Tag Archives: Chassis

Tom’s Car : Started

Well last night we finally got round to starting work on changing Tom’s chassis.  This time round we are going to try and take the body off the car in one piece so that we haven’t got to worry about lining all the panels back up at the end of it.

To do this we have got 3 editions of Land Rover Monthly, which handily show the the process using a 2 post ramp to remove the body.  while we are reliant on human power we think it can be done.

So last night we carried out the following steps:

  • Removed the 10 M8 x 20 bolts from the rear of the tub to cross member tabs
  • Removed the 4 screws holding the filler neck to the tub
  • Removed the Gear lever
  • Removed handbrake cable
  • Removed front bumper

The next steps will be undoing the other connections between body and chassis such as fixing bolts electricals and ancillaries then looking to remove the wings and bonnet to make the body work removal easier.

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Start of a journey

Well Tuesday 9th June marked the start in our next journey, the delivery of the chassis for the 300tdi 90.

Over coming months we are going to be doing the chassis swap on this car and hopefully documenting it the blog.

Keep an eye out for progress and photos.  The plan for this one might be to lift the body off in one go so we all need to hit the gym a bit.

A long needed update

Well things have been a bit manic recently so updates were last thing on the mind.

But alas here we are April 2015 and here is an update on how things are going.

Ian’s Car – 200tdi 90

Well 12 months since the rebuild finished, its MOT time again.  Car went in for its test Tuesday 7th April.  It failed 😦  The issues were headlights weren’t bright enough, the drivers door wouldn’t open from inside the car.

So all in all not too bad, but the worst item was down as an advisory but actually caused the end of the test.  A UJ in the rear prop had failed to the point where the tester wasn’t willing to carry out deceleration tests.  The prop was unbolted and the UJ’s purchased and replaced.  the prop then bolted back on and boy did it make a difference.

The door not opening was a case of adjustments on the mechanism for the handles just shortened them a bit and opening now much easier.

The headlights were the biggest concern.  As I have high performance bulbs fitted to the car when the tester said they didn’t register on the testing machine.  So reading around the subject points at a burnt out light switch causing poor performance.  The solution is to put a relay feed to the lights.  I purchased a Red Bison Boomslang from Paddockspares for £30 it was a bargain for the entire kit.  I had it fitted in no time and made a massive improvement, its a product I would recommend to anyone.

MOT Retest 18 April 1pm.  Result: Car passed

Jordan’s Series II

Well not much work has been done on the car since November, panels are now painted but not yet fitted to the car.  The accelerator has now been refitted and the car can be driven around.

The main reasons for this is we have been busy working on Jordan’s Discovery 2, which since november has had a number of coolant hoses as it has been loosing coolant and the pressure build up has popped them.  We have now replaced the suspected cause of the coolant loss and so far so good.

Nick’s Discovery

It has been plodding along as normal.  We had a bit of fun while jet washing it ready for MOT when the jet wash smashed the sun roof.  so that has been replaced and the alpine windows have been taken out and covered over.

Matthews Series.

As Matthew has decided he isn’t friends with 2 / 3 of us working on Land Rovers there will be no further updates about his car as we dont see him any more.

New Cars:

Yes we have been joined by two more land rovers that we can enjoy working on.

Daisy The Defender is a 2006 TD5 90, owned by some friends we have had a little bit of work to do on the car already including replacing a failed fuel pump and then adding some new bits such as chequer plate wing tops and a new bumper.  With being such a new car there shouldnt be that much to do on it for now.

Tom’s 300tdi 90, this is going to be our next big project, Toms car is in need of a new chassis, due to the amount of rust it has, we could go down the route of repair pieces but Tom fancies doing a chassis, so one has been ordered so big project ahead for the summer.  There should be plenty of updates on this one.

Car 1 : Progressing

Well this update is a couple of weeks over due, namely getting round to writing it but the recent progress has been :

Shocks fitted, after trying to fit the shocks with the poly bushes we found them to be a very tight fit so we ended up making a tool that allowed the pin to be put in while the bush was compressed with a clamp.  this worked a treat and in no time all 4 shocks were in place.

Rear Check Straps, once the shocks were in place we fitted the new straps and bolted up tightly.

Brake Lines, we have fitted a set of standard length braided brake hoses originally planned for car 2, but they were too short. Next step for brake lines will be running the full lengths of copper pipe and completing the brake system.

Front Grill, the front grill section has been painted green, it will have 1 more coat then can be refitted to the chassis along with a new radiator that has been purchased, the original was beyond repair.

Car 2 : Engine and Boxes refitted

Well after a bit of a quiet time following the sore arm and returning back to work this weekend has seen a bit more progress carried out.

After bolting in the gearbox mounts it was time to get the motor back in place.

bit of a jig with the crane and pulling and it sat down nicely and is bolted in. next up start to plumb things back in like fuel and wiring.

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Car 2 : Chassis Rolling

Well after a busy weekend and a hard couple of nights the chassis is now sitting on the axles and rolling on its own.

Having fitted all new poly bushes and BZP bolts, all that is left to do is tighten them to correct torque and mark that they are done.

The one word of warning anyone thinking about doing a rebuild is if the chassis is lifted on a jack make sure you can get your arms out if it slips.  I have learnt this after the rear spring seat landed on my arm.

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Next up is hope the Richards Gearbox Cross Member is delivered soon so that I can paint and fit that before dropping in the engine and box.

Car 2 : Bolts purchased, Bulkhead repairs

Well as the title of the post says today i purchased a number of nuts and bolts that will allow me to bolt the suspension and fuel tank to the chassis, so hopefully by the end of sunday I will have the axles painted and bolted back to the chassis.

Also we have been carrying out more of the repairs to the bulkhead, both top corners are welded up and repaired, and we have cut out the near side footwells, door pillar and bulkhead foot.  The replacements have been tacked in to place, so tomorrow night it should be fully welded and the off side tacked in, if not welded.  then over the weekend we will be finalising the car colour and painting the bulkhead.

Will update the article with pictures as soon as possible

Bank Holiday Bumper Update

First things first, due to computer being a bit of a pain the photos will follow shortly.

Well what a bank holiday weekend it has been, first one this year where we have actually had both cars to work on. Plus maybe a couple of side projects.

So here is the update.

Car 1 :

Well after a bit of time with little progress this weekend has been a big jump. Most of the delays have been down to the issue with the bushes we last reported in the poly bushes being too short and a gap being in the chassis. So new bushes were purchased and then on Saturday using a fly press pushed them in to the axles and chassis.

20130826-225453.jpgAfter noticing a bit of weakness in the rear cross member welding we decided to weld in some plates to strengthen the mount, so some grinding and welding later we are happy its stronger.

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So the paint was touched up and the axles all bolted to the chassis hopefully for the last time.

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Next up the engine came back to the build location after a checking over, a quick coat of green paint it was mounted back to the chassis along with the fuel tank.

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Also trial fitted the bulkhead and wings from car 2.

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Car 2 :

Well this week we have removed all the last bits from the old chassis, the last bits off were the A Frame and brackets, these were heavily rusted so required grinding off.

A number of parts were removed so they could go for shot blasting before refitting, these parts are :

  • 2 x Radius Arms
  • 2 x Trailing Arms
  • 2 x A Frame Arms
  • 2 x A Frame Chassis Brackets
  • 2 x Top Rear Shock Mounts
  • Panhard Rod
  • Fuel Tank front bracket

These will hopefully be in Tuesday morning and back this week.

The axles for the car were also rubbed down and primed ready for painting before they go back on hopefully before the weekend.

While the axles were dry and not yet bolted to the car we decided to change the bearings and brake disks. Again the fly press helped pushing the bearings in to place and in the day the rear axle was done, just the front to do now.

Car 3 :

After a bit of work this project has been put on hold for now and may be scrapped in the future, we shall see.

Car 4 :

A silver 300 tdi disco, this is a normal road car for one of the lads, after smashing a rear diff earlier this year a replacement pan was welded in to place but had always had a little leak as it was welded in place, so as the weather was nice we decided to remove the axle and weld in the garage.

After trying we found it still leaked so the axle is still off for now so this will be on going for now.

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Car 5 :

Well car 5 strictly shouldn’t appear on the blog as its not a Land Rover and the owner doesn’t have a Land Rover but he is one of the group of friends so we are putting it on.

The car is a Toyota Celica Race car that is a just starting project, There is no clear direction yet but we shall update the blog with more information. This weekend no work was done, but we did sell a spare set of wheels that came with the car so all good for now.