Burnt out - rebuild

I had an issue with my 1990 Ninety [ meltdown/smoke ] when driving along last year. I was alerted to the problem when the rear wiper started going on its own and looking back saw the rear filling with smoke! I have a battery cut off so used it quick.
The wiper wires in the flexi bit from door to body had split, chafed and shorted [ permanent live to wiper in it ] Do not have heated rear window so its old wires were removed and a new section of loom made up for the wiper.

Al2O3 said:

They've got 100% positive feedback. You could always ask them a question. Or, they have a make an offer option.

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Well I have purchased that steering column and whereas you are correct they did have a make an offer option every one of my offers (110,120,130) was auto rejected. It really annoys me when people do that are they expecting people to use the make an offer to offer above the asking price?

dag019 said:

Well I have purchased that steering column and whereas you are correct they did have a make an offer option every one of my offers (110,120,130) was auto rejected. It really annoys me when people do that are they expecting people to use the make an offer to offer above the asking price?

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I've never made an offer before, but that sounds shiite. At least you've got one now though.

Al2O3 said:

I've never made an offer before, but that sounds shiite. At least you've got one now though.

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I have used it on buy it now listings. you can set it to auto decline below a certain amount and auto accept above a certain amount rather than having to manually check each offer, but if you auto setting are the same as the price what is the point. but as you say At least I have one now and when it arrives it will mean I can get other things mounted like the pedal assemblies and some more of the inner dash.

dag019 said:

I have used it on buy it now listings. you can set it to auto decline below a certain amount and auto accept above a certain amount rather than having to manually check each offer, but if you auto setting are the same as the price what is the point. but as you say At least I have one now and when it arrives it will mean I can get other things mounted like the pedal assemblies and some more of the inner dash.

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Top man. I'm looking forward to seeing it running again.

Well a bit more progress this weekend but not as much as I had hoped for. In removing the steering column bracket earlier in the week late evening and in the dark I forgot that there were two brackets and only removed the lower one. So I could not fit the steering column as I still need to clean and paint the middle bracket but that is a job for this week.

I did finally get the wiper rack fitted:



I also go the new clutch pipe bracket welded on and seam sealed ready for paint. Apologies I did not take a picture of just the bracket after welding for everyone to critique my poor welding, I am forgetting to document half of the things I am doing.



I finally finished bolting the sills in and removed couple of other parts form the old bulkhead to "restore" this week, so by next weekend hopefully I will have a fully functioning heater box and accelerator pedal as well as the final steering column bracket I forgot. This means that I can hopefully soundproof the footwells and refit the pedals and steering column next weekend.

I (definitely I and not my old man at all) also sanded down some more of the body panels so that I can hopefully get some primer on them this week.



Quick question on vent seals. These had the newer foam seals fitted to the vent flap but I know earlier ones had the rubber seals fitted to the bulkhead (the same as my series). I currently have no seals so will be ordering some which are better and more likely to keep it waterproof?

I had also planned on swapping the wiring loom from the donor bulkhead ot the ne wone this weekend but came across a whole host of wiring nightmares!

Firstly starting easy the plastic surrounding the engine bay fuse box has broken and half of it is missing (the fuse holders are intact) can you get replacements of these so it mounts onto the bulkhead tabs as it is supposed to?



I also removed a lot of additional wiring at the front end for lights. I assumed initially it was for additional lighting but it later became clear that is was a combination of additional lighting and also running both side lights from the same feed. The reason for this is obvious below:



However the obviously melted fuse (side light as mentioned above) is not the only issue here. Who wants to play the fun game of spot the problems?

Because of the above and the amount of chopping and changing it looks like this loom has had to add additional things in (very poorly) and try and repair overloaded circuits (side lights) I am not going to use it. Although annoying as that was part of the reason for buying a complete bulkhead I am not out of pocket due to everything else I have salvaged from it, I am just not quite as quid's in as I had hoped.

I am now left with two options either buy a new loom from auto sparks (or another brand if someone has a good recommendation) or try and find a good, original, complete second hand loom. Neither are cheap options and a second hand loom is slightly cheaper but the price is not the driving decision maker. Which will get me a better product that will be a straight fit and easy install? I know the auto sparks looms do not use the original fuse holders are there any other differences?
Also does any one have or know of a good s/h main loom, otherwise i am back to trawling eBay and facebook for something that is difficult to fully inspect off the vehicle unless you are very familiar with them.

dag019 said:

Well a bit more progress this weekend but not as much as I had hoped for. In removing the steering column bracket earlier in the week late evening and in the dark I forgot that there were two brackets and only removed the lower one. So I could not fit the steering column as I still need to clean and paint the middle bracket but that is a job for this week.

I did finally get the wiper rack fitted:

View attachment 259448

I also go the new clutch pipe bracket welded on and seam sealed ready for paint. Apologies I did not take a picture of just the bracket after welding for everyone to critique my poor welding, I am forgetting to document half of the things I am doing.

View attachment 259449

I finally finished bolting the sills in and removed couple of other parts form the old bulkhead to "restore" this week, so by next weekend hopefully I will have a fully functioning heater box and accelerator pedal as well as the final steering column bracket I forgot. This means that I can hopefully soundproof the footwells and refit the pedals and steering column next weekend.

I (definitely I and not my old man at all) also sanded down some more of the body panels so that I can hopefully get some primer on them this week.

View attachment 259450 View attachment 259451

Quick question on vent seals. These had the newer foam seals fitted to the vent flap but I know earlier ones had the rubber seals fitted to the bulkhead (the same as my series). I currently have no seals so will be ordering some which are better and more likely to keep it waterproof?

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Vent seals onto the bulkhead. The ones that go on the flaps don’t seem to seal.

Not been a lot of progress on the rebuild recently as need to get a new wiring loom (thinking auto sparks) and the dog has been very ill racking up lots of vet bills, not on his second blood transfusion with pancytopenia.

But it has not been forgotten about and earlier this week I picked this up:


It is a discovery 200tdi (same as what I currently have). It turns over and was running when removed about 5 years ago. Mileage is unknown but it came out of a farm discovery in west wales so I guessing lower end as heavy farm use would have accelerated the rot! Although I have not seen it running I do know the chap I got it off so is not an unknown eBay special.

Other than a clutch kit what else should I do before fitting it that is easier to do out of the vehicle (back of the engine).
My plan is to fit it, oil and filters, and start it to make sure it runs. After I have confirmed that I will do the timing belt, lift pump, fan belts.

Is there anything I have missed or other things people would do as a thorough service before running an unknown emerging?

dag019 said:

Not been a lot of progress on the rebuild recently as need to get a new wiring loom (thinking auto sparks) and the dog has been very ill racking up lots of vet bills, not on his second blood transfusion with pancytopenia.

But it has not been forgotten about and earlier this week I picked this up:
View attachment 261265 View attachment 261266

It is a discovery 200tdi (same as what I currently have). It turns over and was running when removed about 5 years ago. Milan age is unknown but it came out of a farm discovery in west wales so I guessing lower end as heaven farm use would have accelerated the rot! Although I have not seen it running I do know the chap I got it off so not is not an unknown eBay special.

Other than a clutch kit what else should I do before fitting it that is easier to do out of the vehicle (back of the engine).
My plan is to fit it, oil and filters, and start it to make sure it runs. After I have confirmed that I will do the timing belt, lift pump, fan belts.

Is there anything I have missed or other things people would do as a thorough service before running an unknown emerging?

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Could you strap it down, put a starter motor on it, connect a battery and do a compression test?

Al2O3 said:

Could you strap it down, put a starter motor on it, connect a battery and do a compression test?

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It has a starter fitted. I could Probably compression test it if needed. But my experience or removing glow plugs is hit and miss from a cold engine!

dag019 said:

It has a starter fitted. I could Probably compression test it if needed. But my experience or removing glow plugs is hit and miss from a cold engine!

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Just a thought mate. I think I'd like to know what is was like before putting it in. I probably worry too much

Al2O3 said:

Just a thought mate. I think I'd like to know what is was like before putting it in. I probably worry too much

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As there are no wings, electrical, or piperwork the actual putting it in is the easy bit!

Well I have managed a little more work towards the rebuild. Due to some very expensive veterinary bills recently the wiring harness is going to have to wait, but I might be able to stretch to some engine parts and clutch towards the end of the mongth so the engine may get fitted before the wiring and the dash.

In the meant time I am busying myself with some more painting, and I have finally managed to fit the steering column after battling with the existing rivnuts and purchasing the tools to install new ones!

If it has stood for five years, I would fit a new rear crankshaft seal

Plus one on above with a proper original seal. Vent seals rubber, the foam ones go porous and retain water promoting rust.

@dag019
On another clear out…. Found you a bonnet catch. Put it in a safe place for you

Hicap phill said:

@dag019
On another clear out…. Found you a bonnet catch. Put it in a safe place for you
View attachment 262847

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Many thanks, Just need to get my act together and actually come down to you to collect things!

A bit of progress form the bank holiday.



Finally got around to soundproofing the drivers footwell so I can install the pedals. These have been installed but I forgot to photograph. I can now plumb in the clutch and brakes and bleed them through so one more things is functional!
What is used to secure the clutch pipe to the bulkhead. my old one is all melted, the galv one is bare and the parts bulkhead was a 300tdi so the clutch pipe goes down the same side as the pedals. On the earlier gearbox the slave is on the passenger side so the clutch pipe travels along the top of the bulkhead before dropping down the footwell. What clips it in place?



I have made a bit more progress with body work and have managed to sand prep and prime one side of the tub ready for paint. I am hoping to get the first oat of top coat on this along with the other panels already in primer above.

I am planning on putting in a parts order to get the engine swapped over (cost reasons, ideally I would start with the loom but a lot of very expensive veterinary bills means I cannot afford a new loom currently)
I know I need a full clutch kit (I have done that before) and it was suggested to do the rear crank seal as well while it is out. What other parts on the back of the engine do I need to order and work on before fitting.

I will do the timing belt and service one it is in the vehicle so I am not looking to order those yet. I am just looking at things that are very difficult or impossible to do once the engine is fitted.