Rear Axle Rebuild/Toyota Conversion - Page 2 - Defender Source
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  #21  
Old October 11th, 2010, 07:42 AM
LFORGUE8
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Lucas Forgue
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the welds look better than mine.....i did mine this weekend with my new to me 220v lincoln and i did more grinding.... anyway i think it should be ok.......now just like you paint next.

im getting to the point where these parts sitting in the garage way to long now
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  #22  
Old October 13th, 2010, 09:31 AM
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Don Bunnell
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Quote:
Originally Posted by LFORGUE8 View Post
the welds look better than mine.....i did mine this weekend with my new to me 220v lincoln and i did more grinding.... anyway i think it should be ok.......now just like you paint next.

im getting to the point where these parts sitting in the garage way to long now
My buddy can really lay down nice beads. He is a welder by trade and wicked into it. I need to get myself one and thinking one of those "suitcase" Miller TIG units.

Yeah, I have had the parts on the shelf way too long but just too damn busy as I want the paint to be dialed and I don't have a full free day to do so.
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  #23  
Old October 13th, 2010, 12:33 PM
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Lucas Forgue
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Don, did you leak test the caps?......as i said before my welds looked like crap and i leak tested them with some used engine oil and found some leaks so off to the grinding again!

just wondering if you checked seeing that it would be easy to fix now than find leaks when its installed on the truck!

fwiw!
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  #24  
Old November 30th, 2010, 08:13 AM
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Lucas Forgue
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Don any updates?
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  #25  
Old November 30th, 2010, 11:19 PM
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Don Bunnell
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Originally Posted by LFORGUE8 View Post
Don any updates?
Nope. The axle and all the parts ready to go on are waiting on the shelf. I have a ton of house projects going on right now (including a new kitchen and extensive landscaping) that need to get done before Xmas. The axle will get moved to the winter project list along with a possible TIG welder and Bridgeport install into the garage.
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  #26  
Old December 1st, 2010, 08:31 AM
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Charles Galpin
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A bridgeport as in a CNC milling machine?
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  #27  
Old December 1st, 2010, 12:06 PM
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A bridgeport as in a CNC milling machine?
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  #28  
Old December 2nd, 2010, 07:48 AM
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Originally Posted by cgalpin View Post
A bridgeport as in a CNC milling machine?
Yeah, looking to work with a buddy and start making bike frames (and maybe some Rover pieces ).

Here is a sample of his work - stainless and some inconel exhaust work actually: http://i32.photobucket.com/albums/d4...Inconel009.jpg
http://i32.photobucket.com/albums/d4...Inconel011.jpg
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  #29  
Old December 2nd, 2010, 10:14 AM
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Charles Galpin
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Sweet! Can I be your new best friend?
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  #30  
Old December 2nd, 2010, 10:43 AM
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Lucas Forgue
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those welds are so sweet!
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  #31  
Old December 5th, 2010, 02:44 PM
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Don Bunnell
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Sweet! Can I be your new best friend?
Sure - although I will need some learning time on it. Hopefully my buddy can pop over and give me some instruction on it. Will post once I get further down that path. Pretty psyched if I can make it happen.
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  #32  
Old November 2nd, 2011, 07:25 PM
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Don Bunnell
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I really take forever to do anything but the scope of this project had me slacking. Got the axle por15 and then primer followed by chassis coat this summer. Started to put it together and needed to shave the stub axles some more. But got new rotors, bearings, and seals in.

This week:

Monday: bust - Halloween with 3 kids is a busy day. I did drive the 90 around so it was down to fumes.

Tues: dive in. Jack up the rear, had some big old blocks of pine that I was saving for just this. Used them as jack stands with some 4x6 timber to get to the right height.

Shocks seemed the easiest target, then trailing arms, then brake line, a-arm was a mother trucker. One of the bolts that hold the ball joint assembly came out no problem. Other one was frozen. Remembered I had a 30mm spanner so did it by the ball joint. I thnk I had the axle out before the kids got home at 3:30 and I started almost at 2. Air impacts were in full swing.

Sprayed the heck out of that a-arm assembley and got it out after the kids were in bed but snotted up the bolt. I plan I revisiting it with a new one when I have some time.

Pics are of the axle out, new axle, and dirty and slightly rusty frame

Edit - one pic is from today - first coat of POR15

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  #33  
Old November 2nd, 2011, 07:39 PM
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Don Bunnell
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Wed: Started off getting the gas tank out. Last time I was in there in was a PITA but copper grease and knowing where things are and it was out quick. Thanks to the guy who posted about using a coat hanger to get the vapor line off. Search for about a half hour last night but rather save my time in the garage.

Also popped off the A arms. Will primer and rustoleum them along with the springs and shock mounts. Fedex Ground dropped a box with some trailing arms from Keith at RovingTracks. Pure beef and they have a nice bend in them.

Lots of prep work but got to the first coat of POR around 4. The Marine Clean and Metal Ready take forever but need to do it for the POR to work, and they do help to clean.

Also got the brake calipers transferred to the new axle and some EBC greens that have been sitting on the shelf for over a years. Just need to fab up a bracket for the brake line split and the axle will be done done. O wait, might put the springs on the axle, to save a step on the truck.

Pics are new axle with parts, POR15 first coat and a shot of the EBC greens.

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  #34  
Old November 2nd, 2011, 07:50 PM
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Looks very cool but shouldn't you be busy making me a bike rack plate?

In all seriousness, you have a galv frame? Looks nice. Also I see this is what Brad was trying to do if we do end up figuring the truck out.
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  #35  
Old November 2nd, 2011, 09:09 PM
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Don Bunnell
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Quote:
Originally Posted by bjf
Looks very cool but shouldn't you be busy making me a bike rack plate?

In all seriousness, you have a galv frame? Looks nice. Also I see this is what Brad was trying to do if we do end up figuring the truck out.
I know - I feel bad but as you can tell I take forever as I always seem to have too much crap on my plate. I might just send out my current setup to you. Biking season is almost done and I can just throw the bike in the back of the 90 or Suburban from here on out. And once I get get my welder I will do up a proper bike rack for the back.

No galvy chassis. That is just the silver POR15. I like to use it so I can see where it is. Then top coat with semi gloss. Wish I had galvy tho as I wouldn't care about the mud and stuff that gets stuck in the tight areas.

I saw Brads post on this thread when I was reading back to see when I started it. Felt bad and sad seeing it. If you guys get the truck and have any questions I would love to help. Not sure if he was doing front as well but the back is straight forward. Time consuming but nothing to crazy yet. I just hope it goes back together easily.
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  #36  
Old November 3rd, 2011, 07:58 PM
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Don Bunnell
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Thurs: Not as much done as yesterday but picking away. 2nd coat of POR-15 in the afternoon when temps were high enough. I like the POR-15 stuff but it would be nice if it had more flexible time between coats. I think 24 hours in between was a bit too long but couldnt go out to the garage to paint at midnight and in 40 deg temps....

Got a bunch of little parts prepped and painted using good old rustoleum pro stuff. POR-15s marine clean and metal ready got the upper shock mount, springs, a-arms, and bump stops all cleaned. The Rustoleum primer and then semi gloss black went down nicely. Got them hanging now in the garage - looks like a meat locker but with Rover suspension parts.

Pics are of parts getting primer then paint. Everything came out great but the springs. Hard to sand them and just as tough to paint them.
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  #37  
Old November 3rd, 2011, 08:02 PM
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Don Bunnell
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Springs. Came out like shit but should still work fine.

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  #38  
Old November 4th, 2011, 08:57 AM
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Charles Galpin
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Don, looking good! I assume you'll be done by ROTR?

Would you mind telling me what size and length the bolts are that hold the a-arm pieces together are? I'm tearing down my suspension and haven't gotten to that yet, but want to order some replacement bolts now so I can get it all back together in time for ROTR.

TIA
charles
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  #39  
Old November 4th, 2011, 12:39 PM
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Don Bunnell
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Don, looking good! I assume you'll be done by ROTR?

Would you mind telling me what size and length the bolts are that hold the a-arm pieces together are? I'm tearing down my suspension and haven't gotten to that yet, but want to order some replacement bolts now so I can get it all back together in time for ROTR.

TIA
charles
Thanks Charles - keeping fingers crossed that she'll be sorted for ROTR. Tear down wasn't bad so I'm hoping I can put it back without too many issues. If it gets too late I'll just not wire the locker. Also have to pop the front diff out to get in an ARB/4.10 Rover diff that's been laying around. I'm guessing I will have a couple of late nights next week.

Charles do you mean the ones where they join at the ball joint? If so I brought one of the snotted ones to Lowes and grabbed 2 Grade 8 1/2" x 6.5" long with lock nuts. It's not exact but very close. I have 2 of those ball joint pieces so I plan on swapping in a new ball joint at some point down the road. There is a thread on discoweb that has the proper size if you are ordering from McMaster Carr.
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  #40  
Old November 4th, 2011, 12:39 PM
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Nice "paint booth"!
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