110 defender rebuild project and v8 conversion

I've a spare set of axles I want to do for my D2 - wonder if the fact that paint takes a while to go off make sit more resilient/flexible?

I used Frost chassis black, 2 coats on top of 2 coats of por15. That also took a while to go off. It's pretty resilient, dropped stuff and dragged bits across chassis and all is well, resistant to gearbox oil, standard thinners, degreaser and a few other things I've spilt on it. Painted in summer and took about 2 days before I could really apply force to it. It's not rock hard like hammerite so things 'bounce' off rather than just chip it.

Bennehboy said:

I've a spare set of axles I want to do for my D2 - wonder if the fact that paint takes a while to go off make sit more resilient/flexible?

Click to expand...

That's what I'm hoping!

Bit of progress on the new one this evening. Took me a while to figure out the best way of getting the rear axle hitched up.

In the end I chose to stick the trailing arms into the chassis bushes, attach the shocks to the top mount, and then lift the axle into alignment to enable the trailing arms to be bolted to the axle. The shocks can then be attached to the axle too.

Then you get this:



Then it was the scary bit!



Then I finished up with this:



I had to leave it like that sadly, still with the spring compressors on. Hopefully I don't find my chassis catapulted across the garage when I check tomorrow.

It's going to take me a little time to figure where the jacks are going and what's moving when I take the spring compressors off. Then I'll tackle the other side.

Got a 2nd hand a-frame from eBay and it arrived today, so I took it apart:



Then I spent 2 hours with a hammer!



And achieved all of about 1mm movement. Stupid bloomin thing!



So I've ordered one of the combined joints and housings.... Phhhhhh. Frustrating.

Progress is looking good bud. Thought you had a press for stuff like a-frame ball joints (Or maybe I've got confused ) even then they can still be tough buggers.
Think I've got a couple of fulcrums with ball-joints already removed if you want one. (edit, just read the rest of post, so a bit late. )

aaronmorris said:

Progress is looking good bud. Thought you had a press for stuff like a-frame ball joints (Or maybe I've got confused ) even then they can still be tough buggers.
Think I've got a couple of fulcrums with ball-joints already removed if you want one.

Click to expand...

Thanks chap, and thanks for the offer. I've been impatient and already ordered one. I do have an OE ball joint as a spare now though.

Yes I have a press, but I can't see a way of pressing the balljoint out. I can see how it presses in easy enough, but the flange would seem to prevent pressing out. Busters guide advocates the hammer too

farmershort said:

Thanks chap, and thanks for the offer. I've been impatient and already ordered one. I do have an OE ball joint as a spare now though.

Yes I have a press, but I can't see a way of pressing the balljoint out. I can see how it presses in easy enough, but the flange would seem to prevent pressing out. Busters guide advocates the hammer too

Click to expand...

No worries, I realised once I'd posted.
Only way I've ever known them pressed out and is how I do it is to cut the lugs off each side of the ball-joint so you can sit that on the press bed.

aaronmorris said:

No worries, I realised once I'd posted.
Only way I've ever known them pressed out and is how I do it is to cut the lugs off each side of the ball-joint so you can sit that on the press bed.

Click to expand...

Balls... Should of thought of that. Still, if 2 hours of hammering doesn't do much... Chances are the 10 tonne press won't either.

I did get the bushes out of the arms though. With about 8 or 9 tonnes.

I would just order the ball joint in the fulcrum next time at I wasted to much time getting the old ball joint out but got it in the end, doing a similar rebuild myself but with a 90 but also a v8 conversion

Cut the tabs off the old joint where the two bolts go so you can rest it in the press.

Bugger, somebody has said that already!

mark-d said:

I would just order the ball joint in the fulcrum next time at I wasted to much time getting the old ball joint out but got it in the end, doing a similar rebuild myself but with a 90 but also a v8 conversion

Click to expand...

ah, we should probably compare notes along the way then

yes I do feel a little annoyed that I wasted an evening with that effort. never mind, it wont be the biggest widnow of time wasted on this project, I'm sure.

There's not enough of these images on the web, so here's my contribution:

Removal of a frame ball joint:

1st, hacksaw off the lugs on the ball joint



Next, stick it in your press now that you have some areas of the fulcrum to rest on the base plates



Next... Realise that 10 tonnes of force is not enough, despite "loosening" it with the previous 2 hours of hammering.

Blooming thing!

Had a decent day yesterday, interspersed with meeting Marmaduke from this forum, who came to collect the spare 300tdi. Getting the engine out of the garage also prompted a big overdue tidy-up. It's a much nicer place to work now.

Did manage to get the seat box out after a lot of grinding a little chisel work:





Drivers side looks especially ropey! I need a new one anyway because of the tunnel damage, but I'm now worried about the integrity of the tub.

I noticed a few cheap puma rear tubs recently, and apparently the 110 versions are the same as the older models, so I might just take that route.

.... And... Anyone know what this is?



It was mounted under the passenger seat... 7 black wires connecting into the loom somewhere... Possibly related to egr stuff? The label machine I bought has just earned its keep labeling the wires before cutting them!

farmershort said:

Next... Realise that 10 tonnes of force is not enough, despite "loosening" it with the previous 2 hours of hammering.

Blooming thing!

Click to expand...

Bit of heat round just the casting should help you press it out....

farmershort said:

.... And... Anyone know what this is?



It was mounted under the passenger seat... 7 black wires connecting into the loom somewhere... Possibly related to egr stuff? The label machine I bought has just earned its keep labeling the wires before cutting them!

Click to expand...

Pretty sure that's the 'spider box' linked to the alarm.
Wish I'd used a labelling machine. The writing on my masking tape labels has faded to illegible

Al2O3 said:

Pretty sure that's the 'spider box' linked to the alarm.
Wish I'd used a labelling machine. The writing on my masking tape labels has faded to illegible

Click to expand...

When I posted up asking for recommendations on a label machine, there were quite a few folk stating how much tape and how many marker pens you could buy for the money... I should point them to your post

I use a £30 brother label machine at work, for chemical dosing pipe work, pumps etc, inside, outside, rain, sun and the labels are quite durable. I never even considered using it on the landy - missed a trick there.

I can recommend not using masking tape