65 Series IIa Rebuild

[MuleShoer]

This is a carry over from a previous thread. Originally this was going to be a present to my wife 18 months ago. It was planned to be a fix the bottom of the doors and service then add a bow and im off the hot list from selling her 88. We based laid plans transitioned into a rebuild project. The main driver was the frame was in worse shape then believed, to quote Evan " I wouldn't drive it much and towing anything was out". So we sat down and laid out a semi plan to replace the chassis and "fix" a few other items.
Much of the work is now complete and we are turning the corner on paint and re-assembly so this won't be along protracted build to follow unlike my Cummins FJ40 project.
So here is a list on what has transpired:
Vehicle was a 1965 Series 109 SIIa cloned into a Stage 1 with 3.9v8, ZF auto, FT 4wd, defender front clip, RR interior seats, rewired with "painfull" circuits etc


Planned finished state of the 65:
Chassis replaced with stretched 1995 disco1 chassis, re-set V8 engine & transmission back to be able to install original series front end, defender front & rear seats in leather, replace missing battery box and storage box, replace door tops with RM tops, undercoated tub with "Lien-X' type color matched, "Line-X" type interior floor with color matched Line-X, Defender steering colum, dual heaters (one for interior & one for defrost), dual batteries, Hella Spot lights integrated into breakfast, repainted and bunch of small stuff.


Much more to follow
cheers

 

[mtnbike28]

Nice truck!

 

[MuleShoer]

More disassembly pics

 

[rokrawlr]

Looking great so far, can't wait to see the finished product!

 

[MuleShoer]

thanks a lot more coming

 

[35xj]

Hmm, where in swva are you? Contemplating a similar project here in asheville

 

[MuleShoer]

surprises are not always a good thing
Basically we kept the rear cross member & front bumper
B&C pillars had "usual" rust

 

[MuleShoer]

last tear down. Right side of frame under passenger seat shows old repair

 

[MuleShoer]

Disco Frame stretch

For the discovery frame stretch Evan Amaya had previously completed several swaps and as luck would have he still had a set of the fabricated parts.
we set the tub and bulkhead in place to get the right length for the frame splice.

 

[MuleShoer]

Frame splicing

 

[MuleShoer]

Final frame joint pictures, then its on to the bottom of the tub

 

[MuleShoer]

Rear tub rebuild, sorta. the rear tub was in decent shape so we decided not to disassemble. Since this 109 lost it's true identity when it was converted to a stage 1 it was never planned as a restoration, more of a rejuvenation. Details like stripping off all the steel parts, re-galvanizing,& re-installing were not in the cards. All rusted area would be repaired though and extra holes and dents removed.

 

[MuleShoer]

So I always liked "Mercedes rover's" quad lights. So instead of another set of head lights we mounted Hellas. we also modified a Series III radiator support since that's what we had:


We then checked the new radiator for fit

 

[MuleShoer]

Finished underside of tub

 

[MuleShoer]

Door bottom repairs