My 109" Series 3 :)

well done fella

bellowhead said:

well done fella

Click to expand...

Thanks



Also have a small update for you all



In one piece at last and the pile of rubbish that was swept up from underneath

Still need to do a few jobs to make it drivable but are small ones in the grand scheme of things

Brakes and clutch still need to be bled, floors and tunnel still need to be fitted and also the exhaust.

Exhaust has been taken into my work tonight so i could use the oxy/acetylene set to heat them up and bend them to fit round the gearbox crossmember.



Hopefully should get that list of jobs done tomorrow and then i can finally take it for a spin :crazy_driver:

air flow meter is upside down.

Rover SD1 Efi System Components

some good reading here.

3.5 efi said:

air flow meter is upside down.

Click to expand...

Ah thank you for pointing that out Didn't realise it would make a difference

3.5 efi said:

Rover SD1 Efi System Components

some good reading here.

Click to expand...

And thanks for the link.
Should keep me busy for a while

Small update

Still not drivable yet as i can't get the engine to rev also still haven't got the exhaust to fit either

Anyway today's job was fitting a discovery fuel pump into my tank as I don't think the inline fuel pump is delivering enough fuel to the engine.

Here's the disco setup before i pulled it apart for the pump itself.




The setup i currently have in the tank. Basically just a long tube with a gauze on the end.





And this is what i now have to go inside the tank.





After that connected the 2 wire that came off the pump, drilled a hole and fed a wire through and sealed it up

Will fit it tomorrow once the sealant is dry and hope the engine gets enough fuel when it's fitted

The disco one appears to have a flow and return will it not over pressure without a return?

Blackburn said:

The disco one appears to have a flow and return will it not over pressure without a return?

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It would but I do have a return feed , you should just be able to make out another pipe going into the tank on picture 2.

Ok missed the diesel return in pic

Well done. Great job :cool2:

Update time

Been a little while since I've done anything as i needed a break from it as the engine is stressing me out big time

Still having issues with getting the V8 running properly (posted about this in the V8 section).
Can get it to tick over but not rev. Anyway i won't bore you with the details and just say that I've removed the flapper system and am now in the process of fitting the hotwire system off of a 3.9.

So here's how the engine sits at the moment.





And this is what will be fitted upon gaskets arriving





Whilst waiting for the engine gaskets, i have pulled my finger out and got the disco front axle finished. All welding done and now painted.
Just need to order all new seals, gaskets, bearings etc then i can stick em back together and sling em under the 109

Couple of pictures.


Axle fully painted and drying.





Stub axles also had a lick of paint where needed

Differential in bits



It got covered in grinding dust when it was sat next to the bench so thought I'd strip it down and give it a good clean shame i can't afford a locker to go in

Update for the disco axles

Got the diff back together and set all tolerances etc. Tis easy enough if you got the rave manual

Yesterday I also had a box of goodies turn up from island 4x4. Basically all new seals, gaskets and bearings.

Luckily i had already rebuilt a disco axle earlier in the year that never was used so stole all the nice new parts from that (bar gaskets which i ordered some new ones ). The discs are new and unused but have gained a bit of surface rust in storage Also fitted was a 4 bolt flange conversion kit. Just need to lob the halfshafts in and it's complete

So here's the rear axle in one piece at last ready to fit to the series






My attention then turnt to the front axle. This is how far I've got






Only one swivel ball with new bearing races fitted

Tomorrow's plan strip another front axle i have and hope i have a decent swivel ball as the other one i have for this axle is pitted and generally fubar. Which is bad especially considering with these axles the hubs and cvs will be run in ep90 NOT one shot ****e!!!

Then hopefully i can fit the rest of the bits and get it in one piece ready to fit..... Oh and strip, clean, check another diff

Just noticed what I've done wrong in the second picture of my last post

I hasn't put the swivel seals on :doh:

Ah well at least it wasn't fully rebuilt before i noticed

Hi all.

Another update. Although didn't quite get as much done as hoped. Spent most of the day stripping down the axle and then meticulously cleaning parts.

So here's the axle i wanted to strip. As i wanted the non pitted swivel off of it.






Stripped down and the mess i made doing it







All the parts in order that they came off ready to be cleaned.







Only other thing i managed to get done after all that (as i wanted to watch the rugby) was fit the other swivel ball this time remembering the swivel seal and retaining plate



[




Tomorrow will finish off cleaning a few bits, then can get on and finish modifying the swivel knuckles.
Will take pics of the knuckles tomorrow and explain a bit more about it
Then can get the rest of it together

Right then.

Series axle has been stripped of it's steering arms.

So here's the plan to get over the problem of steering when fitting a disco axle to a series.

Get your swivel knuckles and cut off the original steering arms.

Get hold of a pair of series steering arms and basically bolt then to the disco swivel knuckles. (stole mine off my series)

If only it were that simple.

To start on the disco swivel knuckles there are only 2 bolt holes. Easy enough just drill 2 more holes i here you say. But no, again not that simple.
You need to keep the lower swivel pin that's originally fitted then plonk the series arm on top. (sfter cutting off the original pin for the series swivel!)
This in itself causes a problem as there is nothing below the other 2 holes on the steering arm.

So a solution. And a few pics to give you an idea.


The disco swivel knuckle with series arm and original lower pin in place.




The series arm and lower swivel pin.




The swivel knuckle bolt holes. Before modifications.





Now the plan from this point is to machine off about 7mm from the outside face of the lower swivel pin.

Thus dropping down the series arm and making the original bolts fit properly.

Will then make up a packing plate for the other side, bolt it all together then drill 2 more holes. Then unbolt it and tap the swivel knuckle to take the appropriate bolt. High tensile m10 bolts to be exact.

Hopefully once the machining and drilling/tapping is done should be a matter of bolting the rest of the axle back together again.

Machining will be done tomorrow so will take some pictures

Are you actually planning to fit this axle to a road use landrover or just for trialling?

Blackburn said:

Are you actually planning to fit this axle to a road use landrover or just for trialling?

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Occasional road use if i get bored of driving the eurobox and fancy the V8 roar on the way to work but mainly an off road toy.

Why do you ask?

very interesting

Are you going to have your steering midifications examined and approved?
As thats a major modification I would be highly worried about it failing and causing a crash and killing you or even worse someone else.