S3 109 Safari project......

Interested to see how you get on with that panel. I've got one in my pile of new bits waiting it's turn. Hope it goes well.

Hopefully.... I will post a few pics and you can see what you think. Looks like a reasonable panel. Quite thick steel. I will try it against the old panel and see how accurate it is first.

Ok, so not as much done as I would like to have today, but something was accomplished anyway
Removed the remaining rear chassis bush first.....

This was way simpler than the front chassis bush, as I was to find out!
I used some new threaded rod I ordered from Orbital Fasteners, whom I would recommend. This time I purchased 8.8 high tensile M12 and M14 as the stuff I bought from Toolstation was made of chocolate and the threads stripped when the load was applied. Not ideal.
Unfortunately, although the rear bush came out and went in no problem with the new HT rod, the front wouldn’t budge! The bush didn’t look to bad, but thought it was worth doing as I had it stripped down anyway.

I resorted to burning out the centre and the rubber bush with oxy propane. I then cut the metal outer of the bush with a hacksaw. It still didn’t move but managed to chisel it out and after an hour of hammering and swearing it came out...

A clean up with some Emery cloth, some judicial greasing and the new bush pulled in nicely

Next week, all going well, I will try the last front chassis bush and get on with some chassis painting.

It will for sure look like it's brand new when you're done with the painting job. I'm pinning this thread! I'm really looking forward for the finish product.

Many thanks. Let’s hope so, as I bought some more corroless primer and black topcoat. I just need some time to do it now Hopefully will manage to make some meaningful progress this week.

Looking good, happy new year I've been a bit in hiding the last while started my own business up in middle of lockdown so been busy with that have just given a customer a rough price to rebuild his series 3 109 chassis so may give you a shout on some of the repair panels

Happy New Year! . Wondered how you were getting on. You’ve been busy anyway.
I have used various different suppliers for bits and made a few myself. Are you documenting the rebuild?
Good to hear from you again.

My 300tdi has sort of stopped at the minute due to starting the business will be documenting the build yes customer has to save up some money first im just going to be doing all the welding work and he will be doing the mechanical side of it as he doesn't own a welder but I don't mind that

Sounds great - let us know how you’re getting on with it!

Removed the last chassis bush, but instead of a big hammer and chisel, I borrowed my mates air chisel with a flat snap on it. What a difference! Once I burned out the rubber, slit it down the middle, I hammered it out with the air chisel in a few minutes. It basically flew out the other side! The new one pulled in no problem....

Thought I would try to clean up some more of the underside of the chassis and get a coat of corroless primer on it. This was before....

This was after.....Oops, better get the grinder back out again!

Welded up the 3 holes, ground the welds flush. Got the big angry grinder out with the wire cup on it to clean the old paint and rust off, then got some primer on.

Then did some more painting on the rest of the chassis. Starting to get somewhere now.

Gonna have to look at these lumps of rust soon, so I can build up the rolling chassis.