Will's Ninety Rebuild!

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No, I think the A Bar is going to stay where it is.......useful piece of kit :D
Plan is to go down Saturday and strip the wing down and take the cab off so I can safely get it onto a flat bed and transport it to a friends.
I will keep you posted on how well that plan goes!

Ive spent the last couple of evenings trawling the internet for bits and pieces and talking to friends and such, think I might be able to get all the pieces I need now at least. However I am still looking so if anyone has any more links or people they know or bits going cheep give me a shout!

Cheers Maramaduke for those links :D
 
Ok, Busy weekend.......Not necessarily all on the ninety thought! :(

On Saturday me and Lauren removed the Drivers wing (Inner and Outer), the front grill panel, the drivers door and the truck cab (roof and back), the truck cab came off in one piece, which was a result of only two bolts still actually doing anything!!

On Sunday we jump started it and I took her for a spin around the yard, nothing seams a miss mechanically which is good news! I will probably do the timing belt and remount the radiator and intercooler an inch lower while I've got it all stripped down though. Who ever fitted the 200TDI made a bit of a mess and the radiator sits proud slightly and the bonnet sits on top of it.
I then got it loaded onto a flatbad and transported it all of 5 miles to a friends farm where I can get it put into a barn fairly soon, then I ran it around for a bit more and we left it in the yard covered up ready for the next chance I get to do some more work.

I have a new windscreen and the frame, now for the rest of the replacement body to be found!
Pictures to follow soon!
 
Ok, here are the pictures as promised.
Here is what state it is in at the moment:
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The Cab, Interstingly the curved glass on both sides poped out and are intact despite the frames being crushed!!

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The drivers door, bent like a banana but the top seams ok. I think this bending into the cab is what gave me the cut and brusing across the side of my head.

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So, work is set to continue this week.....Continue removing the wings and start taking out the dashboard.
 
This weekend and tonight we got quite a bit done, we eventually manage to remove the passenger wing after fighting with the washer bottle bolts (They met an interesting end involving a hammer and chisel ) and some sheep that needed rounding up before I could get to the wiring loom. I think the wiring of both my wings is very interesting......I think the fact its Ex. Army and I am the 8th owner has led to some interesting light wiring in the past which could be fun to rewire/connect up to my replacement wings. The wing came off pretty quick after that.
We have removed the break and clutch pedals and the heater box.
Lauren continued removing the dashboard and has more or less got everything out of it now so all that is left is the steering wheel and the wiring loom which I will disconnect at the weekend, its a bit difficult in the dark :( I think I am slowly converting her to love the landrover!) Once the wiring loom has been removed It will be foot wells removed and bulkhead off and a good inspection of the chassis followed by a clean up and a wax oiling.

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this was the photo taken on saturday afternoon, she is looking a little sorry for herself!



On the plus side, I have hopefully lined up a replacement bulkhead that needs some welding but is otherwise in good condition and some wings which are good. Still need a grill panel, bonnet and truck cab though if anyone knows anyone selling any? Oh.....and Millitary doors!

The next problem I think i am going to have is the fact that the passenger side rear wing on the tub is badly bent and this is causing some debate on what to do, has anyone replaced a rear quaterpanel before?
 
Not personally but my 110 came with anew one already fitted. God knows where they got it from or how much it cost but it was brand new, Land Rover genuine part still with sticker attached. Drill out spot welds and rivet new one on. Seal it up. Job done. Only now my 110 has a line of rivets down one side.
 
Merry Christmas Everyone :)

Bulkhead is out and I am about a 1/4 of the way through welding the replacement bulkhead up. Both corners are pretty much rotten and so is the inner strengthening so lots of fabrication work going on to get it so I am happy with it.

This weekend we are going to take the tub capping off and then we will be knocking the tub about to try and get it some what straight. While the front end is stripped down I am planning to have a look at changing the timing belt and water pump and look at where to mount an airfilter box. I may also have a look at lowering the radiator mounts lightly so the radiator sits below the slam panel, at the minute the radiator sits above the slam panel and the bonnet sits on top of it which isn't ideal, this was obviously overlooked by a previous owner when the engine was replaced for a 200TDI.
 
What i forgot to mention was that I actually clobbered Lauren around the head with the steering column as we took the bulkhead out which left a nice cut and lump just above her right eye :O she's on the mend now but she wont let me forget it! :D

I now owe her some trainers, a hoodie and a pair of boots!
 
I've now got a replacement tub to put on so Yesterday we removed the seat box and tub and got the chassis steamed off. Turns out, to the supprise of everyone involved, the chassis seams in good nick and there's only a small hole to address in rhe drivers side rail.
We did find that the fuel tank had suffered more on holinsclough that what I had originally thought though, it had been dinted AND it's been shoved back into the chassis bending the mounting brackets!!!
The bulkhead repairs are coming along too now, although very slow and fiddly, hopefully getting somewhere with it now. If I get chance some pictures are to follow shortly.
 
In December I purchased a second hand bulkhead which looked fairly solid, the only work that it really appeared to need work was the top corners which didn't look to great. Unfortunately the more I delved into it, the more I have found that is wrong with it, on the plus side it isn't bent like the one I took off!!

Unfortunately I didnt take as many pictures as I thought I had done....or Ive lost some but hopefully it will give you all an idea of what ive been up to :)

Here are a few pictures of the corners, top rail and one of the footwell strengtheners after a slight bit of grinding and a bit of poking around which showed me roughly what needed cutting out. I initially thought that where there were only small holes, just under the top corners for instance, I would get away with just spotting weld on but that just reviled lots of thin metal and rust so I ended up cutting more out but I didnt get any pictures of that.
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On both corners I made up templates using cardboard and measured the holes to try and make sure that I got them in the same place, I then cut out a large section of the front piece:
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As you can see, the inner piece of the bulkhead is very rusty and the strengthening for the windscreen is completely gone in places. My first job was to cut out this inner piece to good metal and fabricate a new top piece making sure it was just as strong as what should have been there, and it stood in the originals position as some of this is used for the door seal mounting. Where the Windscreen brackets are mounted sits some pipe inside of the bulkhead, for mine I borrowed some 1/2" greasepipe from a piece of plant at work and welded it in before anyone realised ;) This meant drilling out the spot welds which held the door seal mounting in place to pri out the rotten bracket before slotting my replacement in and spot welding it in place.
Using magnets I lined my replacement front plate in place and when I was happy tacked it in the 6 places (4 corners and the middles on each long side) to hold it in place. I then replaced the side piece which was also rotten on both sides, same again really, cut out the rotten pieces, measure up for new and tack it in. once the side was in I slowly welded up the front and the side. I repeated the process for the top and the back (dashboard side) on both the drivers and passengers sides, both corners were very rotten and where possible I used Hammerites "Krust" to try to stop and protect the bulkhead steel from any more rot.

Once I was happy I ground the welds up and set about repairing the top rail in a similar manner, however the majority of the rot was around the locating spikes and they had really taken a beating, so I spend a few minutes making some new spike out of M8 bolts on the bench grinder and cut out the rot and welded in fresh metal. I then drilled out the spaces for the locating pins and welded them in place.

The footwell strengthener was a right mess, I could see the extent of the rust and so I ran over it with a wire brush wheel on the grinder and it wasnt even worth salvaging.....in fact there wasnt a lot left. So what I have done here is take some 40mm Box section and sliced it down one way to make a U Section of depth 15mm and welded this in place. I will get a picture of this shortly.

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I think I have now finished welding on the bulkhead, I say I think because everytime I have said that I have finished i always find some more to do!!
I have been cleaning it up ready for painting using a mixture of a wire brush wheel and the Scotch M3 paint striping discs, expensive but effective! I have also cleaned up both wings, some of the filler put in by a previous owner was a little worse for wear so I have replaced some of it while other bits I have actually straightened the dints out.

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Tomorrow I am going to have a look at repairing the hole in the chassis that I found on Saturday, I was going to take the fuel tank off but that is proving to be too difficult since the tank got knocked on hollinsclough resulting in the brackets being bent! Oh well! Wish me luck folks!
 
Christ lucky escape. Looks like you need need a new wing mirror though!

hehe, yea something like that! I was looking in the wreckage box the other night, annoyingly i broke the mirror I hadn't long replaced and not the mirror that was getting a bit tired! Sods law!!!

Some more pictures:
1. Here is the picture of the foot-well strengthening to replace the rotten one
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2. The bent fuel tank brackets, hollinsclough made some nice work of these!!
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3. The hole in the chassis, I cut this out the best I could to remove the rotten top
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4. This is the welded on patch, I decided to weld this over the top in the end as it was proving difficult to let the patch in properly and make a nice job of it, so in the end I came to the conclusion a patch over the top would be more appropriate and prove to be a stronger repair.

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This weeks plan is to wax oil and under seal the chassis, paint the bulkhead and wings in primer (and possibly top coat them). Friday night i'm planning on taking the head off the engine and Saturday replacing the valve guide seals and other seals to hopefully cure my landrover signature blue smoke that its had for a while now.
 
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