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
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