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Series 3 109 Station Wagon, full ground up resto

Discussion in 'Members Vehicles/Projects' started by Wagon Loon, Apr 25, 2020.

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  1. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200618_085707.jpg IMG_20200618_092420.jpg
    Flux cored doesn't look so clean because of the shielding deposits, but they clean off very easily IMG_20200618_092824.jpg
    With a very clean, no greasy ****e, wire wheel, leaving a more palatable looking weld IMG_20200618_085744.jpg
    Decided this part at the bottom was too pitted and nasty, so made a paper former and cut a new piece. IMG_20200618_172606.jpg IMG_20200618_172638.jpg
    And welded it in before going to work this morning. Cleaned it up when I got home again, because grinders are noisey IMG_20200618_175018.jpg IMG_20200619_164045.jpg .
     
  2. Wagon Loon

    Wagon Loon Active Member

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    Removed the brake servo and clutch from the bulkhead IMG_20200623_173426.jpg IMG_20200624_152952.jpg IMG_20200623_173706.jpg The spot welds on the foot well seem to have been done in some interesting positions IMG_20200624_165629.jpg IMG_20200624_183322.jpg
    To make life a little easier I cut much of the foot well out.this also made for better access to carefully remove the Parts of the old of foot well. IMG_20200625_160607.jpg
    The inner upper corner was a proper pain to remove but eventually after it fought me for a couple of hours it came out cleanly IMG_20200625_171829.jpg IMG_20200625_171836.jpg
    It feels great to have got it all out, the temptation was to cut the corner, cut and weld to the part stuck in.
     

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  3. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200626_085031.jpg
    Trial fitting the repair panels IMG_20200626_085038.jpg Separated the reinforcing internal foot well panel which gives extra support to the pedals. It seemed strange that YRM's panel didn't incorporate this, but perhaps their repair panel is of a thicker grade steel than the original.
    IMG_20200626_165617.jpg IMG_20200626_165824.jpg
    Also perhaps this is why the YRM footwell has no finger groves pressed in.
    But what I have recovered is a bit pitted on the inside so I am making a pattern and will make a new one from galvanised steel
     

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  4. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200628_111903.jpg IMG_20200628_111928.jpg
    Made a card template from the replacement footwell, as some bolt holes were drilled in different places.
    IMG_20200628_120243.jpg IMG_20200628_133701.jpg IMG_20200628_134958.jpg
    And after cutting and shaping IMG_20200628_142509.jpg
    Needing to do something about the bottom of the bulkhead tunnel side
    IMG_20200630_190530.jpg IMG_20200630_190519.jpg
    Cut the bottom off where it is corroded and weak made a cardboard pattern, transferred to galvanised steel-cut and shaped IMG_20200630_191019.jpg IMG_20200630_191050.jpg
    So that's the Off Side repair panels made and ready to be fitted and welded in with plug and butt welds, which sounds a bit fruity lol.
     
  5. rob_bell

    rob_bell Well-Known Member

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    Wow, this is looking good :D
     
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  6. LincolnSteve

    LincolnSteve Well-Known Member

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    Really lovely work.
     
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  7. Wagon Loon

    Wagon Loon Active Member

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    Thank you so much for your encouraging words.
    I'm back at work and Daughter's back from Uni and I'm taking her for driving lessons so not getting as much time in as I would if I could each day.
    However been butt welding the bottom repair section I made today IMG_20200701_183601.jpg IMG_20200702_080551.jpg Which is starting to take shape
    IMG_20200702_185144.jpg
    But tomorrow I go on holiday, so am hoping to finish the structural welding and after removing the bulkhead finish it with U-pol 2k car paint. Then I can take the engine and gearbox out and get on to the chassis repairs.
    I will be trawling here to learn how to do the transmission and engine and refurb of the axles. Hopefully with the bulkhead and engine removed access will be better, and I have so much to learn. But I'm really looking forward to it all.
     
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  8. Knappster

    Knappster Well-Known Member

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    Looking good!
     
  9. Wagon Loon

    Wagon Loon Active Member

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    Thank you,
    Hoping to get the metalwork on bulkhead finished next week.
    Dingbro want me to take some panels in to get a good paint match for the marine blue.
    I wonder if there is a paint code out there somewhere, or is every blue series three a slightly different colour lol
     
  10. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200706_154731.jpg H IMG_20200706_154731.jpg Have to start with the foot.
    After having everything fitted and screwed together with roofing bolts, it all had to come apart again; because I have to weld on the new foot first. At least I know everything fits, or will.
    IMG_20200706_154731.jpg IMG_20200706_171616.jpg IMG_20200707_141844.jpg IMG_20200706_163225.jpg IMG_20200708_134422.jpg
    Once the foot was welded the other panels were fitted and screwed together and I started plug welding everything for about a day lol.
    IMG_20200708_134437.jpg IMG_20200708_134453.jpg IMG_20200708_154453.jpg IMG_20200709_112203.jpg
    Next to get fitted was the wee brace and support panel I made to replicate the original layout.
    Having fitted a new reel to the flux cored mig and been up patching some leaky bits on the garage roof, it was lovely to have clean dry welds happening.
     
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  11. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200709_122106.jpg IMG_20200709_122215.jpg IMG_20200709_122305.jpg
    This tunnel panel has rotten ends, so I'm going to make card templates and replace the rotten bits.
    The ends are originally made of the parts, don't know why 15943111183473881263706845193695.jpg Sort of like this.
    So that's a job for Infront of a film later to make card patterns.
    Most of the panel is solid and I've seen quite a few variations. Besides it's more fun and rewarding to make the old knackered panel like new, and it's mostly good. Maybe the ends went because they welded bits on to attract rust 15943114464075572888830360938050.jpg 15943115160824245320766538470487.jpg
    But the top part's pretty good 15943115991246103350215157520719.jpg
     
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  12. GSF 109

    GSF 109 Active Member

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    Looking good. I did the same repair on my bulkhead to tunnel diaphragm. Tricky repair, but you will manage fine I’m sure!
     
  13. Wagon Loon

    Wagon Loon Active Member

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    Thanks GSF 109,
    I did have a look online for new ones, but they all seemed to be ever so slightly different.
    So since we had lovely weather this morning and I'm on holiday, what better than to make some templates over fresh coffee
    IMG_20200710_103241.jpg IMG_20200710_125713.jpg IMG_20200710_171254.jpg
    And viola with some plasma cutting, flappy grinding to clean edges, welding, more grinding, more welding and grinding smooth.
    One end is replaced and galvanised to booty IMG_20200710_172600.jpg
     
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  14. Wagon Loon

    Wagon Loon Active Member

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    And wirh a lot of shaping because of curves formed on opposite directions on the N/S IMG_20200711_164707.jpg IMG_20200711_171859.jpg
    Can't wait to get some acid etch primer on to protect it.
    There is some minor non structural corrosion which I would like to cut out and replace in the centre part of the bulkhead. But now I can remove it for flatting and finishing and finally painting
     

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  15. Wagon Loon

    Wagon Loon Active Member

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    IMG_20200711_171905.jpg
     
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  16. LincolnSteve

    LincolnSteve Well-Known Member

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    That's lovely work again. Also helps me a lot. The ends on mine are so far gone I wasn't even sure what shape they were supposed to be. Good to know what they should look like.
     
  17. Wagon Loon

    Wagon Loon Active Member

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    Getting the N/S to fit round the footwell inner was challenging, but I just kept re fitting it and reworking until it was a really snug fit.
    There's so many places for water to get in and trapped on these landies, but you have to love'em lol.
    Was looking at the new Defender and it's special extreme sport equipment pods lol.
    I can't imagine chucking a sheep in the back of one of those.
    So I suppose their the masculine equivalent of the rangerover evoke. Funnily enough both designed by the same bloke.
    A nice looking SUV, but is it a Disco4 ?
     
  18. LincolnSteve

    LincolnSteve Well-Known Member

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  19. Wagon Loon

    Wagon Loon Active Member

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    It got a kick of undercoat 15946304473748546066997136797358.jpg
     
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  20. Wagon Loon

    Wagon Loon Active Member

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    Yes I watched this and thought Land Rover missed an opportunity here to go back to building a proper no nonsense car.

    It looks like a great car, and almost a clone with useful improvements.
     
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