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  #1  
Old February 3rd, 2016, 12:24 PM
Azarur
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LR 1984 110
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LR 110: Two years and thousands of hours

Over the last 24 months I have started several threads describing parts of this incredible two-year-plus journey, which is now finally coming to an end. Or maybe a beginning... I guess it depends on your point of view.

The journey started with this 1984 LHD. Over the next several pages and weeks I hope to document the evolution of this project, from a pretty normal looking white 110, to the vehicle of our dreams.
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  #2  
Old February 3rd, 2016, 12:27 PM
Azarur
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This is what the 110 looked like in October of 2013
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  #3  
Old February 3rd, 2016, 12:37 PM
Azarur
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What I did not know when we bough the car is that far from the "normal" white 110 designed for Europe, this vehicle had a far more interesting history. It was originally a Russet Brown car destined for Townley Cross Country Vehicles, an outfit that during the 80s modified Land Rovers for clients in Africa and the Middle East. The 110 eventually landed in "West Africa," although I have not been able to find out exactly which country.
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  #4  
Old February 3rd, 2016, 02:32 PM
Azarur
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The 110 eventually found its way back to Europe, whee it underwent a "restoration." The car was disassembled, sanded, primed and re-sprayed. While the restoration was cosmetically pleasing, the foundation was not as solid as it seemed on the surface.
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  #5  
Old February 3rd, 2016, 04:06 PM
Azarur
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I bought the 110 almost two years ago to the date after doing extensive research on an "extensive" list of requirements:
- LHD 110
- Solid frame

That was basically it, as I knew I would most likely replace the engine and do extensive body and interior work. So, in a way, buying a car that had already undergone a partial restoration was a mistake, as I ended up paying more than I should have given the amount of work and the insane number of new parts that would be needed to achieve the end result we were looking for. Lesson learned. Too bad I don't get to apply that lesson any time soon!

Anyway. I picked the car up on a cold morning in February 2014 in Newark and attempted to drive it all the way to our shop, where it would undergo extensive restoration. Well. I didn't make it very far... About 20 minutes into the drive the 110 overheated and I had to pull over. Turns out there was a major leak in the cooling system. So I gave up the idea of driving it and activated the backup plan, which was to have a flat bed drive the 110 while I took a train back...
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  #6  
Old February 3rd, 2016, 04:21 PM
Azarur
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LR 1984 110
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The car arrived at the shop and was basically tucked away until the spring. A combination of lots of snow, the shop being busy and moving locations. Small amounts of work were done, but really we did not begin the renovation in earnest until the early summer.

Job one was obviously to take the 110 apart. And apart it came! Basically no single bolt or nut was left attached. Every. Single. Piece. Came. Off.
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  #7  
Old February 3rd, 2016, 04:32 PM
Azarur
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As we started taking the 110 apart, the "quality" of the previous restoration became apparent. Clearly, the previous shop had patched things up to make them look good, but had spent little time making sure things were structurally and mechanically sound. We kind of knew this going in, but I would be lying if I said I was not surprised by some of the horrible work and amount of bondo and filler we found.

Given that we wanted the 110 to be in as good a shape (or better even) than the day it left Solihull, we proceeded to systematically and painstakingly repair or replace every single part, from body panels to brake lines, from suspension to transmission, from engine to electrical.

Here are some examples of the hidden turd gems we found:
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  #8  
Old February 3rd, 2016, 06:19 PM
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Don't stop now!
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  #9  
Old February 4th, 2016, 09:22 AM
Azarur
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Engine

So. After the 110 was completely disassembled, several workstreams started in parallel. So the following posts will not be in chronological order, but rather follow each of the streams.

The first order of business was the engine. We wanted to get at least 20 mpg. And we wanted an after-market A/C unit. This basically meant a 200 or 300Tdi. I spent many an hour on this board asking people. Several were kind enough to let me drive their 200 Tdis or 300 Tdis. Finally we settled for a 200, as we did not want to modify the frame mounts.

The engine we had needed a complete overhaul. It had seen tough treatment, had a blown head gasket, a busted water pump and slightly scored cylinder walls.
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  #10  
Old February 4th, 2016, 09:29 AM
Azarur
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So. We sent our engine block to be rectified, bought new cylinder sleeves, valves and gaskets. Also bought new water pump, turbo and intercooler. We tried obtaining a new or refurbished fuel pump and injectors, but came up empty handed, so we sent ours to be reconstructed.
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  #11  
Old February 4th, 2016, 09:43 AM
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Quote:
Originally Posted by Azarur View Post
S Finally we settled for a 200, as we did not want to modify the frame mounts.
.

I'm just curious...with this amount of tear down and rebuild...you didnt want to move the frame mounts a couple inches??

With the increasing rarity of 200tdi parts that just seems like a bad decision.

Carry on...


.
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  #12  
Old February 4th, 2016, 10:07 AM
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Quote:
Originally Posted by Nomar View Post
I'm just curious...with this amount of tear down and rebuild...you didnt want to move the frame mounts a couple inches??

With the increasing rarity of 200tdi parts that just seems like a bad decision.

Carry on...


.
Sounds like the decision was made years ago, before it was as known the scarcity of 200tdi parts.
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  #13  
Old February 4th, 2016, 11:08 AM
Azarur
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Quote:
Originally Posted by JohnsD90 View Post
Sounds like the decision was made years ago, before it was as known the scarcity of 200tdi parts.
I should have prefaced the entire thread by issuing a warning: there were a LOT of bad decisions made!! So don't pull on the string of "why this instead of that" unless you want to see a grown man cry!

The decision to go with the 200 TDi will seem even more baffling when I get to the part where we modified the frame ANYWAY to use hydraulic mounts and when we bought a new transmission.

All that said, I love my 200!!
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  #14  
Old February 4th, 2016, 11:34 AM
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This thread makes me feel like I have blue balls.
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  #15  
Old February 4th, 2016, 11:39 AM
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Quote:
Originally Posted by Azarur View Post
So don't pull on the string of "why this instead of that" unless you want to see a grown man cry!
LOL- I dont want to see that!
I'll just keep watching your progress pictures.


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  #16  
Old February 4th, 2016, 01:50 PM
Azarur
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Quote:
Originally Posted by Contractor View Post
This thread makes me feel like I have blue balls.
I'm very sorry for your discomfort!
Unfortunately my job keeps getting in the way of posting on the thread. I could quit my job, but after you see all we did to the 110 you'll agree that I absolutely need to keep my job to pay for it!!!
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  #17  
Old February 5th, 2016, 08:30 AM
Azarur
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So, speaking about decisions that were reversed. After installing the reconstructed 200 Tdi on the frame, I decided the vibration was unacceptable. Why? Because I'm insane. We then started looking at options. Finally, we decided to try out the Mercedes hydraulic mounts. We obviously had to modify the frame (remember when I said that we picked the 200Tdi to AVOID modifying the frame? Well, there you go...) to be able to secure the mounts vertically. We had seen a mod where someone has used the Merc hydraulic mounts at an angle and the results were disastrous. Not only was vibration not mitigated, there was a significant loos of power due to wobble, and eventually the mounts failed prematurely. Once we figured how to locate the mounts vertically we were amazed by teh results. Imperceptible power loss and a dramatic reduction in vibration:
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  #18  
Old February 5th, 2016, 08:58 AM
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Quote:
Originally Posted by Azarur View Post
I'm very sorry for your discomfort!
Unfortunately my job keeps getting in the way of posting on the thread. I could quit my job, but after you see all we did to the 110 you'll agree that I absolutely need to keep my job to pay for it!!!
Ha

Looks good, keep posting.
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  #19  
Old February 5th, 2016, 10:27 AM
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Originally Posted by Contractor View Post
This thread makes me feel like I have blue balls.
Now I really don't need to see that!


Following intently! Carry On...
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  #20  
Old February 5th, 2016, 10:32 AM
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Mike Barnett
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Quote:
Originally Posted by Azarur View Post
So, speaking about decisions that were reversed. After installing the reconstructed 200 Tdi on the frame, I decided the vibration was unacceptable. Why? Because I'm insane. We then started looking at options. Finally, we decided to try out the Mercedes hydraulic mounts. We obviously had to modify the frame (remember when I said that we picked the 200Tdi to AVOID modifying the frame? Well, there you go...) to be able to secure the mounts vertically. We had seen a mod where someone has used the Merc hydraulic mounts at an angle and the results were disastrous. Not only was vibration not mitigated, there was a significant loos of power due to wobble, and eventually the mounts failed prematurely. Once we figured how to locate the mounts vertically we were amazed by teh results. Imperceptible power loss and a dramatic reduction in vibration:
So I'm assuming you used the hydraulic mounts on the engine as well as the transfercase? Do you have photos of that? I've got a pair of the mercedes mounts sitting in my garage..
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