109 Expedition rig build

[James86004]

Tell me how you really feel. Yow! :p

One of the reasons I wanted a one-piece, strong dash plate is these 2.6-style bulkheads are a fair amount weaker than their 4-cylinder counterparts as the boxed section behind the engine is removed on this model. This bulkhead was near cracked in half between the upper and lower parts of the dash box, and the frame wasn't all that bad on this truck. This heavy plate will help hold the bulkhead rigid and with luck will keep it from cracking again.

jim
Hi Jim,

After reading this, I was wondering where I should check for cracks on my 2.6 bulkhead. I have not been able to find any.

James

[Mercedesrover]

Hi Jim,

After reading this, I was wondering where I should check for cracks on my 2.6 bulkhead. I have not been able to find any.

James

Look on the vertical part of the bulkhead just above the foot wells. Mine had a crack about 15" long on the passenger side.

[Mercedesrover]

Not much work in the past week...Me and a fellow Series owner hit the North Maine Woods. For all of you who complain about not having anywhere to go on the east coast, you're sorely mistaken. There is everything from smoothly graded gravel roads to logging trails that fade into the bush. Wash outs, river crossings, rocky terrain, etc. Without exaggeration there are 1000s of miles of roads to explore up there. It may not have the Rocky Mountains that you have in the west, but it's a very beautiful place with its own sights, sounds and smells. Plus lake trout for dinner (if you can catch one :( ).

The main purpose for the trip was to find the elusive land route into the locomotives between Eagle and Chamberlain Lakes abandoned in 1933 as well as the steam powered tramway that ceased operation in 1907. Lots of cool history in the area!

We also stopped in at the B-52 crash sight outside of Greenville.

Anyway, back to work on the 109 next week. In the meantime, here are a couple pictures from the past week.

http://www.seriestrek.com/nmw/nmw6.jpg

http://www.seriestrek.com/nmw/nmw14.jpg

http://www.seriestrek.com/nmw/nmw10.jpg

[frans]

I'm hungry for more progress pictures :beer:

[truck mechanic]

I am hungry for more trail picks, and how to get to the trains ! I am a train nut and my granddad worked for the Bostob Maine line back when it was steam.
Paul

[Mercedesrover]

Here's a link to some more.

http://seriestrek.com/nmw.html

I'm flat out right now (working on the 109) but will post more about them later.

jim

[Mercedesrover]

Here's a link to some good information about the trains.

http://www.maine.gov/doc/parks/programs/history/allagash/rr.htm

If you do a bit of a search you can turn up a bit of info from other sources. Most places say you can't reach them by foot but you can.

As interesting as the trains is the abandoned tramway that ceased use in 1907 but is still mostly in place. Very cool stuff.ye

If you spy the spit of land between Eagle Lake and Chamberlain Lake on a map you will find where these trains and the tramway lies.

[truck mechanic]

Man that is just plain cool ! I was looking to spend some time in Maine doing some fishing this summer, looks like I need to spend some time in the back woods. Thanx for the photos and links.
Paul

[Mercedesrover]

PM me and I'll give you the coordinates and the directions so you can walk down to them. It's a bit of bush-wacking but it's not too bad.

jim

[Mercedesrover]

Back to work. Got the front bumper done and ready for galvanize. There won't be a winch on this truck. Also got the dash buttoned up and all the tranny tunnel, floor panels and seat box panels painted up and installed. Waiting on the T-pillars now.

http://seriestrek.com/109/body17.jpg

http://seriestrek.com/109/body18.jpg

[DCH109]

Looking good. That Dash is starting to grow on me.
Must be nice to have suck a good Galvanizer. The ones here suck and are a bit pricey.

[revor]

Jim! It's going to be too pretty to drive!!!!!

Beautiful work as always but what's the deal with those Chrome shifter knobs? Kinda Bling don't you think?:sombrero:

[Mercedesrover]

...but what's the deal with those Chrome shifter knobs? Kinda Bling don't you think?:sombrero:

Pardon me, but they're stainless! :)

I'm going to paint one red and the other yellow so if I forget what the do I can look in the manual.

[revor]

I'm going to paint one red and the other yellow so if I forget what the do I can look in the manual.

Great minds think alike!

[greenmeanie]

Hey Jim, That's looking really good. Is that the orignal tranny tunnel or did you have to modify it?

Cheers
Gregor

[Mercedesrover]

Is that the orignal tranny tunnel or did you have to modify it?

Everything stayed the same except the last tranny tunnel on top. The hole needed to be moved back and to the right a little bit. Big truck shift boot on the way. Not sure what I'm going to do about carpet/mat for the floor yet.

[greenmeanie]

Everything stayed the same except the last tranny tunnel on top. The hole needed to be moved back and to the right a little bit. Big truck shift boot on the way. Not sure what I'm going to do about carpet/mat for the floor yet.

I was wondering about floor mats too. Don't know why as I am a long way of from that stage but I suppose you have to think of something while driving.

I have one of those molded mats in the front of my 88 and was contemplating whether it could be modified to fit. I would expect to have to cut away some of the profile at the front to accommodate the 6 cyl bulkhead and then spend soem quality time cutting making pockets in the back to accommodate the stepped plates next to the tranny tunnel. After that it is moving the gear lever hole. Using my eyeball MK1 measuring device it could be made to work but it is rather expensive item for an experiment.

I'll probably end up seeign what I can do with some horse stall matting.

Cheers
Gregor

[revor]

Stall matts are a great idea! We use them here at the shop for setting big noisy things on. i never thought of them in that purpose, I've used tractor trailer mud flaps for raw rubber stock.

[Oilburner]

That's what I have as floor mats in the 109 - almost 3/4 inches thick, very heavy and they cut noise.

[Mercedesrover]

Not sure what I'm going to do about the interior. I've got the center bulkhead and tranny tunnel pieces coming from RN. They're not really correct for a 6-cyl bulkhead but I'm hoping I can make them work. The kick-panels and floor will get something generic. Probably something from McMaster Carr. Man, I should have bought stock in that company before I started this project. I've easily spend $1k with them so far.

[seriessearcher]

I have them in the rear of my 88. The tar smell took a little while to go away but you could throw an engine block back there and never hurt it.

I will rhino line the rear of my dormobile and then see what I need to put down on top of it.

[James86004]

Not sure what I'm going to do about the interior. I've got the center bulkhead and tranny tunnel pieces coming from RN. They're not really correct for a 6-cyl bulkhead but I'm hoping I can make them work. The kick-panels and floor will get something generic. Probably something from McMaster Carr. Man, I should have bought stock in that company before I started this project. I've easily spend $1k with them so far.

That is what I did. I bought some medium soft rubber from them, which works okay. It is hard to get a good seal around the tunnel - I am thinking of making a rectangular box to go over the tunnel, which will be easier to insulate.

McMaster-Carr is a privately owned company. I wish I could buy stock in them too, I have probably spent $1000 myself, and had my employers spend well over $100k there over the years.

[Mercedesrover]

Some work from yesterday...Got the T pillars painted and installed. I also countersunk the door hinges and sent them out to be plated. I'm hoping to keep them from rusting as usual.

With the pillars in place I can build the rock sliders this week and get back out to the galvanizer. After that it's on to the tub.

http://seriestrek.com/109/body19.jpg

http://seriestrek.com/109/body20.jpg

[ntsqd]

I must say that I'm fascinated by how modular and bolt together Series bodies are. A big part of my design duty obligates me to design in modularity so that future mods to accommodate new tests are fairly simple to incorporate. So I tend to be studious of how others have implemented this mentality.

Do old trucks sound like a herd of squeaks going down the road? I can see the potential, but I can't say that I've ever read that complaint - at least not any more so than any other brand.

[revor]

More rattles than squeaks. That's only after a few hundred thousand miles..

Once again Jim Great work!!! But is that a Chrome (sorry SS) exhaust tip I see coming out in front of the left rear tire?

[Mercedesrover]

Why, yes it is a SS pipe you see sticking out! But hey, I can get away with it as the entire exhaust system is SS. If I really wanted this thing to be a sleeper I should have welded a rusty old chunk of used exhaust pipe on the end! :)

[Michael Slade]

You should make a bolt-on rusty tip for when you go to car shows and rallyes. It would be pretty funny.

Again, speechless. Just beautiful.

[revor]

You should make a bolt-on rusty tip for when you go to car shows and rallyes. It would be pretty funny.

Again, speechless. Just beautiful.

HA HA !!! That would be classic! Just find a piece of tubing that slips over nicely and put it in the dogs favorite "hydrant" in a couple weeks rinse and install!

I want to know where you are obtaining all the time required to do this job! Is there a special store where I can buy some? It's probably very expensive!

[Mercedesrover]

I want to know where you are obtaining all the time required to do this job! Is there a special store where I can buy some? It's probably very expensive!

I steal if from my wife. She's a very understanding girl and I'm lucky to have her. Building this 109 was all her idea to begin with anyway. Something tells me she has plans for the back seat and what you remember from high school ain't it!

Seriously though, it's parked right outside my office window and I spend 2-3 hours on it every night after work. And by that I mean EVERY night Monday thru Friday. I'm here until 6:00 every night. I even came in and spend 4 hours on it Saturday.

[revor]

Dedication.. Nice.. I normally come home from work and I'm in the shop till 9:30 (I get a Dinner break) I infrequently get to work on my own stuff though.
It's getting better though..

[Michael Slade]

I steal if from my wife.

You're probably really just *borrowing* it from your wife. I'm sure you'll pay her back.

[Mercedesrover]

OT but what do you do for work, Kevin?

I work in a fairly large collision repair shop handling claims, problem solving for the guys on the floor, etc.(when I'm not posting here). It's a pretty modern shop with lots of cool toys. A perfect place to rebuild old Rovers.

[Mercedesrover]

You're probably really just *borrowing* it from your wife. I'm sure you'll pay her back.

I'm sure you're right. Payback's a *****.

[Crazyfish]

I'm just waiting to see how the tub goes on with the t-pieces and the seat box bolted in.

[Mercedesrover]

I'm just waiting to see how the tub goes on with the t-pieces and the seat box bolted in.

Something tells me I'll figure it out....


At most I'll need to remove the two bolts I have in place at the back of the seat box and lift it up an inch or so.

[24HOURSOFNEVADA]

Again, this is just awesome. I hope one day our paths may cross so I can see this in person and shake your hand.

[Mercedesrover]

Repairs to the tub begin....

The floor is shot as are the rear tail-light panels, all the x-members and the front toe-board pieces. I've gotten new x-member galvanized, new tail light pieces on the way and a fresh sheet of .080 6061-T6. Guess I know what I'm doing for the next week or so.....

http://www.seriestrek.com/109/tub1.jpg

http://www.seriestrek.com/109/tub2.jpg

[TeriAnn]

Repairs to the tub begin....

The floor is shot as are the rear tail-light panels, all the x-members and the front toe-board pieces. I've gotten new x-member galvanized, new tail light pieces on the way and a fresh sheet of .080 6061-T6. Guess I know what I'm doing for the next week or so.....


Don't forget to put the access holes for connecting the fuel lines to the top of the fuel tanks. There are 2 holes & cover plates used so you can connect/replace hoses, electrical connections & fuel sender unit without dropping the tank.

Of course you can make the whole rear part of the floor removable for even better access.

Just a reminder

[Michael Slade]

Of course you can make the whole rear part of the floor removable for even better access.

A good reminder. I think I'd do what TeriAnn is suggesting.

[Mercedesrover]

Don't forget to put the access holes for connecting the fuel lines to the top of the fuel tanks.

These holes?

http://www.seriestrek.com/109/tub3.jpg

[Michael Slade]

These holes?

Looks like you're going stock. Nice.

You going to put in a new strip on the rear lip for the bolt holes?

[Mercedesrover]

You going to put in a new strip on the rear lip for the bolt holes?

Yeah, that will get replaced as well as that rusty x-member you see in the photo as well as everything else up front. I want to get the floor and the 5 x-members in place and locked down permanently before I cut anything else off the tub. There's not much holding it together at this point!

[Michael Slade]

While you have the tub off, you might consider putting some recessed tie-downs in the corners. Way back in the day when I had my 109 I thought about actually having them made and sell them. I have an idea scribbled on a napkin if you want to see what I was imagining. You can probably pretty much guess what a pocket and a piece of bar at the corner would look like. ;)

[ttravis5446]

The quality of this build is amazing to me.

[Crazyfish]

take alot of pics please, my tub is in the same place. Love watching your progress. Any reason not to use check axle straps as the buffer between the supports and the frame?

[I Leak Oil]

Any reason not to use check axle straps as the buffer between the supports and the frame?

That's what I did with my check straps when I took them off. Works great!
Jason T.

[TeriAnn]

These holes?


That's them! Of course you would not forget this minor but important detail :)

looking good!

[Mercedesrover]

Of course you would not forget this minor but important detail :)

Don't be so sure!

[locrwln]

I know it has been said numerous times, but awesome work.

I am addicted to this thread like some kind of drug. Loving the work, ideas and execution.

Keep it up (just faster please, to feed my addiction):chowtime:

Jack

[Mercedesrover]

Some more work on the tub in the past few days....

Bonded and riveted the three lateral supports and the two tabs that hold the trap-doors down. After that the floor was again bonded and riveted to the inner fender wells. In "bonded" I mean 3M #8115 panel bonding adhesive. Very strong stuff and will keep any water out of the seams. For rivets I used counter sunk aluminum rivets with coated steel mandrels from McMaster Carr.

After the floor was in for good I fabricated the "heal" board and the little floor fillers, end caps, etc. that make up the front of the tub. These will get bonded and riveted tomorrow night. After that I'll flip it over and move to the rear. I have a good used rear sill that needs to be installed along with new end panels. From there the whole underneath will get painted. The five X-members have been galvanized and won't go on until the underside is painted.

Anyway, here are some photos. One more night's worth of work tomorrow and then we're off to Alaska for a couple weeks. More photos when we return.

http://seriestrek.com/109/tub4.jpg

http://seriestrek.com/109/tub5.jpg

http://seriestrek.com/109/tub6.jpg

http://seriestrek.com/109/tub7.jpg

[stevenmd]

Words cannot fathom how impressed (and jealous) I am of your skills. I follow this thread like I follow my favorite sports team. Pure excitement. Geez... am I OK?:confused: :xxrotflma

[4Rescue]

Holy great work and fab skills batman!!!! I'm really impressed with the build man, well done.

Cheers

Dave

[Crazyfish]

Wow.... On mine, the tub supports seem to bolt to the tub sides, there are 1/4" holes both in the old floor, the tub sides and the supports. I was going to bolt through the floor 8 bolts per side - not pretty but I thought I would need it. Also, I am putting the floor pan on last, as I was thinking everything else would line up. It is an original tub but not to this frame or body.

I riveted the lateral supports to the tub supports, but I forgot to but something between the two. Riveted with alum rivets. Do you think this will be a problem? I get anxious to make progress and sometimes rush things.http://gallery.roversclub.org/displayimage.php?album=lastup&cat=10004&pos=3

[Mercedesrover]

There's no reason that won't work. The only thing with doing it this way is the steel tub supports won't be attached through the tub floor.

I'm going to have the floor all fastened in, sealed and painted before I put the lateral supports in. My supports are now galvanized and I don't want to paint them. I figured that sealing and painting the tub first and then attaching the supports will help keep them appart.

Are you going to run your bolts through the floor pan or cut slots in the pan and drop it in around it?

Riveting your supports like you have shouldn't really be a problem, especially with aluminum rivets. I wouldn't worry about it.

Anyway, not much progress for the next couple weeks. In Anchorage for a backpacking trip and perhaps to drop in on Alaska Mike while we're here.

[viatierra]

Life in Phoenix during July is so hot, just existing is torture. Each day you have to find a reason continue, inspiration to survive another day...

I'm begging for a bone here. I'm at the end of my rope!!

[Oilburner]

Hey,

Sorry to hijack your buildup, but this will probably apply to your 109 as well, so here goes:

What material did you use as a headliner in your 88? It looks like carpet glued to the ceiling, and it actually looks really good. All the other glued-down carpet setups I have seen looked horrible. Just wondering what you used, both your rigs are very clean.

[Mercedesrover]

Life in Phoenix during July is so hot, just existing is torture. Each day you have to find a reason continue, inspiration to survive another day...

I'm begging for a bone here. I'm at the end of my rope!!

Sorry, Viatierra, just back from a couple weeks in Alaska. I'm back on the truck now and will post a couple pictures tonight to get you thru. Nothing too exciting, just some more work on the tub.

[Mercedesrover]

Hey,

Sorry to hijack your buildup, but this will probably apply to your 109 as well, so here goes:

What material did you use as a headliner in your 88? It looks like carpet glued to the ceiling, and it actually looks really good. All the other glued-down carpet setups I have seen looked horrible. Just wondering what you used, both your rigs are very clean.

I used gray felt from McMaster Carr glued over 1" closed-cell foam, also from M.C.. It works pretty well and really helps cut the noise down. I didn't use strong enough glue and a couple spots have started to sag over the years. I'll probably use a heavy brush-on glue when I do it in the 109.

[greenmeanie]

Life in Phoenix during July is so hot, just existing is torture. Each day you have to find a reason continue, inspiration to survive another day...

I'm begging for a bone here. I'm at the end of my rope!!

Tell me about it! Now we have the heat and the humidity. I've even got my wife thinking about getting out. I just about killed myself the other weekend welding in my garage. Even although I was drinking lots I got to the point of having the shakes pretty badly.

I agree though - more pictures Jim. I'm needing inspiration for my 109 build too. I've been getting diverted into the world of hotrods looking at lump port heads for my 292.

Cheers
Gregor

[ntsqd]

3M makes a headliner specific adhesive. I've used it and comparable products from auto upholstery suppliers with good results.

[DCH109]

Tell me about it! Now we have the heat and the humidity. I've even got my wife thinking about getting out. I just about killed myself the other weekend welding in my garage. Even although I was drinking lots I got to the point of having the shakes pretty badly.

Cheers
Gregor

That feeling i know.
Due to heatstroke last month i decided to hold off doing much on my rover until the temp are in the 80s. The last few weekends VA has been brutally hot.

Jim looking forward to seeing more on the build.
Myself i have used the 3M glue in the past and it has held up real well. This is the spray on glue that comes in the cans, and i put a thick coat on to make sure.
Are you going to do anything to the tub. Line-X style like Firemanshort did?
or you going to just paint it (i might have missed that post)?

[Mercedesrover]

Work from the past couple nights....

Got the new (used) rear x-member in and done. It's a used one off of the original tub from the truck. This is a different tub that I'm using and it's had some work done to the back including replacing part of this x-member once. It had been sectioned with a couple extra brackets holding things together, and not very well. This x-member isn't perfect but it's not bad and still better than trying to reproduce it from scratch.

From there I drilled out and removed the old end-panels, cleaned everything up and test-fitted them. They're aftermarket panels but they fit pretty well. Drilled everything, applied a good coat of 3M panel bonding adhesive, set 'em on and riveted everything tight. I would have rather not used rivets on the outside surfaces, and probably didn't really have to, but I'd rather the body strong than pretty. From here I'll fix the few dents in the sides and prime them up, prep and paint the floor before installing the steel floor supports and then I'll paint the inside. It'll go on the truck before the outside is painted so I can install the dog-legs and paint them along with the rest of the tub sides.

Anyway, a picture is worth 1000 words.

http://seriestrek.com/109/tub8.jpg

http://seriestrek.com/109/tub9.jpg

http://seriestrek.com/109/tub10.jpg

http://seriestrek.com/109/tub11.jpg

http://seriestrek.com/109/tub12.jpg

[Mercedesrover]

Some more work from the past week. The tub is together finally...Wish I could have found a better one. Anyway, did the bodywork on the sides and got them primed, then flipped it over and prepped, etch-primed, chip-guarded and painted the underside. Installed the galvanized x-members tonight. I'll flip it over and paint the inside in the next couple days. After that it can go on the frame, get the dog-legs attached and paint the outside. This tub has been a long haul and I can't wait to be finished with it.

http://seriestrek.com/109/tub13.jpg

[EricWS]

Jim,

Did you spot weld or rivet the body? Just curious if you were able to get a road map of the spot welds from the tear down.

ES

[Mercedesrover]

Jim,

Did you spot weld or rivet the body? Just curious if you were able to get a road map of the spot welds from the tear down.

ES

I have a fairly large resistance spot welder and it works very well on steel, but it just doesn't have the amps to weld aluminum. Some of these welds are a long way from the edge so it would take a good size machine to reach them anyway.

No, everything was riveted and glued back together. As strong or stronger then spot welds and the glue seals the joints.

The side panels were good enough so the spot welds are still visible after the body work.

[Michael Slade]

Looking good. Thanks for rescuing me from myself bitching about Subaru commercials.

[Mercedesrover]

Finished painting the inside and outside of the tub. I ended up painting the outside off the frame and sitting in on ready to go. No big deal getting the T-pillars inside the bed.

Anyway, I'm glad to be done with that piece and again some real progress can be made. Still shooting for a November 1st launch date. We'll see!

http://seriestrek.com/109/tub14.jpg

[24HOURSOFNEVADA]

Anyway, I'm glad to be done with that piece and again some real progress can be made.

http://seriestrek.com/109/tub14.jpg


"Real progress" HaHa, too funny. You've been making really excellent progress since you started.:beer:

[Crazyfish]

No big deal getting the T-pillars inside the bed.



You're smarter than I am :) For some reason that was a ***** for me.

[greenmeanie]

Jim,
Did you buy those wee panels that make up the fron of the rear wheel arch panels new or just reuse the originals? After reading Crazyfish's post ove ron G'n'R I had to nip out in a thunderstorm and fish around in the recycling bin for my holy old ones. RN screwed me senfding the 110 ones instead.

She's looking good there. This week I'm welding in the new footwells on my project. I also ordered the NP435 adapter from Ike. Taking it a bit slower than yourself I think.

Cheers
Gregor

[Mercedesrover]

You're smarter than I am :) For some reason that was a ***** for me.

I'm lucky enough to have a shop full of guys to help me with stuff like lifting tubs into place. That helps a great deal. I unbolted the back of the seat box and lifted the back of the T-pillars and stuffed a couple of blocks under the box. Then three guys got on the tub and one guy on the back of each pillar. We "twisted" the pillars inward, slipped the tub by them and it dropped right in. It was a little tricky but worked out fine. It would, however, be pretty impossible to do it this way without a bunch of help.

I also took the time to apply pieces of heavy stone-guard tape on all the surfaces where aluminum and steel meet. At the rear frame tabs, where the T-pillars meet the tub on the sides and the floors, etc. I'm hoping this barrier will slow down if not stop any corrosion that creeps up in these areas.

[Mercedesrover]

Jim,
Did you buy those wee panels that make up the fron of the rear wheel arch panels new or just reuse the originals? After reading Crazyfish's post ove ron G'n'R I had to nip out in a thunderstorm and fish around in the recycling bin for my holy old ones. RN screwed me senfding the 110 ones instead.

She's looking good there. This week I'm welding in the new footwells on my project. I also ordered the NP435 adapter from Ike. Taking it a bit slower than yourself I think.

Cheers
Gregor

Those panels came with the truck. They were among the few new things that the PO had purchased before getting rid of the project to me. They're new but without any markings. Not sure if they're aftermarket or original but they seem pretty nice.

Be careful welding down there in that heat!

[Overland Hadley]

Looking good!

[Mercedesrover]

Doors fitted. They'll come off and get prepped and painted Monday or Tuesday.

http://seriestrek.com/109/body26.jpg

[Michael Slade]

Looking gooder and gooder all the time!

[TeriAnn]

Looking gooder and gooder all the time!

Yeah! If you not careful you may find yourself needing to go out and start collecting horizontal scratches in that lovely new paint.

http://www.tjwakeman.net/1thumb-up.gif

.

[revor]

TeriAnn Has a good point!! It's almost too pretty!

You'd think you were building a Copely truck!

Nice work Jim!!!

[Alaska Mike]

After meeting Jim and Wendy, I'm fairly sure they don't have a problem with a few brush scrapes. If I owned that rig and put the effort Jim has into it, I certainly would. I would probably build another garage for it complete with velvet ropes.

[Mercedesrover]

Nope. Like the 88" I'm building this truck to use. It'll take a trip next summer and if I have my druthers it'll be the Trans-Labrador highway if the third leg is open by then.

No fun in just looking at them!

By the way...Good to meet you, Mike. Maybe next time we're up there it'll be in this truck!

[ntsqd]

I like how it's starting to look. Having been around (but not directly involved with) the rebuilding of a 100 point Pebble Beach Concours vehicle, your effort lacks nothing.

I note that few if any LR folks paint their galvanized parts. Is that because it's an issue to make the paint stick, or is the required prep somewhat diminishing of the reason for it in the first place?

[Mercedesrover]

I like how it's starting to look. Having been around (but not directly involved with) the rebuilding of a 100 point Pebble Beach Concours vehicle, your effort lacks nothing.

Thanks, but, I've seen a 100 point car. I even know a blind guy that built the only 100 point XKE. This is no 100 point car, though it'll probably take me 100 six-packs to build it. :beer:

[ntsqd]

True, 100 point cars are art on wheels and not something you actually drive (My Heavens!), but your level of effort & thoroughness isn't far off.
Now if there were two or three of you working on it.....
I wonder what the PB judges would do with a potential 100 point Series? Would they even have anyone qualified to judge it? LOL.......

[viatierra]

http://seriestrek.com/109/body26.jpg

My oh my this rig looking fantastic!
:26_34_3:

[Mercedesrover]

Been slacking with the photos. Not really a whole lot to show anyway.

In the past week or so:
Seats installed. (yes, I sewed them myself. Sally.)
All the rear lights including an LED in the PTO whole.
All the floor boards painted and bolted in.
Lots of little fiddley bits taken care of.

I got the roof sides apart tonight and will be working on them and the roof for the next week. By next Friday I hope to have all that stuff painted and installed as well as the rear door painted and hung. We'll see!

I'll snap a couple quick picks in the morning for you.

[Michael Slade]

what do you plan to do for the headliner? I did Rhinolining on the CrewCab, but I'm not sure I'd recommend it. I thought it would absorb sound, but I think it really just reflects it. I don't have any other headliner other than the RL.

[Mercedesrover]

Same as the other truck....

http://www.seriestrek.com/headliner.html

[frans]

Been slacking with the photos.

I know I have been hungry for your pictures!


I got the roof sides apart tonight and will be working on them and the roof for the next week.

does the roof panel separate from the front slanted/curved section over the driver?

[Mercedesrover]

Pictures from this morning.

http://www.seriestrek.com/109/body29.jpg

http://www.seriestrek.com/109/body30.jpg

Home made seat covers.

http://www.seriestrek.com/109/body31.jpg

[revor]

"we're not worthy !"

[Mercedesrover]

"we're not worthy !"

Oh, please! If a dumb-arse like me can do this, anyone can.

[Hltoppr]

The build just keeps getting better...makes me want to give in and turn to the dark side...black oval that is....

-H-

[Overland Hadley]

Pictures from this morning.
http://www.seriestrek.com/109/body30.jpg



She is a beauty!

[revor]

Oh, please! If a dumb-arse like me can do this, anyone can.


I know I can do it, I've spend plenty of time 'primer,sand,primer, sand, primer sand, primer, sand then.... Paint..
I just don't have the time (and I suppose patience) these days, there really needs to be 32 hours in a day!

It's just looking great!

Well and I had to get the Wayne and Garth thing out of my head.....

[Mercedesrover]

'primer,sand,primer, sand, primer sand, primer, sand then.... Paint..

Not on this thing. It's a Rover. 320, seal, paint.

But I've been there with the sand and block. The straightest car I ever did was a Camaro project I did the body and paint work on for Popular Mechanics. Hate to brag but that car was pretty nice.

http://media.popularmechanics.com/images/tb_0012AURESTOREWFGB-LEAD.jpg

[I Leak Oil]

Pictures from this morning.


http://www.seriestrek.com/109/body30.jpg


Ummmm.....Jim.....There's no provision for the tire on the hood.....Now that's just not right! :violent-smiley-031:

Looking Good!
Jason T.

[Mercedesrover]

Ummmm.....Jim.....There's no provision for the tire on the hood.....Now that's just not right!

I've got a second hood. This truck is the same color as my 88" so I can swap them back and forth. :)

[TeriAnn]

Ummmm.....Jim.....There's no provision for the tire on the hood.....Now that's just not right! :violent-smiley-031:



The term is bonnet, a hood is a canvas top. Some people just have a hard time with the English language :) ;)

Actually it is best not to have a bonnet mounted spare tyre when performing technical trail work. You need every bit of forward visibility you can get. For technical trail work a rear (up high) mounted spare or inside mounted spare is best.

Whenever the trail gets a bit sticky I always wish I had my spare on a rear swing away.

[flyingwil]

WOW! Looking really good!

[marke]

Truly awesome build! Your quality and skills are unbelievable!

[4Rescue]

I'm sure you've explained this, but there are lot of pages to this thread now so I'll just ask:

Didi you use a series-1 Grill/light assembly and a SII or whatever fenders/lights, or is there a series of Rovers that have both sets of lights like yours? I don't know alot about the various series, but I thought SI had lights between the fenders and the SII moved them out the the fenders them selves. Whatever the case, I like how your's has both. All the added light of some Off-road lights but in a stock mounting location that doesn't block the radiator flow, awsome.

Love the truck.

Cheers

Dave

[Mercedesrover]

The truck is a Series "IIA" which is supposed to have the lights in the radiator support (breakfast) only. Late Series "IIA"s and Series "III"s had headlights in the fenders (wings). The IIA fenders with no headlights are not easy to find and as I already had a set of III fenders I went this way. I also want this truck to look like the 88" which also has the headlights in this configuration. Most purists don't like this look but it has its advantages. Like you said, it gives me a second set of lights in a stock location and they don't stick out, get in the way, get hung up on brush like driving lights hanging off the bumper.

This is the 88. The 109 will is the same color.

http://www.seriestrek.com/labrador/lab11.jpg

[4Rescue]

Thanks for the lesson mate. Like I said, I really like the way yours is set up because of the previously mentioned reasons. Puristys be damned, they probably LIKE the locas electrics to eh ;) I'm getting a bit of the Series Rover bug eh.

Cheers

Dave

[Mercedesrover]

I'm getting a bit of the Series Rover bug eh.

There's a shot you can get. Should cure you if it's not too late.

[KevinNY]

I can't wait for you to get this on the road to see how your gearing combo works for you. Your motor should have more HP than mine, but with the added weight of it being a 109 it may be pretty close. It would seem the 2-3-4 ratio gaps might be a bit wide especially with the 4.10s and HRTC. We'll see I guess. Of course we can always trade my late Santana Series III gearbox for the NP435 if you need to:D .

[Mercedesrover]

I can't wait for you to get this on the road to see how your gearing combo works for you. Your motor should have more HP than mine, but with the added weight of it being a 109 it may be pretty close. It would seem the 2-3-4 ratio gaps might be a bit wide especially with the 4.10s and HRTC. We'll see I guess. Of course we can always trade my late Santana Series III gearbox for the NP435 if you need to:D .

I'd be lying if I told you I wasn't a little nervous too! At worst I'll put the 4:56 gears out of the 88 into this truck and re-gear these to 4:88 for the 88. But of course I'm hoping I won't have to do that.

Hey Kevin, you going to Guy Fawkes?

[Mercedesrover]

Work from Friday night. The one dent fixed in the roof, holes for the sunroof and alpine windows cut out. Hoping to have it in paint before I go home tonight.

http://www.seriestrek.com/109/body32.jpg

http://www.seriestrek.com/109/body33.jpg

[KevinNY]

Hey Kevin, you going to Guy Fawkes?

What are the dates? I have Moab in 2 weeks and this years Trans Vermont in October. Somewhere between them I am supposed to be moving house too.

[Michael Slade]

Sa-wheeeeet!

[4Rescue]

There's a shot you can get. Should cure you if it's not too late.
HAHAHAHAHAHA.

[laurie-the-lorry]

Hat's off to you Sir!

I started reading this thread almost 12 months ago, at the time I was mainly lurking around and hadn't really posted.

After another trip of our own (Without much internet connection) I returned to the forum a month or so ago!

I have just spent the last hour reading through this thread! What a wonderful job, the patience and attention to detail is Soooo commendable!

I salute you Sir that's one fine truck you are near to completing. Thank you so much for sharing.

[Mercedesrover]

Some progress from the past few days.

Roof sides painted, assembled and on the truck.
Installed the headliner tonight. Tomorrow I'll install the alpine windows and the sunroof. Thursday I'll set the roof on the truck and start fine-tuning the doors. That sounded funny as I typed it....Fine-tune the doors on a Land Rover. As long as you can't throw a cat through the gaps you're good.

http://www.seriestrek.com/109/body35.jpg

http://www.seriestrek.com/109/body36.jpg

http://www.seriestrek.com/109/body37.jpg

[Lynn]

You know, I upset some folks a long time ago on this board when I said, "Personally, I wouldn't drive a Defender if you gave it to me," but I would like to now append "unless it was one of the ones custom crafted by Mercedesrover."

I've only known one other person who rebuilt classics with the care and attention to detail you have displayed.

True artisans, with an obvious passion that most of us lack.

Thanks for sharing the journey.

[Mercedesrover]

Got the roof on a day ahead of schedule and started fitting things. Should have all the posts, doors, etc. where they need to be by the end of tonight. Then I just need to paint and assemble the 5 doors. I'm hoping to be driving this truck next weekend? We'll see!

http://www.seriestrek.com/109/body38.jpg

http://www.seriestrek.com/109/body39.jpg

[01001010]

I'll be honest and say I havent read through the whole thread but have you fired the engine up already? May I request a youtube...I'd love to hear someone else's diesel 109 fire up, since I had to sell mine.

[DCH109]

Jim it is looking great. have to say it is one of my favorite builds happening right now.

I have a question on the engine and the Parabolics.
You have the RN parabolics correct?
The 5 Cyl diesel is about 740+ lbs with everything attached. How is it holding up on the 2 leaf front springs?
I am now (3rd engine change) dropping a 6.2 L diesel into mine. It is about 750 lbs with everything attached.

I know your has not moved much other then around the shop and outside. but have you noted any sag yet? How about on the 88, did it have the 2 leaf Parabolics as well? how is it for sag.

Before i dump mine, i wanted someone with a nice heavy engine and real world experience, to see how they are holding up.
Let me know
Dave

[Mercedesrover]

I'll be honest and say I havent read through the whole thread but have you fired the engine up already? May I request a youtube...I'd love to hear someone else's diesel 109 fire up, since I had to sell mine.

Yup, it runs and drives though I haven't hit the open road with it yet. Might just throw a dealer plate on it tonight and run up to the package store.

I'll try and get some audio for you in the next couple days. It's very, very quiet (especially compared to my 88 with the 616 engine) and I'm regretting putting a muffler on the truck at all. It would have probably been fine with just a straight-pipe.

[Mercedesrover]

I have a question on the engine and the Parabolics.

Yes, I have two-leaf RN springs in the front of this truck as well as the 88". The 88 also has a winch on the front.

No, I haven't noticed any sagging in the little truck and they seem to be just fine. I did bend one of the original RM front springs about 5 years ago and replaced them with RN fronts. The rears in the little truck are still 3-leaf RM springs and haven't sagged enough for me to notice.

As well with the new truck, though it's only had the weight on it for a few months, nothing seems to have moved. I still haven't tightened the shackles up until the truck is at full weight.

I have 4-leaf rears in the new truck and am hoping it's not sprung too heavy. Time will tell. At worst I'll have to peel one leaf off of it.

Some people really hate parabolics for some reason. I wouldn't think of putting anything else under these trucks.

New picture...Couldn't resist.

http://www.seriestrek.com/109/body40.jpg

[DCH109]

Hey nice to see it out of the Shop. I think the galvanized sliders and bumper look great.....How do you like those Mirrors on the wings?


Thanks Jim on the Parabolic info. I think i will give it a shot then and see how it goes. I really do not want the ride the 1 ton spring will give.
The GM 6.2L and the Mercedes 5 cyl are about the same weight with all accessories. Hard to believe but that would explain the stoutness of the MB engine. That block is heavy.
As your runninga 5cyl and that 4cyl with a winch and you have not seen any sag...i figure i should be ok.

I think with the 5 door and loaded the 4 leaf will be fine, you might find it hard when empty, but loaded......My 3 door should be ok with the 3 leaf, but if they suck then i will switch......

[01001010]

Jim...

You're the man! I can't wait to see the truck moving through its natural habitat. I really do hope to droul over this truck in person some day. I'll bring my own rag.

Also, I can't help asking...

Is that an LED brake-light in the PTO opening at the rear cross member?

[Mercedesrover]

Is that an LED brake-light in the PTO opening at the rear cross member?

Back-up light! I went with an LED so I can leave it on as a camp light when the truck is parked at the campsite.

[01001010]

Niiice! Brilliant!

[greenmeanie]

Jim...

I really do hope to droul over this truck in person some day. I'll bring my own rag.




Oh don't worry about the rag. Everything that could possibly be galvanised/painted/plated or otherwise corrosion proofed is.

No jealousy here. I think the wing mirror probably just fell off my project while it sits mouldering in my garage.

[Mercedesrover]

With the headway I made last night I'm further along this week than I hoped to be.

A funny thing happened when I was putting this truck together. As I was bolting the body pieces on one by one the truck had a funny look that its "back was broken". That's a term we use when dealing with frame damage on a collision in a full-frame truck. It's when the center of the frame has a sag in it, either on one side or both. Well, as this truck was coming together it had the same look. It appeared the center was low or the ends were high. Setting the roof on last night confirmed this. Both the center pillar and the front of the roof sides appeared low when you were looking down the truck. I ended up unbolting the back of the seat box and the front of the tub and jacking the center of the body up. When I did this everything seemed to drop in place. With this, however, the bolt holes from which I just removed all the body mounting bolts were off a bout 3/4". I ended up re-drilling the holes in the body and bolting the truck to the frame thru the new holes. I don't know if the frame was built wrong or if a Stage One frame is a little different than the standard Series truck in terms of body mounting but this did the trick. The doors and roof fit well now and I can move on.

With the quick hour it took to reposition the body on the frame I had time to get the 5th door hung and the hinge holes drilled. Fits pretty well. Next step is to remove all 5 doors, change around the door-check mounts and prep and paint them. The goal is to have all five doors hung with latches and glass by the end of next week. We'll see.

http://www.seriestrek.com/109/body41.jpg

[traveltoad]

Back-up light! I went with an LED so I can leave it on as a camp light when the truck is parked at the campsite.

Is it a sealed unit?

[ntsqd]

Even the non LED versions of those 4" torsion mount (rubber grommet) lights are sealed.

Why no paint on the galv'd parts? The look (which I like), or is there an adhesion issue with galv?

[Mercedesrover]

Why no paint on the galv'd parts? The look (which I like), or is there an adhesion issue with galv?

There is a bit of an adhesion issue painting galvy stuff but it can be overcome. I did actually paint some of the galvanized stuff on the 88 but this truck I wanted to leave it as it's supposed to be. I don't mind the painted look either but some people really have an aversion to it.

[ntsqd]

Clarification: I like the mixed surfaces (painted & galvanized) look.

[kevb]

Very nice, you must be well pleased with your progress.:bowdown:

[pint]

WOW! Just wow...great work!

[Overland Hadley]

http://www.seriestrek.com/109/body41.jpg

Looking really good!

Now that the roof is on, can we see a photo from the front? (And from the side, and another from the rear!)

[kevb]

The truck is a Series "IIA" which is supposed to have the lights in the radiator support (breakfast) only. Late Series "IIA"s and Series "III"s had headlights in the fenders (wings). The IIA fenders with no headlights are not easy to find and as I already had a set of III fenders I went this way. I also want this truck to look like the 88" which also has the headlights in this configuration. Most purists don't like this look but it has its advantages.
http://www.seriestrek.com/labrador/lab11.jpg

Surely even the most die hard purist would have to acknowledge the quality of this build! I am not normally a fan of this set up (maybe a result of seeing too many shoddy conversions here) but I do like what you are doing.

There is another quality ser11 build going on here....

http://forums.lr4x4.com/index.php?showtopic=18520

What is it with you North Americans and series trucks?:) :)

[Michael Slade]

Feels good don't it! :D

[Mercedesrover]

Feels good don't it! :D

It'll feel good in a couple of weeks when its done!

[frans]

It'll feel good in a couple of weeks when its done!

I bet it will! Like a new pair of boots, I bet you get a scratch in it real quick!


Could you tell me about the hinges on the rear door? I am wondering why the one at the top is different than the others. Is there a strength reason or what?

[Mercedesrover]

Could you tell me about the hinges on the rear door? I am wondering why the one at the top is different than the others. Is there a strength reason or what?

It's just longer because the edge of the door isn't straight. It curves in a bit at the top and as such needs a longer hinge.

[frans]

Thanks

[preacherman]

Looking good. I cannot wait to see it finished!

[Mercedesrover]

Got the last of the paint work done last night. From here it's fitting the five doors and getting the latches, glass, door checks, etc. together. Getting close to the end here. I still need to fabricate some fender splash shields and do a final bleed on the brakes but I might just drive this home this weekend. We'll see....

http://seriestrek.com/109/body42.jpg

[Hltoppr]

Amazing work! I can't wait to see the final product!

-H-

[Mercedesrover]

Well, it's not quite done, but close enough to take a couple more pictures. The list of things to do is getting shorter by the day. I need to install the windows in the rear doors, bleed the brakes and make the splash shields for the four fender wells. Two more nights and I should be coming home.

http://www.seriestrek.com/109/done1a.jpg

http://www.seriestrek.com/109/done2a.jpg

[Overland Hadley]

:bowdown:

Good work!

[N8URE2]

Amazing !!!!
I've been following this from the start, It's great that this thread was started 09/21/07 and here we are 09/25/08 AND THAT THING IS BEAUTIFUL!

:bowdown:

[Mercedesrover]

Thanks.

Thought I'd post a before and after....

Before:

http://seriestrek.com/109/2.jpg

After:

http://seriestrek.com/109/done1a.jpg

[01001010]

Wow wow wow....

GREAT WORK!!!

[greenmeanie]

Jim,
So when's the first big adventure planned ?

So now you're about done you'll not know what to do with all that spare time - how about a trip to Phoenix to keep your hand in? I've just about finished all my bulkhead and control mods so I'm now inspired to go and pull the engine and gearboxes.

Cheers
Gregor

[Mercedesrover]

Jim,
So when's the first big adventure planned ?

So now you're about done you'll not know what to do with all that spare time - how about a trip to Phoenix to keep your hand in? I've just about finished all my bulkhead and control mods so I'm now inspired to go and pull the engine and gearboxes.

Cheers
Gregor

Sorry I haven't answered your latest email. 6:00am mornings and 8:00pm evenings at work make for a short night!

We're talking about that now. Maybe a trip around Lake Superior. More scenic than remote but it looks like it could be fun.

I was telling Wendy last night that I'm going to be a little depressed when I'm finally done with this truck...Like kidnapping victims forming a bond with their captors. I'm sure I'll get over it. Besides, I get to drive it around now!

Call me around February 15th and I'm sure I'll be up for a trip to Phoenix. They have beer in Phoenix, right?

Speaking of beer, I was wondering how many beers it took to build this truck. I'm thinking at least 1000.

[Christian P.]

wow CONGRATULATIONS.

Almost a year to the day. This is quite an accomplishment.

[KevinNY]

If you get bored Jim you are welcome to refresh my bulkhead for me so we can paint the Goat Sandglow this winter.:)

[mtnbike28]

The before and after pics are great! Congrats

[Hltoppr]

Now what you want to do is trade it for a Troopy....:sombrero:

Can't wait to see this thing in person sometime! What a great build, solid attention to the details that will make it very reliable, and keeping with the classic lines!

-H-

[24HOURSOFNEVADA]

Congratulations and thank you. I've enjoyed watching and learning as this has come to completion. Most impressive.

[viatierra]

Fantastic job! You have the skills and now a second rig for us all to envy. Now crack open #1001...

:friday:

[troy]

Speaking of beer, I was wondering how many beers it took to build this truck. I'm thinking at least 1000.


My wife once asked me to estimate how much I've spent on beer for a project I'm working on. I told her there are some things you do not discuss.

Your project looks great!

Troy

[nickw]

Jim,
Great job man, really impressive.

I am surprised nobody has asked this yet, but how the does it drive? I have been waiting to get a drive report on this thing for a year, I really want to know how the tranny/engine combo works for you.

Are you going to keep the 88" or get rid of her?

[greenmeanie]

My wife once asked me to estimate how much I've spent on beer for a project I'm working on. I told her there are some things you do not discuss.


Troy

To paraphrase fromthe aviation industry "When the beer budget exceeds the project budget the truck will drive."

[Overland Hadley]

We're talking about that now. Maybe a trip around Lake Superior. More scenic than remote but it looks like it could be fun.


Let me know if you come this way! (I am on the North Shore)

[Mercedesrover]

Jim,
Great job man, really impressive.

I am surprised nobody has asked this yet, but how the does it drive? I have been waiting to get a drive report on this thing for a year, I really want to know how the tranny/engine combo works for you.

Are you going to keep the 88" or get rid of her?

Well, I took it for a short drive this afternoon. I really need to put a few miles on it but I'm afraid I bit off more than I can chew with the 4.10s. it feels too tall to me. Of course I've driven it a total of about 4 miles so it's a bit early to say for sure but I think I see a set of 4.88s in my future.... Oh well, if that's the worst thing I find I'll consider myself lucky.

No, I'll have the 88 forever along with this truck.

[KevinNY]

At least that is about the easiet bit to change as far as the gearing goes.

[Mercedesrover]

At least that is about the easiet bit to change as far as the gearing goes.

Relatively cheap and easy. Like I said, if that's the worst of it, I'm lucky. It'll take some road time to see exactly how it feels. I'll bum around town for a couple weeks before I start pulling axles.

[greenmeanie]

Jim,
If you choose to sell the 4.10s give me a shout as I can see a set in my future. I'll be pushing out 200 odd hp by the older system that hotrodders use. I'm planning on starting with a set of Rover 3.54s cause I'm cheap but can see the 4.1s being more realistic.

Cheers
Gregor

[KevinNY]

Jim's are Toyotas not Rover R&P.

[grahamfitter]

:bowdown:

Cheers,
Graham

[frans]

Congratulations on the resurrection!

Are you gonna name it Lazarus?

[greenmeanie]

Jim's are Toyotas not Rover R&P.

Yup,
Once I've torn that 3.54 to pieces I'll need something stronger. At the mo the idea is to start cheap and see what that ratio feels like. If I don't like the 3.54 I'm going 4.10 and doing Jim's hybrids.

I don't think the stock rover axle/diff will be strong enough for my engine and drivetrain so whatever ratio I end up with will need beefing up.

There are other possibilities but if the man chooses to put them up for sale it is not an opportunity to be wasted.

[Stock Tyres]

Looks brilliant!

Flawless build. Great work :bowdown:

[Yorker]

At least that is about the easiet bit to change as far as the gearing goes.


Well it is either that or swap back to a regular gear ratio series transfer case- right? I think Jim is running the Ashcroft high ratio transfer case?

[For non Rover people following this thread- Land Rover didn't use a 1:1 high range ratio like most US/ Japanese manufacturers use. Rather than use a variety of R&P ratios they used a variety of underdrive high range T-Case ratios and 3.54 R&Ps(or 4.7 in the case of Series trucks). I think the Ashcroft is effectively .87:1 high range ratio vs 1.15 for the stock T case.]

Changing the R+P to 4.88s would make them the same as ~4.25 R&Ps - so that might be the way to go depending how the engine likes to run. 4.56's would give you ~3.9's. Right now I think you are around 3.57's

Awesome truck though! I'm really interested in knowing what gearing you finally end up with. Do you end up using 1st gear?

[Mercedesrover]

Took the truck for a good ride this morning....Yes, I need gears.

Just got off the phone with Marlin Crawler and now have a pair of 4.88 ring and pinions on the way. They had the cheapest price I could find on-line. When I called them they said that price was wrong but honored it all the same. Good for them. They didn't have minor install kits so those I had to get from Randy's Ring and Pinion.

Everything should be here by Thursday so I may take the day off work Friday and do this. We'll see how the week plays out.....

[Yorker]

That is awesome! I can't wait to see the truck. Hopefully you can make it to Guy Fawkes on Oct 31, Nov 1-2? Since it is a weekend earlier than I originally was told it was I can actually go!:sombrero: woo hoo!

[Mercedesrover]

Good news on Guy Fawkes. We may be going to Ottawa that weekend but nothing's in stone.

By the way, two sets of 4.88s, minor install kits and gaskets including shipping were under $500. Another reason to run Toyota diffs.

[Monkeyboy]

Show off...you know what the 3.54's for the Swalsbury cost!?!?

Looks great Jim.

[ntsqd]

$382.10? (http://www.ringpinion.com/ProductDetails.aspx?ProdID=6247)

[The Swiss]

Thanks.

Thought I'd post a before and after....

Before:

http://seriestrek.com/109/2.jpg

After:

http://seriestrek.com/109/done1.jpgIf you havent done so, you should write an article and send it to the Land Rover Owner Magazine; they are running wrecks to riches stories; not sure if LAnd Rover World is doing the same.

The transformation is just friggen AMAZING. Congratilations!

[RETROFIT]

An inspiration !!!

Very well done.

What wiring harness did you use ?

Pat

[Mercedesrover]

What wiring harness did you use ?

Made it from scratch. A dozen rolls of wire and a soldering iron.

[RETROFIT]

My hat is off to you good man !

Pat

[Gore Ranger]

Hi, Jim. Your truck is awesome! Kudos on this build! Let us know if you sell the 88"...

I have a basic question from a post way back for you: I bought a used rear housing for my RRC that has the toyota conversion already performed on it. I want to get it cleaned up and painted like you did using the SEM products. I have already cleaned it with a good degreaser and also brake cleaner, and I wire wheeled the loose rust. For all the other minor rust, did you use SEM rustmort on it or not? Do you need a primer or do you just put the gloss black with hardener down over the existing paint on the housing. These are basic questions but I do not know much about paint, and I have had bad luck with the POR15 products in the past, even following their prep instructions thoroughly. Thanks!

[Mercedesrover]

Just clean them up best you can, wash them with brake cleaner and have at it.

[Mercedesrover]

Well, I just got back from a test drive with the 109 and the new 4.88 gears in the back. I think we have a winner. I only did about 8 miles and will let them cool off and do another 12-15 tomorrow and let them cool off again, but the feel really really good. I still need to put the gears in the front diff but I'm going to drive it around for the weekend and make sure I'm happy with it. No 4WD for a few days....

Removing the diff, pulling it apart, putting it back together and setting it up took me about 6 hours over two nights. I'm not a pro at setting diffs up and I was trying to be careful and get it right. Pinion depth was perfect with the original shim. Lucky me. Setting back-lash would have been much easier with the proper spanners but I got it done anyway. Set it a little loose at about 0.009"-0.010" but I'd rather that than noisy and hot. The pattern looks really good. I took pictures but I'm too tired to post them right now. Tomorrow.

[mnfeo2]

Very nice!

[Mercedesrover]

Gear pattern:

http://seriestrek.com/109/chassis27.jpg

[Mercedesrover]

Alright, that's about it. I did the rear diff the other night and have been driving it around for a few days and I'm happy with it. The front will get done early this week. So, for all intents and purposes this build is done! Of course, like any Land Rover this truck will never truly be done and I'm sure there will always be small things that will get added or changed over the years. I also need to build a fuel can holder for the back door and figure out something for the interior panels on the doors. But this little stuff doesn't count.

I want to thank everyone who followed this build with interest and also for your input, advice and suggestions as it was coming together. I really appreciated all of it.

Anyway, here are a few pictures from this afternoon. Thanks again to everyone! See you out on the trail.

Jim

http://www.seriestrek.com/109/done1.jpg

http://www.seriestrek.com/109/done2.jpg

http://www.seriestrek.com/109/done3.jpg

http://www.seriestrek.com/109/done4.jpg

[02TahoeMD]

wowowwowwow WOW! She turned out stunning! Fabulous work. Bravo! :bowdown: :bowdown: :bowdown:

[Michael Slade]

Beautiful. Ditch the rack and it'll be even better.

But really, a very very nice build. I know you'll be very happy with it. There are many here who are very envious of a build like that...myself included.

Keep us posted on the little things...you know, the ones that aren't *quite* right? I know that you've done a lot of thinking about this, but there's bound to be little things.

[cumminsrover]

Don't know why I didn't look here for your build progress....

Looks AWESOME!!!! I am still working slowly :/

Patrick

[junkyddog11]

well done mate.

[4Rescue]

BEAUTIFUL!!!!!! Well done mate, you've really done a great job with the build, congrats and now go get her dirty...

Cheers

Dave

[KevinNY]

First of all, well done Jim. Second of all, thank you for using "intents and purposes" correctly as opposed to "intensive purposes" which makes me cringe everytime.

[AFSOC]

thank you for using "intents and purposes" correctly as opposed to "intensive purposes" which makes me cringe everytime

:iagree: You too? It's funny how many people just look at you with their heads cocked like a dog and a blank expression when you try to correct them.

[Alaska Mike]

Ok. I call Photoshop. Those doors are closing way too evenly.

Amazing work. I think you balanced the stock with the non-stock to create something that is truly incredible. If my own project ends up being 1/10th as good, I will be satisfied.

Bravo.

[viatierra]

Envy? Of this rig?? So much it hurts.

Your sexy 109 is one thing but the whole process and focused way you confronted the build is something I aspire to in my most lavish fantasies. It takes quite a pile of resources to pull it off.

Although its not in the cards for me... following your work for the last year has been surprisingly rewarding and satisfying. Thanks again for sharing your project with us!

So... who's next?

[Maryland 110]

I have followed this build and think the end product is absolutely stunning in its practicality. The engines in Series trucks always seemed to be the short coming. Awesome choices made and phenominal build/craftsmanship.
Like others have said, I wish I was so talented.
If you ever run down this way I would love to run some trails with you.
Cheers,
Doug

[Mercedesrover]

Holy cow! A sticky? I'm honored!

Anyway, we've been driving it around for a couple weeks and all is well. Of course there were a couple little glitches. Had to tune in the fuel gauge, the air switch that shuts the fuel off was leaking vacuum and had to be changed. Little things like that. I'll change the oil, tranny and transfer case oil and the rear diff oil in it this weekend. Heading up to the Guy Fawkes event in New York state Saturday. It'll be it's first long-distance run...about 150 miles each way with a little off-roading in the middle.

[Michael Slade]

Let us know how it goes.

How's the noise in the cabin? I seem to notice it is pretty bad on any series vehicle with an engine swap...mine included. Am curious how yours is sounding. Hopefully it passes the 'conversation test'...i.e. can you have a normal conversation with the person sitting next to you.

Again, congrats and job well done!

[Alaska Mike]

Holy cow! A sticky? I'm honored!
This build is incredible, and it sets the bar for future ExPo Series builds. The thread is a great reference for me, and I got tired of searching for it on the bottom of the page. Hopefully you'll be driving it next time you visit Alaska. Just install drool guards first.

[Mercedesrover]

How's the noise in the cabin? I seem to notice it is pretty bad on any series vehicle with an engine swap...mine included.

It's not too bad...a bit quieter than the 88. Neither of them are Cadillacs but both are very livable for long distances.

[revor]

Rattle,Rattle,Rattle,Rattle,Rattle,Rattle,Rattle,W hat?!Rattle,Rattle,Oh yeah!?Rattle,Rattle.

Gotta be less noize than a 300......

[Yorker]

Rattle,Rattle,Rattle,Rattle,Rattle,Rattle,Rattle,W hat?!Rattle,Rattle,Oh yeah!?Rattle,Rattle.

Gotta be less noize than a 300......

Jim brought the 109 to Howard Smith's Guy Fawke's rally,


there were a number of other diesels there- the Mercedes seems to be much quiter than the 300 TDi's for some reason- and Jim doesn't have any sound deadening under the bonnet IIRC?

http://i94.photobucket.com/albums/l119/sepp45/Guy%20Fawkes%202008/GF-Img_0092.jpg

It was a great time, I posted some more pics here:
http://gunsandrovers.yuku.com/topic/4848?page=2

[Alaska Mike]

Does this rig look familiar?

http://www.paintman.co.uk/paint-colour-chart-series-3.html

World-famous builder of Land Rovers.

[Mercedesrover]

No, it's got the original nozzles and injectors. Truth be told it sounds pretty good for an engine who's history I know almost nothing about. Not even sure of the mileage...The guy I got it from said somewhere short of 200k. It seems well cared for with very little crank case pressure.

Those nozzles do sound interesting. (I poked around a bit before replying) Might have to look into them a little further. I've changed injectors as a unit on these engines but never just the nozzle. Do the injectors come apart easily?

[RgrBox]

Merc,

I just joined this forum, and have enjoyed everything I've seen so far. But this thread has been the best. Our work, and result of your work is a dream come true just to witness. I'm new to the Landrover world, and love my 2008 Defender.. I wish I was still living in the USA somtimes due to the fact that these kids of projests are easier to do and come by.. Over here, it's money, money, money.. anyway, great job, and a beautiful result..

RB

[Funrover]

AMAZING! You have done a great job and I am highly impressed. This is a great thread with a great turnout!

[Wander]

New to this forum-amazing build. I enjoyed reading about your trek in the 88 in OJ-this one looks equally impressive!

I had a thought about the instrument panel- how about engine turning the surface? If you already did something to it and I missed that-sorry!

If not the engine turning might look nice- very aviation inspired- and break up the flat finish of the surface. How about finished/complete some interior pics?

Again-amazing work.

[Mercedesrover]

Hey all. Been a while since I posted here so thought I'd give an update.

We took the new 109 on what was supposed to be a two-plus week trip into the North Maine Woods in June. An uneventful first couple of days up there and into the bush ended 70 miles north/north-west of Millinocket when driving along on a relatively flat road we broke the main-shaft in the transmission. So much for bullet-proof. We were about 10 miles north of Haymock Lake on Haymock Lake Road when it broke and after a few hours a couple of guys came along and dragged us down to Haymock Lake Campsite. A game warden radioed for a flatbed truck and the next day he dragged us down to a friends house in Brewer Maine where we rented a U-Haul and trailer for the sad ride home.

Tore the truck down the day after we got home and found out the main-shaft was improperly welded and never had a chance. I found a shop that agreed to build me a one-piece shaft properly and a month later was back on the road. Another long trip with this truck will have to wait until next year but in the meantime we're having fun bombing around the local roads and all-else has been fine with the truck. By the way, we were getting 20mpg loaded heavy and pulling highway speeds on the way up to Maine. Pretty happy with that.

Some pictures:

http://www.seriestrek.com/images/nmw2.jpg

http://www.seriestrek.com/images/nmw1.jpg

http://www.seriestrek.com/images/nmw3.jpg

[evilfij]

...we broke the main-shaft in the transmission. So much for bullet-proof.

Why was the main shaft welded? Is that how they came or was it because of the use of adaptors that it needed to be welded?

[Michael Slade]

Note to self: Choose your welder carefully.

[Mercedesrover]

Why was the main shaft welded? Is that how they came or was it because of the use of adaptors that it needed to be welded?

It was two shafts that were joined...Front half NP435, rear half Land Rover. It was supposed to be inertia-welded but turned out to be only mig or tig welded and never re-hardened. The new shaft was annealed, machined from an original NP435 shaft and re-hardened properly. I have complete faith in it. ( famous last words! :) )

[I Leak Oil]

Sorry to hear about the shaft. I've never been comfortable with a welded shaft. I know, if done right, bla bla bla but there's always that little guy sitting on your shoulder asking "what if it's not right..." I've got an SM465 I want to mount to a series transfer case but I don't want a welded main shaft. Someday...

[Snagger]

Sorry to see you had such a problem. This is always the problem with modifications - some parts are subjected to much greater strain than they were designed for or have to be adapted to fit, and the quality can't always be relied upon. I consider myself lucky to have few such fitting problems mating a 200Tdi to a SIII box, only suffering problems like oil leaks, but I still worry about breaking the transmission. It's a good lesson to all, though, that no matter how well prepared the vehicle is, breakdowns can still occur and yo have to be prepared for them, just as you were.

[JSBriggs]

Sorry to hear about the shaft. I've never been comfortable with a welded shaft. I know, if done right, bla bla bla but there's always that little guy sitting on your shoulder asking "what if it's not right..." I've got an SM465 I want to mount to a series transfer case but I don't want a welded main shaft. Someday...

Get a 2wd 465 and have the rear of the shaft recut and re heat treated.

-Jeff

[Mercedesrover]

Get a 2wd 465 and have the rear of the shaft recut and re heat treated.

That's just what I did with the NP435 shaft. Started with a 2wd shaft, annealed, machined, re-hardened and the last bearing surface ground after heat. Ended up with only 0.002" deflection after heat too. I've got faith in this shaft over a welded shaft for sure.

[Oilburner]

I have to come to the defense of the welded mainshaft method. If done right it is as strong as a single piece shaft, cheaper to manufacture and does not need to be rehardened. All the ones I have had were still hardened after welding at the splines, the HAZ was limited to fairly close to the weld, not into the splined areas. The one you got was just junk. The weld looks super cold with tons of inclusions. I would love to see it up close.

The Series shaft end has a big dumb huge huge stress riser right where the T case input gear splines end (like every splined piece in a Series Rover, but I digress). This is a way weaker spot than where the welded mainshaft would be. I ran a welded mainshaft in my T18 for years, never a problem with the weld, it actually tore off the threads to the gear locknut once and I broke three series T cases with that setup, broken teeth, nothing wrong with the shaft.

[TeriAnn]

Sorry to hear about the shaft. I've never been comfortable with a welded shaft. I know, if done right, bla bla bla but there's always that little guy sitting on your shoulder asking "what if it's not right..."

That's where you need to pick someone who knows what they are doing. The main shaft on my T-18 was welded by Timm Cooper 10 years ago this month and is still holding up behind my Ford 302.

[muskyman]

wow ...what a bummer to have a big trip end like that, sorry to hear about the vacation.

For such a crucial part I would have called up the great guys at Novak conversions and had a custom shaft made from scratch. I have bought a number of them from them and never had a failure and one was running behind a truck with over 500ft of torque.

hind sight is always 20/20(one way to have 20/20 after 40:D)

glad to hear its all fixed!

[Mercedesrover]

That's where you need to pick someone who knows what they are doing.

Man, tough crowd.

I did pick someone who knew what he was doing. Unfortunately this shaft, unlike many, many he's done, had a problem. He made right by me and I'll never have a foul word for him. He's always been a stand-up guy and continues to be. He just happened to have a problem with this particular shaft...S#*t happens.

[Mercedesrover]

For such a crucial part I would have called up the great guys at Novak conversions and had a custom shaft made from scratch.

Dutchman's made me a shaft starting with a 2wd NP435 shaft as I was in a bit of a hurry and they could get on it right away. From the time I shipped it out to the time I got it back was under 4-weeks. Not bad for a one-off piece right in the middle of race season.

[James86004]

Do you have any photos of the new shaft? Me like pictures of pretty gears and shafts!

[Mercedesrover]

This is the end that Dutchman's did. Annealed the shaft, hobbed the splines, cut the threads, roughed out the bearing surface, re-hardened it and finish ground the bearing surface. Everything inboard of this is standard NP435 shaft.

http://www.seriestrek.com/images/newshaft.jpg

[James86004]

Thanks. Nice work.

[Monkeyboy]

.. hobbed the splines...

Dang, learn something new every day. Thanks to our friends at Google, I now know about "hobbed" and "involute" splines.

That looks like a nice piece indeed Jim!

KAA

[Oilburner]

That's really nice! What's next? MAR? Guy Fawkes? I will probably try and make the Fawkes event but it sure as heck won't be in my 109 :sombrero:

[Mercedesrover]

That's really nice! What's next? MAR? Guy Fawkes? I will probably try and make the Fawkes event but it sure as heck won't be in my 109 :sombrero:

I really like Guy Fawkes. Great bunch of guys. I'll be there.

Put on the muffs and bring the 109! I'd love to see it!!

[Jnich77]

One word:phenomenal

[Oilburner]

I really like Guy Fawkes. Great bunch of guys. I'll be there.

Put on the muffs and bring the 109! I'd love to see it!!

No, no - I'd definitely drive it if I could, I drive it everywhere. I'm in the middle of an NV4500 conversion and am building a new frame, plus we're moving, so no time. I might bring my new beater FZJ80 down.

[I Leak Oil]

Mercedes, you've earned some fame in the north woods. I was coming out through the Telos checkpoint yesterday and the woman asked me if I was the one who broke down up there this past summer. After telling her it wasn't me she said on his way in some guy was telling them how he can fix the entire truck by the side of the road if necessary. Next thing they know it's being carted out on a flat bed! She mentioned a broken transmission so I knew for sure who it was.
I came to your defense and told her not to worry as it wasn't a stock Rover tranny!:elkgrin:

[Mercedesrover]

Too funny. Yeah, in most cases I can fix it on the side of the road. This failure was a little too deep. I supposed I could have pulled a Bogart in The African Queen and forged a new shaft up there. Not sure how that would have worked out.....

That lady at the Telos gate is a sweetheart. She sent a note to the NMW headquarters about what happened and they sent me a check back for my two-weeks worth of fees. Pretty cool of them.

[Yorker]

I really like Guy Fawkes. Great bunch of guys. I'll be there.

Put on the muffs and bring the 109! I'd love to see it!!

You guys both missed Guy Fawkes- it qould have been nice to have another FJ-80 there. ;)

Quentin has already uploaded some pics on:
http://www.fourfold.org/qrover80/guy09/index.html

Guy Fawkes 2010 will be (4), 5, 6, & 7 of Nov


there Jim mark your calendar now. ;)

[dino2000]

Jim, I absolutely love your work so far but that instrument panel aesthetically sucks big time. It would maybe work on a CJ5 but not a Series Land Rover. It just strikes a loud aesthetic discordance with the rest of the vehicle.



Really?!

This thing is amazing in every way. The layout seems to me to be straight forward and well thought out. Simple is good.

(forgive me, I'm a little behind on my reading.......)

[Viggen]

Hows the power delivery with this motor? Its hp numbers are good but the tq numbers arent earth moving. Just curious.

[Mercedesrover]

North Maine Woods, Redux

Once again Wendy and I will be pointing the 109 north and heading back to The North Maine Woods for a couple of weeks. We leave Friday. Wish us luck! The truck has been running flawlessly this year and I really feel good about the trip. Still, the number for John and Son's Towing in Millinocket is in my wallet! :)

Hope to find a place to camp somewhere just east of Churchill Depot. Cliff Lake or Spider Lake will be our first choices. We'll be doing a lot of exploring, fishing and canoeing. Hope to take the short water-route to the trains too.

Anyway, we'll be back in a couple of weeks with a few stories and hopefully a better ending than last year!

jim

http://mhf.ronmeldrum.com/assets/road_northern_maine.jpg

[smithco1]

Have a good trip Jim! I think we know what won't go wrong on this trip. Fingers crossed.

[ruditron]

mercedes is this your dog? http://www.seriestrek.com/images/nmw2.jpg


i have one just like her.....

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs262.ash1/18961_286805045930_505790930_5069554_2289114_n.jpg

[aka rover]

Very nice build :safari-rig: nice to see a build to come togather and look so good.

Nice job

Cheers Ed

[rfun]

absolutely great job...

[atancreti]

AMAZING. I know this is rude to ask, but, how much money did this cost? How many hours did this take? Great job.

[bluejeep]

I NEVER read threads this long. Especially since I'm not a Land Rover guy. This time, I read all 49 pages, and when I finished I wanted another 49.

[EricM]

This thread represents, in my opinion, "what Expedition Portal is about". It serves an example of both the intent of all of us here, and the attitude that permeates throughout the whole web site.

Thanks for sharing with us and as serving as inspiration, very real inspiration.

[Juergen Richter]

Hi,

this is the car I meant in my last email you.
Could we get in touch about this ?

[98dango]

Holly read batman I found a link on 4bt about the mo617 and now i want a rover

[Sean VHA #60013]

How is the build holding up?