go wrong?
I'll pick up 20 litres of diesel this week, fill one tank and prime the system up!
REVERSE GEAR SWITCH
Jeez. This switch has been sitting in my garage for a year (actually +3 years but the first one went AWOL) and a break in the hale allowed me to mod the gear selector and make up a basic plate to activate the switch.
Now to find a 'suitable' light to use as a reverse lamp?
BRAKING SYSTEM....AGAIN!
Well 'we' are nearly there.
Placed an order with Automec and another (what I thought would be the last) bunch of fittings arrived. Both the master cylinder and shuttle valve now have a full compilment of CORRECT fittings for the 3/16" brake pipe. For info in the end the M/C used 10x1mm and 12x1mm. The shuttle safety valve is 3/8" and 7/16".
The brake hose brackets to fasten either front hub arrived courtesy of 'Smokey IIA' on the Series 2 forum - now dry after 3 coats of smoothrite. But the connection from the Goodrich flexible and the hard pipe at the hub is now the final problem that needs resolving.
Full details at the link below but in summary the hose end is 3/8" male and 'meant' to fit to the hub piston? So somehow this needs the fit to the hub pipework..and be secure on the bracket?
Thread link--> http://www.series2club.co.uk/forum/index.php?topic=31958.0
HEATED WINDSCREEN!
Now I had seen a few comments on various fora(?) regarding the possible availiabilty of a heated windscreen glass to fit in the existing Series windscreen frame. But they seemed expensive and hard to obtain. Then a thread popped up on the Series 2 forum suggestion a 'group buy'!
So....thinking 'why buy both sections of heated glass when the drivers is the only one that needs vision' I have ordered a pair to be split with Twizzle. £55 per section. A bargain. Now to wait 8-10 weeks for delivery and then I need to get up to Aylesbury to collect.
Now to look into heated wing mirrors not that I am wandering off the parts of the project I should be concentrating on? ;)
Now hopefully (I am not putting a wager on it) the rad panel will be in/cooling system filled/oil cooler filled/fuel system ready to run...this weekend. So it will take very little to run the engine up in the chassis.....so ;)
Watch this space, but don't hold your breath!
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