1976 series 3 rebuild

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We decided to remove the sills so they wouldn't get damaged if we were tempted to lean on it
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Top of the fuel tank
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The data plate (just thought I'd include it really :) )
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The fuel tank removed, There was about an inch of muck that was compacted behind the tank.
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Removed the prop shaft
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Notice the water on the floor which came out of one of the rear shocks :eek: New ones shall be bought I think ;)
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We also removed the handbrake to clean all the parts, here are a few pics of that (may be of use to someone I suppose)
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Grinding the rot back into a square which makes it easier to make an accurate template and apply to the metal The metal we're using to weld to the crossmember are new discovery sills which are roughly the same thickness of steel as the crossmember and as we don't have the disco anymore we might as well as put them into use for something :cool: )
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I also decide to fill in the hole where the old towing electrics went to (just to make the back end look a bit neater really) which are now next to the back door of the vehicle.
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Welding in the square plate
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Cleaning up the welds with the grinder
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Metal trimmed to shape for the towing electrics hole and temporarily pushed in to sow the nice fit achieved
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After painting black to see how it looked
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Now on to the inside edge of the crossmember
There was a small-ish hole either side that required patching and the vertical angle strips needed a part chopping out and replacing
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Then a plate was welded in at an angle which will hopefully remove some of the water traps in the crossmember

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And finally the rear section of the chassis was painted in red-oxide
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And that is all of you finally up to date (at last) :) The axle has been red oxided and we'll fit it back to the chassis within the next couple of days
 
Thank you all for the nice comments :)
This weekend we removed the hand throttle from the fron tof the cab
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components on the other side of the bulkhead for the hand throttle
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The rear axle was also refitted and giving a coat of red-oxide
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The new shocks were fitted
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The handbrake linkage was removed to allow the gearbox to come out easily
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The cable for the speedo drive was disconnected next, it is held on by three screws which need a flat bladed screwdriver to undo

The nuts around the bellhousing were the next things to be undone which was carried out with a 17mm socket
Gearbox mount
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Undoing the mount using 14mm spanners/ sockets
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Transmission brake drum
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Clutch slave cylinder was the next thing to be removed
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A pulley block was attached to a beam running along the garage cieling and was used to take the weight of the gearbox as we slid it off the bellhousing to reveal this:
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The gearbox, we believe an oil seal may have gone on this due to the abundance of oily sludge in the bellhousing and around the gearbox (some over 10mm thick :eek: )

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If you have any questions on what we're doing please feel free to ask :)
 
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Good God, I seem to be making regular updates for once, I must be ill :rolleyes:

Today me and my dad hoisted the engine (the mighty 2.5 n/a diesel) out of the front
We started by removing the front panel and radiator as one piece and then disconnecting various ancillary components such as the fuel filter, throttle cable, clutch pipes, various wires etc. The battery holder was also removed using a grinder (It needs re-welding anyway)

The engine mounts were next to come off (these had thankfully been copper greased before so came off pretty easily, much easier than the gearbox mountings in fact). The whole vehicle was then shoved down the garage until the engine was under the hoist and a pallet truck slid underneath the front of the chassis.

The engine was hoisted up and the rolling chassis rolled back, the engine was then lowered on the pallet truck without any hassle. The landrover was then pulled back up the garage using my Dad's Defender 110 after we moved our trailer out of the way first.

The final job of the day was to remove the front wheels and place the front on axle stands, this gives us much better space to get at and clean the chassis at the front.

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You're really piling into that now, does it need much sorting out?

Not much :) The chassis was caught just in time before the rot set in so theres only small holes in the chassis left to weld now as well as the compulsory rotten footwell to replace. The engine is going to be rebuilt with new piston rings, bearings, gaskets and seals. The loom will also be replaced as some of it was shocking (if you'll pardon the pun :eek: ). I suppose it didn't really need stripping down this far but as we've got the space and tools we might as well do it :)
 
well done ,you have been lucky with the chassis my 76 s3 chassis was way beyond repair and i had to fit a new galv one .keep it coming you are doing great ,check the inside of the fuel tank before refitting i didnt and ended up with all kinds of probs
 
Right then, the chassis has been welded and given a coat of redoxide. The new footwells have come, a brake servo for the series 3 is on order (after a while of searching for one), front axle has been cleaned and painted in redoxide. A few other bits and pieces have been cleaned aswell. After the chassis the next job is the engine, that shouldn't take as long seeing as we'll be working in the workshop which has proper heating in there :) Pics tomorrow as promised ;)
 
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