Crashbox's Series 3 rebuild thread

[crashbox]

My pooter went on the blink just over a week ago. Fortunately I had a weeks holiday and the weather was brill so I got on with the chassis repairs. I will post a few photos of the work so far. It has had 2 coats of red oxide and 2 coats of Massey Ferguson red tractol paint. Dont know if it will hold back the tinworm but time will tell. Its had new outriggers and a number of patches. Engine and gearbox removed for work on the oil leaks and some teeth fell out with the gearbox oil so a replacement gearbox will be fitted.

 

[crashbox]

This isnt really a full resto thread but I will update it from time to time. I removed the windscreen prior to rolling it on its side and found some rot on the bulkhead under the screen seal.

 

[Land Raver]

Liking that Massey Fergy red paint! Keep the pics coming

 

[pef77]

that paints almost glow in the dark

 

[johnny curt 1]

verry nicely done so far mate i wish id have thought of tipping mine over i might have avoided the bomber as big as a garden pea burning into me elbow if id done that :flame::flame::flame:

 

[crashbox]

Tipping it over was only as an after thought. I dropped the oil out the gearbox but there were 2 teeth and 2 thumbnail plates in the oil so I took the gearbox out, then decided to remove the engine to get better access to the chassis. When I flipped it over I found another 7 bits needing welding. I fitted two new rear springs just loose fitted for mobility as I will renovate the axles later. When I fitted the new rear shackles I found that one of the threaded shackles wasnt threaded parallel so when I tried to thread the second bolt in, it wouldnt thread in. I may post a photo to show it better. I used the old non threaded shackle as a temporary measure. I will be using 50% waxoil/diesel to rustproof the inner chassis box sections. More photos will follow....eventually.

 

[nrgserv]

:nothingtoadd:
for now at least!

 

[crashbox]

:nothingtoadd:
for now at least!

I know that feeling well.

 

[crashbox]

I decided to remove the bulkhead to do a better job on the patches and it will give me better access to rub down and paint the front crossmember and bits under the bulkhead. Ive had to roll it onto the drive as I have a disabled buggy to store in the garage (and sell) from the late father-in-laws estate. Here are some photos of it minus the bulkhead.

 

[defender11069]

looking good so far mate keep the pic's coming

 

[crashbox]

looking good so far mate keep the pic's coming

Ta

 

[leg oot the bed]

big job??

 

[crashbox]

big job??

Turning out that way.

 

[leg oot the bed]

i know the feeling i decided to pop a 200tdi into my s3, its a heavy lump ill give it that

 

[crashbox]

Well I've spent the last couple of weeks fighting with the chassis bushes for the front springs. I burnt out the inner bush and cut two slots in the outer shell and when I knocked the cut bit out the rest was easily forced out. Getting the new ones in was a different story.I wasted 2 bushes trying to force them in but eventually realised that being pattern ones, they were too big so with some filing down and after purchasing the correct tool, they fitted in. Thank goodness for that as its held me up no end.

 

[crashbox]

Friday night, home from work, had my tea, cut the lawn then straight out to the garage.Started dressing up the top of the bulkhead, the shelf that the window sits on. It looked good before I removed the screen and the plastic then found some rusty holes. Will have a go at welding them up tomoz.

 

[owl]

Them front chassis bushes can be a pig, I have cut the new ones in half before and pressed half in from each side, as for your bulkhead get a new top piece folded up that will just drop inside after cutting the rust out and it won't distort as easily as a flt piece.

 

[crashbox]

So then, nowt done over last couple of weeks as I was on me hols. I took the axles off and my son 'n me carried the chassis into the garage for safe keeping. I cannot believe I found yet another weak point on the bottom of the chassis about 6 inches long. I will patch it up if it ever stops raining. I went down to Englandshire near London and bought a load of stuff off a guy who had an abandoned project. Wish he was closer as he had a good part restored s2a chassis. Took me 12 hours driving but was worth the trip.

 

[crashbox]

I have repaired the top part of the bulkhead and will take photos once the welds are dressed up.

 

[treeman]

Nice work, very jealous lol
Keep it up looking good