200Tdi into 109 - Defender Source
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  #1  
Old August 13th, 2011, 11:29 PM
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200Tdi into 109

Hi All,

Some of you know that I started RedSq's (my 1960 109 SII LWB) engine swap over to a 200tdi this past weekend. Here is a link to a facebook album of photographs of the work so far. I think everyone should be able to see it.

http://tinyurl.com/3tmp9ab

Cheers
Dave
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  #2  
Old August 14th, 2011, 01:02 AM
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Looks good... what are you going to do with the turbo?
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  #3  
Old August 14th, 2011, 09:33 AM
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Hi Andrew. Was planning to move the turbo using a schedule 40 elbow and some flanges. I also bought a set of defender manifolds and turbo on ebay uk. Not really sure what I am going to do but will have a better idea once things start coming together.
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  #4  
Old August 14th, 2011, 10:00 AM
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Looks interesting, I'll be watching.
It might though if you were drinking more appropriate stuff.
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  #5  
Old August 14th, 2011, 09:03 PM
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Nice work Dave - I thought you had all but given up on the Red Square with your cushy new 300 Tdi D-90.
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  #6  
Old August 14th, 2011, 10:54 PM
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I'm too deep in the hole with that thing to give up on it

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Nice work Dave - I thought you had all but given up on the Red Square with your cushy new 300 Tdi D-90.
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  #7  
Old August 15th, 2011, 08:21 AM
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LOL. Looking good man!
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  #8  
Old August 15th, 2011, 06:38 PM
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Hey, nice job on the timing pin thingy.
I have been scalloping out the cross member and welding in a section of tube....similar to the modification for frnt driveshaft clearance on SOA conversion. Allows the use of standard tooling.
I might like your idea better.
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

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  #9  
Old August 15th, 2011, 08:02 PM
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Thanks, yeah, I didn't want to do all that to the chassis. Especially since I have a habit of re-arranging those crossmembers...

Now I do still need to figure out how to make a useable drain plug. Hoping there is enough room to get the factory plug in and out.

Quote:
Originally Posted by junkyddog11 View Post
Hey, nice job on the timing pin thingy.
I have been scalloping out the cross member and welding in a section of tube....similar to the modification for frnt driveshaft clearance on SOA conversion. Allows the use of standard tooling.
I might like your idea better.
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  #10  
Old August 16th, 2011, 01:16 AM
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Quote:
Originally Posted by Ren Ching View Post
Hi Andrew. Was planning to move the turbo using a schedule 40 elbow and some flanges. I also bought a set of defender manifolds and turbo on ebay uk. Not really sure what I am going to do but will have a better idea once things start coming together.
I think the defender manifolds will work with a lot less fuss, you were lucky to find them.
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  #11  
Old August 16th, 2011, 07:14 AM
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I took a pile of steering conversion photos yesterday and now cant find the damn cord for the camera to get them loaded........and my card reader seems to be non functional.........hopefully shopgirl can get it sorted and up on the facebook.
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

"Dedicated to the resurrection of junk through engineering?"
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  #12  
Old August 16th, 2011, 07:46 AM
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Thanks Matt, I'll look for 'em.

Mike, I have been surprised at how often the defender 200tdi stuff comes up on ebay uk.
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  #13  
Old August 16th, 2011, 11:20 AM
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Quote:
Originally Posted by junkyddog11 View Post
Hey, nice job on the timing pin thingy.
I agree! But I have a 200tdi defender motor and that boss is still blank... if there is a notch in the flywheel what models had that hole (just curious??)
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  #14  
Old August 16th, 2011, 01:37 PM
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there isn't a pre-existing notch. but there is a pair of hash marks. I'm pretty sure my 5 bearing 2.25 petrol had a plug in that location and have since seen a few photos of 200tdi's with one as well. You can really make the hole anywhere since you are drilling your own hole for the pin. I was a bit concerned about upsetting the balance of the flywheel but i decided that the amount of metal removed was so small and the amount of imbalance created would probably be no more than that caused by the clutch pressure plate being bolted on any which way. I could always drill another hole 180 degrees out, but that is just getting a bit beyond "Ren good"

I was a bit bummed that I got the thread pitch wrong. Anybody know what the proper thread is for these flywheel housing plugs?

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I agree! But I have a 200tdi defender motor and that boss is still blank... if there is a notch in the flywheel what models had that hole (just curious??)
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  #15  
Old August 16th, 2011, 02:57 PM
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Isn't it BSP?
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  #16  
Old August 16th, 2011, 04:02 PM
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I tapped mine to 1/4" BSPP and I couldn't even get the original plug started in the hole. The 1/4" BSPP plug from McMaster Carr fit perfectly.

Could be metric or maybe 1/4 NPT. Dunno...
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  #17  
Old August 16th, 2011, 04:45 PM
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Do you have a thread gauge?
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  #18  
Old August 16th, 2011, 05:12 PM
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so what the flywheel locking tool wont thread in ? Thats the only reason you went to this trouble right ?
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  #19  
Old August 16th, 2011, 05:13 PM
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Somewhere...don't know if it has one for 19. Or the metric pitches. I've been pretty successful with figuring out threads by other means. On this one I just ass/u/me(d)

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Do you have a thread gauge?
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  #20  
Old August 16th, 2011, 05:15 PM
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Originally Posted by oilburner View Post
Do you have a thread gauge?
Was that a Canadian bitch slap ?
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