Project "Frank" - The Un-Gaying of a 110 - Page 12 - Defender Source
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  #221  
Old July 15th, 2010, 11:55 AM
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Good looking build!

Very clean.
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  #222  
Old August 19th, 2010, 09:26 PM
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Door Repair

My right rear door was held together by bondo and paint. The bottom of the frame is completely gone and there is some serious rot on the upper frame (see pics). So before spending $600 on a new door frame I decided to make an attempt at repairing the door.

First, I cut out the rotten areas on the bottom of the door, careful to peel apart the skin. Then using some of the old rusted chunks I bent up and fabricated some new lower and side channels, epoxy primered them inside and out, and welded them to the existing good hunks of metal. They were also glued in with panel adhesive.

So far I have the bottom of the door done, next I will do the upper frame rot. More pics to follow.....
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  #223  
Old August 20th, 2010, 08:23 AM
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Thanks for the pictures Jonathan. I am comtemplating doing this myself. I see you did the welding with the skin on? Was it easy to peel the skin back? Did you use heat to bend the skin to avoid cold/stress hardening? Any advice after doing it yourself? Thanks
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  #224  
Old August 20th, 2010, 12:44 PM
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I did it with the skin on as I only needed to replace a few sections of channel and to ensure the door kept it's proper shape. The aluminum skin is pretty thin so I didn't use any heat - it was also very easy to pry away from the steel channel. Just take your time. No real advice, but it does suck doing it. Then again, it saved me $600. Now, of course this is only a temporary solution and should last at least 5-10 years minimum as long as I occasionally pull the door cards to check for new rot. The best way is to galvanize the frames and re-skin.

I'm still only half way through the project, so my opinion could change!
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  #225  
Old August 22nd, 2010, 01:56 PM
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Wow, I wouldn't wish this project on anyone, it sucked! The more I poked around the more rust I found. The upper horizontal brace was pretty bad, so I fabricated a new one, epoxied inside an out, and glued and welded in place. Then I cut out the cancer on the rear vertical channel and bent up a replacement piece.

I stripped off the old Bondo at the bottom of the door and worked it smooth.

The door feels a lot more solid now and is good as new.
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  #226  
Old August 28th, 2010, 09:50 PM
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T-Case Rebuild

I started the last of the real shitty projects this weekend - rebuilding the Disco 1.2 t-case with 1.4 gears. Running 35" tires made the truck a little sluggish off the line so I am hoping this works before I move on to swapping R&Ps.

The rebuild is pretty straight forward. Special thanks to Doug Crowther for posting the LT230 rebuild manual on his website. It's invaluable for the rebuild.

Dropping the t-case was actually the shittiest part and mine was held on by 25 years of grease and corrosion. First, I removed the intermediate shaft and dropped the 1.2 intermediate gear. Then, per the manual, I removed the front output to get access to the high range gear at the back of the case. Getting to that gear was as simple as unstaking the retaining nut and swapping on the new gear. After reassembling, I installed new bearings and races in the 1.4 intermediate gear with a new crush sleeve and installed the intermediate shaft with new o-rings and lock nut. The nut gets torqued until end-play in the intermediate gear is gone.

Simple as that. The t-case is sitting on the garage floor waiting for a buddy to come help lift it into place tomorrow. I took random pics along the way. It was hard to do a step-by-step photo shoot with greasy hands.
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  #227  
Old August 29th, 2010, 10:52 AM
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Wow, what a difference in drivability! The 1.4s are awesome. The truck is no longer sluggish off the line. Guess that's why Defenders had 1.4 gears in the first place.
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  #228  
Old August 29th, 2010, 08:31 PM
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Well done. Now let's see pictures of it on 35's.
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  #229  
Old August 29th, 2010, 08:38 PM
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Well done. Now let's see pictures of it on 35's.
Here ya go
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  #230  
Old August 29th, 2010, 08:43 PM
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Looks good
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  #231  
Old August 31st, 2010, 11:58 AM
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Quote:
Originally Posted by Wolf Fabrication View Post
Here ya go
Rig looks beastie with the 35's on Wolfs and all blacked out.

Those are KM2's right? How are you liking them? And how do they fit in the wheelwells - do they stick out any?
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  #232  
Old September 23rd, 2010, 02:04 PM
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Quote:
Originally Posted by don

Rig looks beastie with the 35's on Wolfs and all blacked out.

Those are KM2's right? How are you liking them? And how do they fit in the wheelwells - do they stick out any?
I love the KM2s and they fit perfectly after some adjustment to tire stops.
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  #233  
Old September 23rd, 2010, 02:13 PM
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Coming to the end of the project (yeah, right). Installed a MudUK rear door panel, Terrafirma caster corrected radius arms with new bushes, KAM HD rear shafts, and HD drive flanges at all 4 corners. Also finished the auxillary air tank install using a 4 gallon stainless tank.
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  #234  
Old September 23rd, 2010, 02:38 PM
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Question

Quote:
Originally Posted by Wolf Fabrication View Post
Coming to the end of the project (yeah, right). Installed a MudUK rear door panel, Terrafirma caster corrected radius arms with new bushes, KAM HD rear shafts, and HD drive flanges at all 4 corners. Also finished the auxillary air tank install using a 4 gallon stainless tank.
So now are you going to use it ?
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  #235  
Old September 23rd, 2010, 02:54 PM
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Quote:
Originally Posted by 130Tdi

So now are you going to use it ?
The truck or the air tank?

Air tank is for small stuff like tires and air mattreses, and big stuff like Gustavos blow up doll. I've got a nice low CFM air ratchet and drill I use too.
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  #236  
Old September 23rd, 2010, 03:04 PM
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So now are you going to use it ?
Probably not. Anyone who runs a 35" tire and posts a pic of it on pavement, will only be using it to go get ice cream....
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  #237  
Old September 23rd, 2010, 03:28 PM
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Originally Posted by wolf fabrication View Post
the truck or the air tank?

air tank is for small stuff like tires and air mattreses, and big stuff like gustavos blow up doll. I've got a nice low cfm air ratchet and drill i use too.

the whole damn thing !

.
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  #238  
Old September 23rd, 2010, 05:03 PM
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the whole damn thing !

.
Ah, now I understad your question. It will primarily be used for curb crawling, grocery getting, and occasional Starbucks runs. It will continue to suck the $$ out of my wallet, and I'll eventually sell it at a $5k minimum loss. I'll probably trailer it to all the MARs and then splash mud on to make it look like I wheeled it too. If you want to know what I really do with it, buy the Lucky8 Easter Expo 2010 DVD at MAR.
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  #239  
Old September 23rd, 2010, 08:13 PM
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If you want to know what I really do with it, buy the Lucky8 Easter Expo 2010 DVD at MAR.[/QUOTE]


Yeah, there are some talented folks out there who know how to use photoshop rather well.....
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  #240  
Old September 23rd, 2010, 10:28 PM
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[QUOTE=Wolf Fabrication;242643]If you want to know what I really do with it, buy the Lucky8 Easter Expo 2010 DVD at MAR.[/QUOTE

know you used it once since you have had it. meant going forward since its finished
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