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  #1  
Old May 3rd, 2013, 01:51 PM
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J. Michael McCaig
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68 Series IIa Awakening

The old girl has been sleeping in the barn for for awhile and, after I sold my D90, I decided I wanted to put her back on the road. I thought about sticking this in the Series Tech section but one thing is leading to another as so often is the case with Rovers and its turned into a project. Itís not a restoration as the truck is in pretty good shape but the original engine leaks oil profusely, needs brake work, steering work, etc.

I got this Rover while I was a senior in high school in 1971. I rebuilt it on a good used frame back in the early 80s as salt from running on the beach had worked its magic on the original frame. At the time I didnít do much to the engine as it was still in pretty good shape.

My plan is for it to get a 2.5TD as a repower and Iím working on a power steering conversion while I'm gathering other parts. I'm keeping my original steering wheel and most of the column as I want things to look as original as possible...plus you kinda get attached to things after 40 years. Using a P38 steering box and intermediate shaft. I've married the internal IIa shaft with a RRC shaft which works with the intermediate shaft.
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  #2  
Old May 3rd, 2013, 01:54 PM
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Giampaulo Cinquegrana
95 DI SR Extreme Kit - 94 RRC LWB
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Cool!!!!

Perfect timing, I'm looking into a 66 SIIa and have a bunch of RRC and DI parts I was wondering if I could use on the Series.

I'm very interested in your project. Thanks for sharing!
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  #3  
Old May 3rd, 2013, 02:06 PM
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Bill Adams
66 109 sw 94 lwb
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Mike, just FYI, the 3/4-48 steering shaft is a common size. It is standard V-dub, so there are oodles of steering shaft pieces available. You can get the u-joints fairly cheap, and a flange mounted 3/4 inch bearing from mcmaster. I know you are already along the way on this aspect of the project, so I am not second-guessing you or anything. There are plenty of ways to make it work.
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #4  
Old May 3rd, 2013, 02:21 PM
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I love the capstan and the rare tropical pick up can roof.
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  #5  
Old May 3rd, 2013, 03:16 PM
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J. Michael McCaig
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Bill - thanks for the info. I didn't know that the shaft had a common spline count. I had an extra Series steering box so it got sacrificed for the project. The P38 box came with the intermediate shaft and is working out to be the right length. I'm working on the steering box mount now so I hope to have some more photos up once is is bolted to the frame.

Ron - I don't know if I can use the capstan with the 2.5TD. The front pulley bolt looks different from the 2.25 petrol.
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  #6  
Old May 3rd, 2013, 03:18 PM
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Certainly 2.5 were fitted with capstans. I hope it is just a matter of finding the right crank part and adapting the shaft (maybe). If nothing else, I would leave it on for decoration.
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  #7  
Old May 3rd, 2013, 03:27 PM
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Steve Maietta
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There a couple different "starting dogs" for the capstan winches. For sure there was one that will fit your engine.

Your winch looks like this one, is it?
http://www.ovlr.org/jberg/capstan.pdf

great story BTW.. restoring your HS truck. -awesome.
~Steve
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  #8  
Old May 3rd, 2013, 03:39 PM
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J. Michael McCaig
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Steve - Thanks for the pdf. Looks like there is a different starting dog for the 5 bearing engines so hopefully I can track one down. My winch is made by Fairey so it is a little different than the one in the pdf.
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  #9  
Old May 3rd, 2013, 03:56 PM
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Bill Adams
66 109 sw 94 lwb
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For the capstan drive, I would be caught trying to adapt a 30MM socket to the drive. chuck it in a lathe and bore the square drive out, and then weld it on the drive shaft (or cross drill it for a shear pin). I'm not 100% on this but I'd be willing to bet that the Fairey drive, if it is square shaft, is your standard issue farmer Bob 15hp square PTO drive stuff, available from every Tractor Supply on earth.

Hey if it fails, you can try taking it back to Sears.
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #10  
Old May 3rd, 2013, 04:21 PM
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Steve Maietta
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Aah a Fairey, yep thats different. Check Ebay for the part, you'll probably find what you need! At least a pic is something to start with.

Not a bad idea Bill, and the torque load on the parts is not beyond good socket specs I'm sure. The shear pins are pretty thin.
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  #11  
Old May 3rd, 2013, 06:59 PM
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So clean how they trimmed the front apron panel and riveted on side pieces and I like the extra supports under the bumper there. Very nice mount. Nicest I have seen.
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  #12  
Old May 6th, 2013, 08:34 AM
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J. Michael McCaig
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Thanks for the comments on the capstan. I installed that back in the early 80s when you could still by them new. I did find the right winch drive/starter dog and bolt for the 2.5 on ebay UK and it's on the way so I hope to get it working after the engine swap.

I had some time on Sunday afternoon to work in the shop and got the powersteering box mounted. Still have to fab up a draglink. I'll work on the hoses after I get the 2.5 in.
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  #13  
Old May 24th, 2013, 04:25 PM
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J. Michael McCaig
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Finally had some time to make up the drag link. I'll try to post up a photo or two later. The capstan winch drive for the 19j came in from HNJ Engineering in the UK. Really a nice replacement with the correct metric bolt with a dished head. I've been giving a lot of thought to a disk brake upgrade but in the meantime I will work on pulling the old 2.25...
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  #14  
Old May 25th, 2013, 03:20 AM
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Mike Hammond
110 200Tdi and a 2005 Scorpa SY250
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2.5 TD... Not the most reliable engine ever produced. I've heard putting an intercooler on but not upping the fuel/boost helps with the reliability. They had a tendency to blow the engine oil through the intake and rev to destruction on the engine oil as they couldn't be shut off
200 tdi's can do it too!


Bad maintenance I think has much to answer for

Great job on the steering, look forward to reading about the rest of the build.
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  #15  
Old May 30th, 2013, 04:43 PM
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J. Michael McCaig
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The 2.5TD does have a bad rep in some circles but plenty of well maintained examples have clocked over 200k miles. I think it is a good choice for a light weight IIa 88 like mine because it allows me to do the install with a minimum of mods and is an upgrade from the 2.25. Seems to be a fairly common engine swap for Series trucks in the UK from what I've read. If this was a heavy equipped 110 it might be a different story. The engine I'm using has very little blowby so oil in the intake shouldn't be an issue.

The old 2.25 is out and the battery tray and right side engine mount are gone so there is no turning back now. I have decided to go to a dual brake circuit and disc brakes. I will run the new brake lines and clean up some wiring before the 19j goes in. Photo of the extended drag I worked up is attached. It will do until I can get someone to make one for me out of stainless
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  #16  
Old May 30th, 2013, 07:32 PM
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Bill Adams
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I see you are of the rag-joint-at-the-top school of thought. I put mine at the bottom.
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Bill Adams

1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #17  
Old June 1st, 2013, 08:59 AM
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Jimmy
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Quote:
Originally Posted by mikeslandrover View Post
2.5 TD... Not the most reliable engine ever produced. I've heard putting an intercooler on but not upping the fuel/boost helps with the reliability. They had a tendency to blow the engine oil through the intake and rev to destruction on the engine oil as they couldn't be shut off
200 tdi's can do it too!


Bad maintenance I think has much to answer for

Great job on the steering, look forward to reading about the rest of the build.

Why didn't they just put it in gear and let it stall out?
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  #18  
Old June 1st, 2013, 12:49 PM
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Mike Hammond
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It's doing Max revs! It'd just take off across the field until it crashed into something immovable!
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  #19  
Old June 1st, 2013, 12:56 PM
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Quote:
Originally Posted by mikeslandrover View Post
It's doing Max revs! It'd just take off across the field until it crashed into something immovable!
Fifth gear, handbrake, standing on the brakes might have worked.

Plywood over the air intake might have worked.
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  #20  
Old June 1st, 2013, 01:51 PM
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Mike Hammond
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I think that by the time an engine does that it's pretty much toast.

Proper maintenance would have prevented it!
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