The bulkhead Part 4 (patching up)

Well there wasnt much left to do except re-attach the left hand side bonnet hinge, re-inforce the right hand side hinge and patch up any holes remaining(which wasnt much).Heres a picture of the left hand side of the bulk head completed with the hinge re-attached!

and heres the right hand side done with the old hinge re-attached!

and ofcourse we re-inforced this hinge aswell by connecting the inner pannel to the outter pannel which is connected to the hinge.This way, it makes it stronger for taking the wheel on the bonnet

The bulkhead Part 3

Heres the left Footwell. Thankfully the left hand side of the bulkhead isnt as bad as the right, so it was really just small patch up jobs. Here we just did what we did with the other footwell, the rust was cut out, the measurements were taken, the steel was cut and we put the grooves in, and then patched it in with the migwelder, and this is how it looked in the end!

The bulkhead Part 2

Due to the way the old series Land rovers were made, alot of condensation used to build up behind the dash which created electrical problems in the short term and bulkhead rot in the long term. Heres how we refabricated the inside of the bulkhead behind the dash and also the footwell.

We started off by cutting all the rot out which due to its condition didnt take that long. Then measurements were taken and Francis used some 3 mil plate to do the job. After the shape was cut out, the two of us went over to the sheet bending machine and put it into shape. Thankfully theres a mig welder in the themetalbenders workshop so the plate was easily put to the bulkhead without anything being burnt through.

The result was this . . . it looks almost new doesnt it?

We decided we wanted to keep the footwell looking original so, after we had our measurements taken and our steel cut for our new piece of the footwell, we placed the sheet over an open gap the size of some round bar, on the vice.Then we hammered the round bar into the steel until the steel started to go through the gap in the vice. This gave us the groove in our new piece of the footwell which left it looking original!

The bulkhead Part 1

Look how bad it is!




















Current state of bulkhead . . . there was just so much rust and rot that the best thing to do was to just cut it all out, this corner here is the worst of the bulkhead , but youll see from the other pictures, theeeres so much more!




















As you can see, the ten years out in the field hasnt done the bulkhead any favours but on the bright side, the rust hasnt rotted through to the inside panels so its quite repairable!




















Heres a picture of the handy work of old franky! He litterally just looked at the hole, took a few measurements and disappeared! within five minutes he came back and this is what he had, its not even welded in or anything, that plate is just sitting there!





















Theres the genius at work!




















and theres the ouput! We decided that when the jeep is done that the tyre will always be on the bonnet, however even then , because of the the thin steel on the bulkhead where the hinges are placed, every time that youd need to open the hood, youd have to take the wheel off to avoid creating damage. However we have devised a simple solution, we linked the inner pannel with the outer pannel with solid steel inbetween before we put the hinge back on, making the bulkhead as sturdy as ever!

Exams

Sorry guys I havent been updating the blog, ive been at the study and doing my exams the last few months but ive been doing a good bit of work since then, Ill go through it in the next few posts, but heres just a picture to show yous just where im at!

Break and Clutch cylinders

Okay so We said wed give the clutch and break cylinders a go! Weve decided to go the whole way with this project and actually strip the landy right down to the chassis and get it galvanised so ideally, we want to be taking everything off and restoring it before it comes back around to the time where we need to put everything back on! As you can see, our bulkhead needs a bit of work but well do that some other day down the line!

Heres the clutch cylinder before we got the spring and seals actually out of it!The solution for getting them out was WD-40 , a hammer and a vice, and just go mad!You would hit it downwards against the vice until the piston gets so far, then youd turn it around, fill it with oil and then hit it back down again, by repeating this over and over again, the piston eventually works itself out and you have yourself a nice clean chamber!

the actuall pedal boxes dont need much work, just a bit of oil and a wire brush!

After we took everything out, cleaned and oiled everything, this was the end result after reassembling!

theres just a few pictures of the wire bush effect!

Off goes the rest of the body

Since we have a perfect engine, our main objective now is to strip down the rest of the body and refurbish and repair the chassis and sand-blast and zinc it so that it'll last atleast my life time anyway!

Well the diesel tank may look nice and square there, but when we took it out, which didnt take much effort, there was a massive dent on the bottom side of it.I ve been told that were just going to weld some flat bar to the dent, and pull it out, doesn't sound too complicated does it?Its funny that when we emptied the tank there was over €70 worth of diesel in it!!

Apart from that, the chassis is actually in great nick! The front half is near enough to perfect because of all the diesel that used to fall on it, and the back half is pretty much the same. The only pace that needs some attention is the rear crossmember (the back of the chassis). I think were just going to fabricate a new one, and fill in any weak spots, sand blast the whole chassis, and then paint it with zinc.

Although this may sound perfect, its still not as good as the whole chassis being galvanised,so, in theory, our chassis could still rot from the inside out, so what were going to do is, were going to screw in two holes through the back bucket and into the chassis, and were going to have two screw caps to close them and seal them. What were going to do with these is, every so often we'll pour in old engine oil into them which will keep the inside of the chassis in perfect nick. Every time I change the oil, ill pour the old oil in, that should keep everything under control!

Theres the whole exhaust system,which Im going to replace. My plan is, to buy a mild steel exhaust system for my series 3 and galvanise it, which will save me the hassle of ever having to replace the bugger again!

Heres all the bits and pieces I took off the rear bucket before we took it off the chassis!

and of course, Id just like to point out that there are some luxuries in life, you cant do without, like this good ol burner! In the freezing cold mornings, this has kept us going!!!