63 Series IIA 109 PU Hybrid Electric - Page 14 - Defender Source
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  #261  
Old April 15th, 2015, 10:23 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Quote:
Originally Posted by lordhelemt View Post
Looking good. I can appreciate how much of a pita it is to prep all those greasy and rusted parts.
Yeah I know better and I am still amazed at how much time it takes.

Quote:
Originally Posted by Brewie212 View Post
Can we get a side shot of the rear of the chassis with that cool custom gas tank cradle?
You mean those sweet things you got cut and bent up for me?

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More in my build album

109" Project - Our Albums - Powered by Phanfare


A little more progress

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  #262  
Old April 15th, 2015, 10:40 PM
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Brian Kandefer
1957 107 wagon, 94 arles St, 101 FC
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Looks awesome man
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  #263  
Old April 15th, 2015, 10:55 PM
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Don Bunnell
'86 110 3dr ST
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Wow - looking really good Charles!
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  #264  
Old May 3rd, 2015, 08:34 PM
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Charles Galpin
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I got some garage time this weekend and made some progress, although it took way longer than I would have thought (as usual). Someone didn't order new inner mud shields for the rear so I couldn't finish the rear outers (and need to rebuild my diffs anyway). Did some bushing prep and tapped the holes for a-arm ball joint. Hopefully it won't take too much longer to press in all the bushings and get these finished up and under the frame!

Rear housing. Didn't take any detail pics of the front, but had to clean the inside out as it was really dirty (didn't do so before powder coating).
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Rear hub. Hopefully the powder coat on the rotor mounting faces won't be an issue. I'll check the runout once the hub is on the stub axle.
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Front hub
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Front stub
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Current status
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Check out the grease I am using (what I had on the shelf). They had me at "irregular maintenance". LOL

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  #265  
Old May 4th, 2015, 09:26 PM
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Brian Kandefer
1957 107 wagon, 94 arles St, 101 FC
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Looking awesome!!
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  #266  
Old May 5th, 2015, 03:50 PM
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Ron Dade
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Looks like progress, Charles. Nice job.
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  #267  
Old May 5th, 2015, 07:38 PM
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Charles Galpin
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That's a cheap kit from HF!

Yeah I figured I'd keep the ABS rings in case I want to use the wheel speed sensors. For now I'm going to just 3D print plugs and not install the sensors, but it will all be ready if/when I decide I want it.
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  #268  
Old May 5th, 2015, 09:02 PM
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Don Bunnell
'86 110 3dr ST
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Ultra clean axle build!

Btw - got that piece out today in the post - you should see it in a couple days.
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  #269  
Old May 5th, 2015, 09:14 PM
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Charles Galpin
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Thanks Don!
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  #270  
Old May 25th, 2015, 03:32 PM
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Charles Galpin
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Finally got some time to work on the truck. I had started pressing in the a-arm ball joint a few weeks ago and broke my (ok, Loic's) little 12 ton press I have had in the garage for years.

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I decided was time for an upgrade and scored this 20 ton press on Mothers day with a 25% coupon!

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Anyway things went well after that. Pro tip - clean out the bushing surfaces really well or you might struggle pressing in the bushes. The a-arm ball joint was the only one to give trouble but I think it's because it is solid and has no give, but if I were to do it again I'd clean most if not all of the galvy out of that hole. The rest went fine, although it could have been because of the new press.

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I did the pan hard rod bushings too but forgot to take pictures.

Then I chased some more threads and put the rear stub axles and hubs on.

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Oh and I bought these sweet thread finders which make it super easy to identify the thread and pitch on all the bolts I need to replace or get nuts for

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  #271  
Old May 31st, 2015, 12:32 AM
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very nice!
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  #272  
Old May 31st, 2015, 02:09 AM
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Quote:
Originally Posted by cgalpin View Post
I need a 8mm and 10mm tap if anyone has one.
I have not followed your build... Good progress! is it fair to say you find those taps already? If not, I should have them.
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  #273  
Old May 31st, 2015, 04:03 PM
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Charles Galpin
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Yeah I borrowed a tap set from Jeff. I have been able to do everything needed so far, although still have a few left to do.
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  #274  
Old June 7th, 2015, 08:30 PM
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Charles Galpin
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Not making a tremendous amount of progress, but I did manage to break a rivet tool and a 2 jaw puller today, so job done! I have acquired 24 spline axles (thats Randy) and diffs (thanks Carlos and Jeff) and have stripped the old diff bearings and pulled the old R&P. Once I get bearings I will rebuild them with 4.75 gears and get these axles under the frame. I'm 4 months in to what feels like should be a 4 week effort!

I did make some plugs for the ABS/speed sensor holes until I use them. Here is the front

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And then the rear. Note the screw hole to make it easy to pull them one day.

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In case you were wondering they are not solid. I could make them solid, but to speed up printing and use less ABS I made them 25% internally.

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  #275  
Old June 7th, 2015, 09:20 PM
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nicely done!
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  #276  
Old June 7th, 2015, 09:57 PM
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Don Bunnell
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Charles - do you have any more of those? Those look slick!
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  #277  
Old June 8th, 2015, 05:40 PM
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Charles Galpin
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The plugs? They are 3D printed, so I guess I have an endless supply of them. Need some?
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  #278  
Old June 8th, 2015, 07:24 PM
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Quote:
Originally Posted by cgalpin View Post
The plugs? They are 3D printed, so I guess I have an endless supply of them. Need some?
I am probably fine using the brake line brake bracket with sealant to keep gear oil in but those look so much nicer!
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  #279  
Old June 20th, 2015, 01:49 PM
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Nice plugs. I made a plug then filled the holes with liquid electrical tape.
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  #280  
Old June 22nd, 2015, 09:21 PM
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Charles Galpin
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Some updates

On the plugs, it's easy if you have toys like a 3D printer, so why not. And in general I figure if you are going to bother doing something, you might as well do it right, or just don't bother.

I got held up on the axle build because I need to rebuild the diffs to continue, but before that I did finish mounting the swivel balls and setting the preload.

Fresh seals and bearings
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I have one of these damping thingies on backwards. Need to figure out which one is right.
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Checking the preload with a fish scale I picked up
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And I manage to have lost one of these little bolts or I'd call this part done.
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