Series 3 109 Six Pot Rebuild Thread

[6pot]

Well I rebuilt the PWDA valve, unfortunately found the switch was a bit dicky but I'll get a new one on my next Blanchard order.
Then I thought about how to do the steering relay and made the tool to put it together.
With this and a little bock of wood and a couple bits of tube it didn't take long to get it together using the press. Not sure what all the fuss is about these.
The only special tools other than a couple of bits of tube lying around to use as spacers were the slotted bit of stainless and the little bit of wood in the pic.
I just pressed it in with a spacer pressing down on the tube which was pressing the slotted steel onto the spring, put two screws in and released the press, put on the spacer and bushes with a hose clamped, pressed it to release the tension on the spring, took out the two screws to release and then put in the vice and tapped it in. no BotherView attachment 245325

Nice work.

 

[Wagon Loon]

Awesome, I need to sort her alternator belt as payment lol.
My kind of trade lol

 

[BikerB]

Steering relay finished tonight ready to fit, also blasted, powdercoated and fitted the gearbox mounts.
A little progress regularly will eventually finish it. Its just taking longer than I had originally thought because it is coming down to every nut and bolt and being rebuilt, determined to have it as mechanically sound as a new 109 when finished.
Then it may be just a bit unreliable the same as a new one was rather than break down every week and leak everywhere

 

[Wagon Loon]

Your relay looks like new,
Really nice job

 

[6pot]

Yes, looks really great.

 

[BikerB]

The only original parts of it are the case, the two end caps and the arm which have all been blasted and powdercoated. I replaced everything else inside with NOS parts.

 

[6pot]

It basically is new really, at least as good a quality as new now.

I'd better hope my parts are in good enough nick because all this stuff is beyond me, I haven't got the tools or facilities for it.

 

[BikerB]

It basically is new really, at least as good a quality as new now.

I'd better hope my parts are in good enough nick because all this stuff is beyond me, I haven't got the tools or facilities for it.

Little of this is beyond the average joe with basic handtools. Even the blasting, powdercoating, zinc plating and other facilities can be got round with other methods, they just take longer.
You would be surprised just how much you can do at home on one of these, just look at Wagon Loon's work on his and he isn't using much, if any, special equipment.

 

[6pot]

Little of this is beyond the average joe with basic handtools. Even the blasting, powdercoating, zinc plating and other facilities can be got round with other methods, they just take longer.
You would be surprised just how much you can do at home on one of these, just look at Wagon Loon's work on his and he isn't using much, if any, special equipment.

Yes I suppose that is true, that is one of the beauties of working on what is almost Meccano and you're right about other methods or improvisation for certain things. I'm probably too cautious about taking things apart which on the surface seem complicated and require special tools or parts. I've got all the basic tools plus torque wrench, grease gun, welding gear etc and so far welding has only been practice stuff like fixing the wheelbarrow, fixing the cement mixer and making up some frames for some drainage grates so I'll probably manage - eventually!

Re. the steering mine was always really light and positive before I laid it up and there is no noise or play in any of the components so I'll probably leave that alone unless anything comes to light.

 

[BikerB]

Steering relay in, just need to paint and fit the lower arm. Shimmed it inside the tube and fitted a CNC uprated bottom collar. Seems very solid now.
parabolics arrived and cleaning and painting all the shackles ready to fit them, will need to give them a coat of black first though!

 

[BikerB]

Finally got the bike engine together and on the bike so I could get the bench free for the tank.

So tank off and onto the bench so I could grind and cut off the existing mounting flange. Now off and once I have cleaned it up I'll spot weld it on and then weld it on permanently and repaint it. I also put a light coat of smooth hammerite onto the springs but ran out of paint, oh well more to buy to keep going.
I asked GB springs why they just didn't supply them in black and was told it so that folk know they have GB springs! Its a bit of a pest having to paint them again as I supposed most folk do.

 

[Wagon Loon]

Is there a stronger spring for the offside, both front and rear; or is it only the front?
I just know they have a weaker sprung near side, for mostly not having a passenger.
How British is that lol

 

[Turboman]

Is there a stronger spring for the offside, both front and rear; or is it only the front?
I just know they have a weaker sprung near side, for mostly not having a passenger.
How British is that lol

Nothing to do with not having a passenger.
All the four springs are different, and it is to do with torque reaction of the vehicle when pulling away.

 

[Wagon Loon]

Darn now I'm totally confused, I saw in a program about early Landover said it was because of the driver's weight, which had me scratching my head

 

[BikerB]

Darn now I'm totally confused, I saw in a program about early Landover said it was because of the driver's weight, which had me scratching my head

Both front and rears are biased to the drivers side.

 

[Turboman]

Darn now I'm totally confused, I saw in a program about early Landover said it was because of the driver's weight, which had me scratching my head

TV programmes are made by journalists, they know about making TV programmes.

Motor engineers design vehicles, they know how to do that.

 

[BikerB]

Bits cleaned up and spot welded into position, just need to run a bead around the edges to finish the tank and then redrill the holes further in.. Repainting the whole tank is a bit of a pain though I suppose the spit through paint that was on there could do with being a bit better than it was. Once its on you shouldn't be able to see the cut off section as it will face the chassis.

 

[BikerB]

Tank finished and first coat of anti rust primer on, only three more coats to go!

 

[BikerB]

Second coat of Correless primer on tonight, hopefully start getting the Corroless S topcoat on tomorrow. Blasted and powdercoated all the tank mounting hardware, even NOS it was not painted or treated. Also did the bottom steering arm ready to be mounted on the relay
Still a bit confused about where the two thick spacers go on each rear mount, is it one on each side of the rear crossmember or both on the tank side of it. The parts and repair manuals are not clear and my original was held on with all sorts of rubbish.

 

[BikerB]

Tank now painted with two coats of Corroless S and two coats of Corroless RF16, will give it a day or two to cure and refit the tank, hopefully permanently this time. I think I'll give it a coat of waxoyl externally once its on, at least on the exposed bottom parts of the tank.

Next are the brake lines, then the fuel lines, which I am awaiting parts for as we speak. I can't find the PDWA mounting bracket so I may have forgot to take it off the chassis, may have to make one as they don't seem to be available.