1970 IIa 109 ex mod build thread

[masonater]

I started this project in February 2010 with a 109 that has been in the family for about 20 years. It spent its ex mod life on Nantucket island where the salt gave it a real beating. It was getting to the point where I either save it now or it would have been beyond repair and required at least a new frame and much more im sure. I have never done a restoration before but have always been obsessed with rovers and wrenching on them. I figured taking one apart and putting it back together would be a great way to learn.

Anyway this is the start of my build thread. I welcome any criticism or questions. There is no way I could have made it to where I am now had it not been for this forum and the folks on it. February of last year it was running and driving perfect before I started taking it apart. I spent each and every day until end of May wrenching on it. This year my quest started up again on new years day 2011 and I have been going ever since. Currently I almost have a rolling chassis (waiting on tires) and I have now taken on the bodywork and wiring process.

Some background info on the rover: 1970 IIa 109 ex mod with 46,000 miles. Started life as an ambulance but when purchased in 1990 it was fresh off the boat with no more ambulance box. It was converted to left hand drive and had a pick up bed and soft top added. It was also still camo though not for long.
http://i1183.photobucket.com/albums/x478/masonater84/P3280258.jpg
http://i1183.photobucket.com/albums/x478/masonater84/PB260590.jpg

[masonater]

Removed soft top and some other small bits, started to see what i was getting my self into.
http://i1183.photobucket.com/albums/x478/masonater84/P2050114.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P2050116.jpg

[masonater]

Started the long fight with rusty old nuts and bolts removing the seats, seat box, and floor boards.
http://i1183.photobucket.com/albums/x478/masonater84/P2050134.jpg
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0119.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P2070144.jpg

[masonater]

next came the bed. Not nearly as hard as I thought it was going to be. Started to see some of the rust I was up against...
http://i1183.photobucket.com/albums/x478/masonater84/P2070145.jpg
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0125.jpg

[masonater]

Then on to the front wings, this is when I found my new friend the cut off wheel.
http://i1183.photobucket.com/albums/x478/masonater84/P2080156.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P2080159.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P2080160.jpg

[masonater]

Rear crossmember in very rough shape
http://i1183.photobucket.com/albums/x478/masonater84/P2090162.jpg
A few years back i removed a beach sticker and with it came some metal revealing how bad it really was.
http://i1183.photobucket.com/albums/x478/masonater84/P2090163.jpg

[masonater]

Front drivers side frame horn, or what was left of it...
http://i1183.photobucket.com/albums/x478/masonater84/P2090172.jpg
More parts coming off
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0131.jpg
door rot. probably going to scab patch and save up for some new tops this summer.
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0136.jpg

[masonater]

before and after some time in the bead blaster
http://i1183.photobucket.com/albums/x478/masonater84/P3160363.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P3160361.jpg
Wiper motor rebuild start. not sure why i did this because it worked fine, i guess i just wanted to see its guts.
http://i1183.photobucket.com/albums/x478/masonater84/P3190382.jpg
After powder coating, time to rebuild
http://i1183.photobucket.com/albums/x478/masonater84/P3210399.jpg

[masonater]

Pulled out the motor with no problems at all. Hoist didn't break a sweat.
http://i1183.photobucket.com/albums/x478/masonater84/P3220406.jpg
Lots of oil in bell housing, seemed like a mix of engine and 90w oil
http://i1183.photobucket.com/albums/x478/masonater84/P3220410.jpg
Motor after a steam bath
http://i1183.photobucket.com/albums/x478/masonater84/P3240426.jpg
bell housing after bath
http://i1183.photobucket.com/albums/x478/masonater84/P3240429.jpg
Started coal slag blasting because I thought that was as far as I would go in the disassembly, we all know how that goes...
http://i1183.photobucket.com/albums/x478/masonater84/P3260442.jpg
Cut out rusted frame horn
http://i1183.photobucket.com/albums/x478/masonater84/P3310466.jpg

[masonater]

baking powder coated drive shaft
http://i1183.photobucket.com/albums/x478/masonater84/P4120522.jpg
Removing swivel assembly was a nightmare. All the nuts were caked with undercoat.
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0232.jpg
Removing military undercoat was the worst. Spent a few days with an air chisel and scraper chipping away...
http://i1183.photobucket.com/albums/x478/masonater84/P4180551.jpg
Got my new used crossmember in the mail (thanks Ike)
http://i1183.photobucket.com/albums/x478/masonater84/P4180554.jpg
Another before and after bead blast of the swivel housing.
http://i1183.photobucket.com/albums/x478/masonater84/P5090575.jpg
Powder coated housing and swivel balls.
http://i1183.photobucket.com/albums/x478/masonater84/P5210626.jpg

[masonater]

Before and after hub blast
http://i1183.photobucket.com/albums/x478/masonater84/PC310266.jpg
OCD taping prep for powder coat
http://i1183.photobucket.com/albums/x478/masonater84/PC310269.jpg
came out great!
http://i1183.photobucket.com/albums/x478/masonater84/P1010272.jpg
Cut the old crossmember off
http://i1183.photobucket.com/albums/x478/masonater84/P1020298.jpg
Dumpster time
http://i1183.photobucket.com/albums/x478/masonater84/P1020296.jpg
Home built frame horn (first time playing with metal so forgive me)
http://i1183.photobucket.com/albums/x478/masonater84/P1030299.jpg
Time to learn how to weld
http://i1183.photobucket.com/albums/x478/masonater84/P1030305.jpg
After a little practice i went for it...
http://i1183.photobucket.com/albums/x478/masonater84/P1100328.jpg

[masonater]

Frame coal slag blast, turned that snow into black gritty mud.
http://i1183.photobucket.com/albums/x478/masonater84/P1140340.jpg
Few hours and 100 pounds of slag later...
http://i1183.photobucket.com/albums/x478/masonater84/P1140342.jpg
Front axel ready for primer
http://i1183.photobucket.com/albums/x478/masonater84/P1200356.jpg
Used eastwood extreme chassis black primer and satin black top coat
http://i1183.photobucket.com/albums/x478/masonater84/P1200359.jpg
Done
http://i1183.photobucket.com/albums/x478/masonater84/P1230370.jpg
Spent 8 days painting the frame. 4 on top and sides and 4 on bottom once i flipped it over. Paint took 24 hours to cure between coats and about 2.5-3 hours to brush it on. 2 coats of primer and 2 of top coat.
http://i1183.photobucket.com/albums/x478/masonater84/P1230369.jpg
my 5 second tape job (should have spent a little more time making it right but i was too excited to paint it)
http://i1183.photobucket.com/albums/x478/masonater84/P2060431.jpg
Duplicolor Detroit Diesel Alpine Green
http://i1183.photobucket.com/albums/x478/masonater84/P2060432.jpg

[masonater]

dug into the transmission and resealed the whole thing. Took a lot of guts for me to start, i had never seen the inside of one.
http://i1183.photobucket.com/albums/x478/masonater84/P2090459.jpg
New ebrake shoes and springs and naturally, some powder coat
http://i1183.photobucket.com/albums/x478/masonater84/P2110466.jpg
All back together and looking nice
http://i1183.photobucket.com/albums/x478/masonater84/P2110469.jpg
painted the wheel cylinders just because.
http://i1183.photobucket.com/albums/x478/masonater84/P2140474.jpg
replaced the rear main seal and put the flywheel housing back on the motor
http://i1183.photobucket.com/albums/x478/masonater84/P2230497.jpg
Started coming together!
http://i1183.photobucket.com/albums/x478/masonater84/P2230499.jpg
Frame bushing removal. Tried torching the rubber and pushing out the inner sleeve first then splitting the outer one with a sawzall, thought i cut through but once i got it out saw that i didnt in the middle. Oh well, 12 ton press made it easy.
http://i1183.photobucket.com/albums/x478/masonater84/P2160479.jpg
Beat up old bushings
http://i1183.photobucket.com/albums/x478/masonater84/P3020526.jpg
New bushings did not want to go in, press made them
http://i1183.photobucket.com/albums/x478/masonater84/P3040528.jpg
Powder coated table at its peak
http://i1183.photobucket.com/albums/x478/masonater84/P2200482.jpg

[ducttape]

Haminah, haminah, haminah... the details are magnificent.

[LaneRover]

I think your front horn repair is pretty ingenious! Not sure I would have thought of that.

Also like the fact that it looks like you are powering stuff off of a plane!

[jac04]

Awesome!

[stonefox]

Come on now! Don't you think you could of put a little more effort into this restoration and not cut so many corners :D Seriously,fantastic job!

[masonater]

Thanks guys! The frame horn came out great I forgot to take a picture of it when it was done. The welds were ugly but lots and lots of grinding and sanding later it actually looks better than the original one.

I'll bring you up to date as of a few days ago...

I had just received the parabolic springs from RN and painted them with the chassis black because they got a little scratched in shipping. They were still tacky but i couldn't wait.
http://i1183.photobucket.com/albums/x478/masonater84/P3050531.jpg
Then came the bump stops and axel housing.
http://i1183.photobucket.com/albums/x478/masonater84/P3050532.jpg
Got the swivel balls all together after a little fighting with the nuts on the lower pin. One was rounded off from disassembly and of course it is not your standard thread size. I guess BSF? I was lucky enough to find one in the hangar because there used to be a P51 Mustang in here and i guess they were all BSF stuff.
http://i1183.photobucket.com/albums/x478/masonater84/P3050533.jpg
Attached to the axel and put on the U bolts. Went with the original U bolts because the ones i got with the parabolics didnt match up with the arches in the U. 2 of mine were flat on top to sit on the axel bracket and only one was with the new ones.
http://i1183.photobucket.com/albums/x478/masonater84/P3050536.jpg
coming along...
http://i1183.photobucket.com/albums/x478/masonater84/P3060538.jpg

[masonater]

After a little trouble getting the springs into the holes i managed to get the brakes on. Im sure there is a better way then how i did it.
http://i1183.photobucket.com/albums/x478/masonater84/P3060542.jpg
Hub on with bearings all packed and spinning nicely.
http://i1183.photobucket.com/albums/x478/masonater84/P3060543.jpg
Axel flange on and torqued down (thanks to Terri Anns website)
http://i1183.photobucket.com/albums/x478/masonater84/P3060544.jpg
Getting carried away with powder coating but it is just so cool!
http://i1183.photobucket.com/albums/x478/masonater84/P3070552.jpg
This was a big day, got the motor and trans mounted back together. Would have been a lot faster and easier if i had a helper but i managed.
http://i1183.photobucket.com/albums/x478/masonater84/P3080559.jpg

[Broadstone]

Very impressive work!! I have never owned an MOD truck but I am curious why the steering arms are mounted to the top of the swivel housing? Is there a reason for this like extended shackles need clearance or something?

[masonater]

Soon after it was time to place motor and trans back in.
http://i1183.photobucket.com/albums/x478/masonater84/P3090564.jpg
Everything lined up great and I was surprised how easy it all went it.
http://i1183.photobucket.com/albums/x478/masonater84/P3090573.jpg
Got Ikes bracket and new alternator with the dual pulley, having 2 belts is so neat i think.
http://i1183.photobucket.com/albums/x478/masonater84/P3100576.jpg
Gas tanks going back on...
http://i1183.photobucket.com/albums/x478/masonater84/P3120587.jpg
Borrowed a friends fancy camera and had a little photo shoot:thumb-up:
http://i1183.photobucket.com/albums/x478/masonater84/P1000338.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P3130600.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P3130602.jpg

[martindktm]

Nice job. And nice garage by the way...:thumb-up:

[Terrys]

Very impressive work!! I have never owned an MOD truck but I am curious why the steering arms are mounted to the top of the swivel housing? Is there a reason for this like extended shackles need clearance or something?
Early ones were on top, later ones were on the bottom, Though somehow I thought 1970 used later type axle.

[Broadstone]

Terrys I do not know how to do the quote thingy! I agree about early ones being on top but I was informed that they were switched to the bottom with the IIA.

[masonater]

I was very lucky to find this was the worst of the rust on the entire bulkhead.
http://i1183.photobucket.com/albums/x478/masonater84/P3210618.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P3210620.jpg
Cut out
http://i1183.photobucket.com/albums/x478/masonater84/P3210621.jpg
old vs. new
http://i1183.photobucket.com/albums/x478/masonater84/P1000356.jpg
Welding in new piece, drilled and cut holes to match old one.
http://i1183.photobucket.com/albums/x478/masonater84/P3270630.jpg

[masonater]

Got a 25 foot roll of brake line to make all new ones along with all new fittings. I used the entire roll and just made it by inches! (a few throw aways ill admit)
http://i1183.photobucket.com/albums/x478/masonater84/P3290632.jpg
powder coating the rear line. Ran it on inside of frame rail after reading another thread a while back. I assume that the holes through crossmembers and a few other brackets were for this?
http://i1183.photobucket.com/albums/x478/masonater84/P1000375.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P1000365.jpg
Got new rubber exhaust hangars in the mail. Hung the exhaust after some hi temp black powder coat.
http://i1183.photobucket.com/albums/x478/masonater84/P1000380.jpg
Now my attention is turned to body work. I already got my paint (Tan 686) same as Jac04's beauty. I am sanding as much as i need to get to good paint/metal. Enough for a self etching primer to stick.
http://i1183.photobucket.com/albums/x478/masonater84/P3280631.jpg

Now all that is left is more body work, all new wiring, and assembly.:eek:

[jac04]

Powdercoated brake lines! Wow! I thought that I was going overboard by clear coating mine. :thumb-up:

[masonater]

Powdercoated brake lines! Wow! I thought that I was going overboard by clear coating mine. :thumb-up:

The bronze T blocks and all drain plugs are done with clear powder too! Can you tell i love powder coating?:D

[Terrys]

Terrys I do not know how to do the quote thingy! I agree about early ones being on top but I was informed that they were switched to the bottom with the IIA.
The switch was within the 2A models, but I am not sure when. If I had guessed, I would have said well before 1970. I had a '70 ExMod, and mine were mounted to the bottom of the SBs.
To do the 'quote thingy', instead of hitting 'reply', hit 'quote'. Then if you only want to quote a small bit, delete the rest, just leaving the bracketed (the parts inside the [ and] symbols) parts

[masonater]

There have been a couple odd things along the way I have discovered about this 109. The frame bushings on the rear were the smaller diamater ones, and ones up front were larger series 3 ones. Did all military rovers come with salisbury rears? mine has rover axels with added on supports i assume for bracing? One of these days I want to send in my info i have for the rover to Early Military Land Rover Association and see what they can dig up...Painted on the side of the seat box was "T.M.P. O.R.D." That ring a bell to anyone?

[Broadstone]

symbols) parts


You learn something new every day. Thanks Terrys!

[scatterling]

Build looks great! :thumb-up:

[I Leak Oil]

Looks good and you work quick. All that in a day huh?;)
Not to hijack but any info on the flattie? Looks like USN issue?

[stonefox]

Powdercoated brake lines! Wow! I thought that I was going overboard by clear coating mine. :thumb-up:
Yes Jeff you definately cut some corners on your lightweight , I was gunna call you out on it but I'm glad you came clean to all of us about it.:D
Mason, I truly am having second thoughts about starting my build thread.You have raised the bar . I know the hours and coin I have put into my project and it pales in comparison to your build. Each new entry makes my jaw drop.
You must be divorced by now:D

[masonater]

Not to hijack but any info on the flattie? Looks like USN issue?
47 CJ3A restored about 8 or 9 years ago. It is my wiring inspiration, all done like an airplane with brakers and very simple. Not military just painted like one. Only has about 350 miles since rebuild about 300 of which i put on last spring...Runs amazing, pretty much a hangar queen sadly. I do cruise it around the airport a lot though...

[masonater]

You must be divorced by now:D
try 26 and single! I figure i have about 2,000 hours into the build so far and probably close to that in $$ give or take a few hundred. Helps to have access to a mega shop :D and a seasonal job, although that doesn't really help with cash flow. Eat. Sleep. Rover. :thumb-up:

[masonater]

Before a huge thunderstorm passed through today i had the bulkhead outside. Lots of sanding and grinding away a combination of surface rust and layers of paint and undercoat. Glad i took it down to metal because i found some sneaky rust around the door posts. I will probably just fill in the holes with weld. Found lots of bondo around the seams on the front side. Wonder who did that? doubt the military folks took the time to seam seal with bondo...
http://i1183.photobucket.com/albums/x478/masonater84/P4010637.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4010638.jpg

[jac04]

Found lots of bondo around the seams on the front side. Wonder who did that? doubt the military folks took the time to seam seal with bondo...

I found dried-out seam sealer on almost all my bulkhead seams. It was so dried-out that it looked like Bondo. It was definitely doing more harm than good. After sandblasting, I slightly thinned some Eastwood Rust Encapsulator and poured it into all the seams.


try 26 and single! I figure i have about 2,000 hours into the build so far ...

Wow, reminds me of the good old days! Must be nice to work during daylight hours. All my work gets done between 8pm and about 1am when my wife and 2 kids are sleeping.

[rbbailey]

RV-4, Citabria, Pacer, a Skymaster, something sporty under the cloth... oh, and a Series 109. .......I could live in that hangar and be happy for the rest of my life. So. Cool. :thumb-up:

[masonater]

RV-4, Citabria, Pacer, a Skymaster, something sporty under the cloth... oh, and a Series 109. .......I could live in that hangar and be happy for the rest of my life. So. Cool. :thumb-up:

RV-8 with a 540, 240z under the cover, and i live up in the loft:thumb-up:

[rbbailey]

RV-8 with a 540, 240z under the cover, and i live up in the loft:thumb-up:

Too... much.... to.... comprehend. What a collection!

I'm just hoping to get my IIa up and running some day. The Pacer is actually the plane I want to buy -- but each of those birds would be on my short list, although to fill it out, I'd have to add a Cessna 180 and probably a Maule. :D

[TSR53]

RV-8 with a 540, 240z under the cover, and i live up in the loft:thumb-up:

Exceptional build thread, very nice shop hanger too! We like your powder coated brake lines. Very nice to have your loft right off the tarmac, lucky you - test the 240Z and all the other goodies.

Since you gurus are straying off-topic I might as well chime in... Great to see all the pilots come out the wood work. Getting ready for flying season soon with piloting my electric powered RC Sailplanes. My hanger is filled with a 2 meter and several 2.35+ meter planes; Radian, DG-1000, ASK-21, Ventus and a Discus.

[masonater]

went away for a week back home to pick up some BFG muds 255/85/16 i scored for free. Hope they fit
http://i1183.photobucket.com/albums/x478/masonater84/P4140646.jpg
Pressure washed the hood and the old crappy paint job just flaked right off.
http://i1183.photobucket.com/albums/x478/masonater84/P4140647.jpg
Hung the bulkhead, radiator support, and seat box and got them ready to start painting
http://i1183.photobucket.com/albums/x478/masonater84/P4150651.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4150652.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4160653.jpg
Used some aircraft etch primer called dupont variprime 615s, after some research it appears that you have to prime over this primer. I had already ordered some etching primer from eastwood but couldn't wait to start.
http://i1183.photobucket.com/albums/x478/masonater84/P4160654.jpg
I had only one quart of eastwoods primer and ran out after the bulkhead and radiator support.
http://i1183.photobucket.com/albums/x478/masonater84/P4160663.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4160665.jpg
Filled a couple holes in the tailgate and sanded it ready for primer.
http://i1183.photobucket.com/albums/x478/masonater84/P4160658.jpg
Sanded the hood to try and smooth out the 4 layers of old paint.
http://i1183.photobucket.com/albums/x478/masonater84/P4160659.jpg

[rwollschlager]

went away for a week back home to pick up some BFG muds 255/85/16 i scored for free. Hope they fit
http://i1183.photobucket.com/albums/x478/masonater84/P4140646.jpg


those should fit fine, if you suddenly decide you don't like them shoot me a pm and I will gladly purchase them from you.
keep up the great work! :thumb-up:

-Rob

[masonater]

Got the sills apart and sanded them down good enough for a primer.
http://i1183.photobucket.com/albums/x478/masonater84/P4170668.jpg
After a battle with the 20 something flathead screws and nuts holding the spare tire plate on the hood, i used a cut off wheel and zipped them all off. All those layers of paint and rust was making it next to impossible to get a good bite with a flat head.
http://i1183.photobucket.com/albums/x478/masonater84/P4170669.jpg

[masonater]

tornado sirens going off now so i figure i'd update my build thread in case this is it. Today i finished sanding and prepping the doors for paint along with a few smaller bits.
http://i1183.photobucket.com/albums/x478/masonater84/P4180670.jpg
Also used some sticky screen stuff then bondo to patch the missing corners of my doors. Not a fan of bondo but someday ill get new ones so it will do for now.
http://i1183.photobucket.com/albums/x478/masonater84/P4180673.jpg

[masonater]

my misson for tomorrow is to prime all these parts along with the hood and 5 wheels. Bulkhead, radiator grill, and seat box are already primed. If i can, im going to shoot all the parts in desert tan by the end of the day.
http://i1183.photobucket.com/albums/x478/masonater84/P4180675.jpg

[morgant]

Also used some sticky screen stuff then bondo to patch the missing corners of my doors. Not a fan of bondo but someday ill get new ones so it will do for now.
http://i1183.photobucket.com/albums/x478/masonater84/P4180673.jpg

I'd just POR-15 over it. It'll seal it against rust nicely, add some strength, and you'll still have plenty of drainage. Although, you'd probably want to prep the surface underneath it first and I'm assuming the sticky screen stuff is mostly aluminum, so I'm not sure how well the POR-15 would adhere to it.

Regardless, I'm with you that you can just plan for new doors. Considering the rest of your build quality, I think you can skimp on door corners a bit. :)

May the tornados pass your hangar by.

[jac04]

If i can, im going to shoot all the parts in desert tan by the end of the day.


I can't wait to see how they come out. Keep up the good work. :thumb-up:

[cousindave]

I ABSOLUTELY love this post! Good luck! Keep the posts coming. I am addicted!

[masonater]

Thanks guys! I am so excited to finally be doing things that are near the end. UPS has my primer on the truck for delivery. Here is a shot of post bondo and sanding of the doors. Came out pretty good considering the corners did not exist.
http://i1183.photobucket.com/albums/x478/masonater84/P4190682.jpg

[masonater]

Huge day of painting today. 28 parts i think at last count. All done in eastwoods self etching primer, with the exception of the seat box that was done in dupont variprime 615s and 620s converter (wanted to try it). I used a Croix HVLP system that has painted many airplanes in its day and it worked pretty well. Aside from auto shop in high school this was my first try at painting car parts. I think i went a little too heavy on the primer because i used the about 3/4 of a gallon on all this stuff. I wanted to get into top coating with tan today, but after 6 hours of priming I needed a break. UPS didn't show up with the primer until about 4pm which set me back.
http://i1183.photobucket.com/albums/x478/masonater84/P4190689.jpg
Before primer
http://i1183.photobucket.com/albums/x478/masonater84/P4190683.jpg
After
http://i1183.photobucket.com/albums/x478/masonater84/P4190684.jpg
This was round 3 or 4 of parts
http://i1183.photobucket.com/albums/x478/masonater84/P4190688.jpg
Also did a little powder coating while waiting for the primer. I managed to score some desert tan a while back and i think its almost a dead match to the paint i have.
http://i1183.photobucket.com/albums/x478/masonater84/P4190679.jpg

[masonater]

Awesome day today, finally painted a bunch of parts desert tan. Spent about 8 hours spraying 3 or 4 coats on most all of the parts. I didn't get as good of a coat as i would have liked on 2 of the wheels so tomorrow i will reshoot them. After all that time spraying, my goggles got pretty covered in paint and i guess i just couldn't see well enough to notice. In the end i was pretty happy with how it came out considering this was my first time. I also realized that after ordering 4 gallons of paint and only using 3/4 of one today, i will have lots left over. Maybe ill paint my grand cherokee too!
http://i1183.photobucket.com/albums/x478/masonater84/P4210001.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4210003.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4210009.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4210012.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4210007.jpg

[rejeep]

Sweet

[jac04]

Looks great Mason! You're really moving on this project.

[masonater]

Thanks Jeff, I had already started painted before i got your PM. I put 3 or 4 coats on wheels already but I think im going to try a sling like you did and shoot one or 2 more. I have plenty of paint thats for sure! Should I wait a while after they dry before mounting them on rubber? I was thinking a day or 2?

[martindktm]

What kind of paint are you using?

[jac04]

Should I wait a while after they dry before mounting them on rubber? I was thinking a day or 2?
I waited a little over a week, but I wanted to be really sure that they were dry. I was worried that the rubber would 'pull' the paint off when the tires were mounted.

[masonater]

What kind of paint are you using?

Enamel from Rapco Parts. Seems to dry pretty quick. Im itching to get this thing rolling!

[martindktm]

Is it a spray can or you are using a spray gun?

[martindktm]

Spray gun I guess....I just saw it in the pictures....

[masonater]

Got the bulkhead on and then got a few hundred nuts and bolts from the hardware store. As soon as i got back i realized i needed a bunch of shorter bolts than i got. Oh well, get them monday.
http://i1183.photobucket.com/albums/x478/masonater84/P4230018.jpg
Put on a wheel to see how they will look. Made me very happy!
http://i1183.photobucket.com/albums/x478/masonater84/P4230020.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4230021.jpg
Started assembling the pedals and got a little confused how the gas pedal linkages go together. Anyone have a shot of inside footwell for reference? Could use one of the area outside the footwell near the steering box too, my book is for RHD
http://i1183.photobucket.com/albums/x478/masonater84/P4230025.jpg
I think this is how it goes...?
http://i1183.photobucket.com/albums/x478/masonater84/P4230028.jpg
Couldn't resist placing the seat box, floors, and tunnel covers to see how it looks. That really put a smile on my face
http://i1183.photobucket.com/albums/x478/masonater84/P4230023.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4230026.jpg

[siii8873]

Here are some ok pictures of linkages from engine side. That gas pedal rod looks way to long for a LHD vehicle. Should just go past pedal a little and the LH support bracket should be mounted in the closer holes. Good looking project and progressing very fast. Making the rest of us look like slugs.
Nice work!!

[masonater]

HThat gas pedal rod looks way to long for a LHD vehicle. Should just go past pedal a little and the LH support bracket should be mounted in the closer holes.

Ah yes, makes sense it used to be RHD. Who ever did the switch must have used the original one. Good call on the bracket. Thanks. Rod is off to the band saw

[masonater]

powder coated lugs satin black
http://i1183.photobucket.com/albums/x478/masonater84/P4220014.jpg
Going to try and finish steering and pedals today...

[JackIIA]

looks just great. man you are moving!

[Broadstone]

You have your gas pedal installed as a RHD would be across the floorpan. This would be for LHD. The silver stuff is just anti-sieze. Looks great keep up the good work!! It took me years to do what you have been doing in a short period of time.

[masonater]

Cut the rod down to size and got the rest of the linkage put together correct (i think)
http://i1183.photobucket.com/albums/x478/masonater84/P4240037.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4240038.jpg
Also put the 5 rims and tires in the the pickup ready to bring to the tire shop tomorrow, 85 bucks to mount and balance them seem right? sounds a little high to me for maybe 30 min of work tops...

[swray]

Excellent photo documentation. Really good stuff here!

[jac04]

Also put the 5 rims and tires in the the pickup ready to bring to the tire shop tomorrow, 85 bucks to mount and balance them seem right? sounds a little high to me for maybe 30 min of work tops...
Sounds like a fair price. The local shop charges me $100 to mount & balance 5. If they are being careful, it will take them about 75 minutes. Mine came out perfect and after putting a few fingerprints (easy to remove) on the first wheel, the guy put on rubber gloves to make sure it didn't happen to the others. IMO, you usually get what you pay for.

[masonater]

Sounds like a fair price. The local shop charges me $100 to mount & balance 5. If they are being careful, it will take them about 75 minutes. Mine came out perfect and after putting a few fingerprints (easy to remove) on the first wheel, the guy put on rubber gloves to make sure it didn't happen to the others. IMO, you usually get what you pay for.

good point, and good call on rubber gloves. Ill mention how easy finger prints show up on our paint...

[masonater]

Got the wheels mounted on the BFG's today. The guys at the shop made me promise to show them the rover once it is done, they had only seen pictures of one before. They only scratched the lip on the outside of one wheel, easy to touch up with the spray cans i got...
http://i1183.photobucket.com/albums/x478/masonater84/P4250040.jpg
Got the rear ones put on and realized what a monster i am creating. Much taller than it was before, i love it.
http://i1183.photobucket.com/albums/x478/masonater84/P4250041.jpg
Sitting on her own weight for the first time in 13 months. Today may have been the best day for me so far.
http://i1183.photobucket.com/albums/x478/masonater84/P4250042.jpg
Pushed it outside for a so i could blow some air through all the holes in the frame. After many times coal slag blasting and being 41 years old, lots of junk flew out into the air. All this was prep for a waxoyl session.
http://i1183.photobucket.com/albums/x478/masonater84/P4250049.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4250045.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4250048.jpg
Wanted to see how the radiator and support would look mounted. Im going to hook it up for good in the next couple days.
http://i1183.photobucket.com/albums/x478/masonater84/P4250056.jpg
Couldn't resist putting on grill and bumper. Then i sat at looked at it with a glass of Colonel E.H. Taylor Kentucky bourbon (amazing) for about an hour.
http://i1183.photobucket.com/albums/x478/masonater84/P4250059.jpg

[jac04]

Looks fantastic!
I didn't notice any weights on the outsides of the wheels. Did they put all the weights on the insides?

[masonater]

Looks fantastic!
I didn't notice any weights on the outsides of the wheels. Did they put all the weights on the insides?

Yeah i asked them to put them inside only, i have always hated how you have to bash them on and if they ever need to be moved with changing tires you see where they were. Plus after the paint job i couldn't stand to see them. Max speed limit on island is 45 and i dont think i have ever been over 55 in the rover. Can't imagine getting much vibration at those speeds.

[ccec]

I Give!!!

You're killing me!

Offering $54,000 here and now!

--ccec

[scatterling]

:thumb-up: Looking awesome!!

[masonater]

I Give!!!

You're killing me!

Offering $54,000 here and now!

--ccec

I hope your joking! i really want to finish it:thumb-up:I learned to drive on this car, dont think i could ever part with it...especially now!

[LaneRover]

That is looking awesome!!

[cousindave]

Would you like to restore mine after your done?!!

[kwd509]

I learned to drive on this car, dont think i could ever part with it...especially now!

Great looking work....

But now I'm curious (I learned to drive in an 88- and it now resides in my back yard waiting restoration)....... do you have any 'before' pictures?

[masonater]

Great looking work....

But now I'm curious (I learned to drive in an 88- and it now resides in my back yard waiting restoration)....... do you have any 'before' pictures?

Thanks!

There are a couple before pictures at the very beginning of my build thread. The rest are all before the days of a digital camera and stuck on the fridge in my garage on island.

[shawn88]

I'm doing my 1960 88" in the same color. It's heading to paint next weekend.

[masonater]

I'm doing my 1960 88" in the same color. It's heading to paint next weekend.

It looks very cool, nice and flat. Also very easy to touch up. It is a magnet for greasy finger prints though

[masonater]

Got the fenders ready for paint again today. I thought they were ready a few days ago but a closer look revealed more i could sand for a better overall finish
http://i1183.photobucket.com/albums/x478/masonater84/P4280073.jpg
I remember years ago trying to replace a headlight that was out being a huge pain, there seems to be a lot going on with the military headlight assemblies. I took the ring that surrounds the lamp off and left the rest in to tackle another day.
This picture is also of some of the parts i powder coated desert tan, its a little lighter than my paint so i figure why not spray them the same color.
http://i1183.photobucket.com/albums/x478/masonater84/P4280075.jpg
Used eastwoods chassis black primer on the bumperettes i scored off ebay for cheap.
http://i1183.photobucket.com/albums/x478/masonater84/P4280077.jpg
Got the windshield sanded and taped off the glass ready for primer. Tomorrows mission, along with hood and fenders.
http://i1183.photobucket.com/albums/x478/masonater84/P4280076.jpg
Mounted radiator for good and installed the cowl and a few other bits that go along.
http://i1183.photobucket.com/albums/x478/masonater84/P4270068.jpg
Fastenal mother load
http://i1183.photobucket.com/albums/x478/masonater84/P4280070.jpg
Glad i took http://i1183.photobucket.com/albums/x478/masonater84/P4260064.jpg blinkers and running lights out, corrosion was underneath

[masonater]

Got a few coats of tan on the fenders and hood last night. Also did tailgate parts. All that is left to paint are the door tops and truck bed.
http://i1183.photobucket.com/albums/x478/masonater84/P4290079.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4290080.jpg

[masonater]

Spent a while getting the truck cab ready for paint. Lots of taping.
http://i1183.photobucket.com/albums/x478/masonater84/P4300091.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P4300092.jpg
Got 3 coats on this afternoon. Very happy with how its looking.
Anyone have a picture of the lower window track on the inside of the cab? Mine seems to be custom made by PO, the thumb sliding lock does not line up with the holes in track so it just slides back and forth.
http://i1183.photobucket.com/albums/x478/masonater84/P4300095.jpg

[badvibes]

masonater-

Bad cell phone pics so if they don't show what you need let me know. Really digging what you're doing, looking forward to your next update!

Jeff

http://i55.tinypic.com/ifpy84.jpg

http://i52.tinypic.com/6gykih.jpg

[scatterling]

hope this helps

[masonater]

Thanks for the cab pictures...They guy who gave it to me did some homebrew mods to the window tracks I'll try and post pictures tomorrow to see if anyone can see what is going on. Seems like to much distance between the top and bottom tracks. Looks like he installed a long shim strip to lower the upper track down but it seems to not be enough.

Anyway...not much action in the last couple days just bolting on lots of random parts.

Got the fuel switch back on after a cleaning and some powder coat. My thumb lever has been broken for years so ill have to come up with something, anyone have an extra??
http://i1183.photobucket.com/albums/x478/masonater84/P5020096.jpg
Got the side marker light housings back on with new hardware, look much better than before thats for sure.
http://i1183.photobucket.com/albums/x478/masonater84/P5020102.jpg
Put some krylon fusion satin on the steering wheel, it was pretty faded. I wonder how it will hold up?
http://i1183.photobucket.com/albums/x478/masonater84/P5020098.jpg
Got the hood parts all bolted on, good thing i got so much stainless hardware. 24 bolts alone hold the spare tire plate on.
http://i1183.photobucket.com/albums/x478/masonater84/P5020100.jpg
Stated putting my round Smiths heater back together. The foam that was in there before was all torn up and nasty, found some lying around of almost the exact same stuff and i cut to match.
http://i1183.photobucket.com/albums/x478/masonater84/P5020104.jpg

[badvibes]

the thumb sliding lock does not line up with the holes in track so it just slides back and forth.

Silly question but have you checked that the little "pin" is still inserted in the lock mechanism? About 3/8" long, rounded on one end, pointed on the other. They are easy to loose if the lock is taken off or falls apart while driving around. Ask me how I know.....

Jeff

[masonater]

the thumb sliding lock does not line up with the holes in track so it just slides back and forth.

Silly question but have you checked that the little "pin" is still inserted in the lock mechanism? About 3/8" long, rounded on one end, pointed on the other. They are easy to loose if the lock is taken off or falls apart while driving around. Ask me how I know.....

Jeff

Yea, checked that, both are there. One looks like it was made with cutting a bolt down and grinding a rounded point.

[masonater]

Installed the wiper assembly today and got the steering column tightened up.
http://i1183.photobucket.com/albums/x478/masonater84/P5030111.jpg
Did more work on getting the heater back together
http://i1183.photobucket.com/albums/x478/masonater84/P5030112.jpg
Need to reattach a wire that broke off. This will be the beginning of a complete rewire of the 109. I'm pretty scared i must say.
http://i1183.photobucket.com/albums/x478/masonater84/P5030113.jpg
Took the tape off the windshield and truck cab that i painted a few days ago, real happy with my 2 hour tape job i did.
http://i1183.photobucket.com/albums/x478/masonater84/P5030105.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5030106.jpg
Here is a shot of the window track on the cab, not sure how or why it is not straight?
http://i1183.photobucket.com/albums/x478/masonater84/P5030110.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5030109.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5030107.jpg

[masonater]

Got the Smiths heater installed last night and started plumping the washer jets. Also ordered 2 gallons of Lucas gear oil and picked up some coolant and motor oil from the store. Getting ready!
http://i1183.photobucket.com/albums/x478/masonater84/P5040115.jpg

[rejeep]

just a quick question..
what are you running Lucas in?

[masonater]

just a quick question..
what are you running Lucas in?

The whole rover is dry now so i figure ill put the heavy duty 80/90W lucas stuff in everything. Steering box already has some type of red grease in it so im not sure its a good idea to add gear oil to that. But everything else. I have all brand new gaskets and seals so we'll see...

[masonater]

Been a few days since i could work on the 109. It was derby weekend and things get pretty wild in KY. Today i started work on the truck bed. Lots of corrosion around the frame mount holes and where the seatbelt brackets are. Not really sure what im going to do about it at this point. Since this 109 was an ambulance in its previous life, the shop that put the bed on did not do a great job. Instead of fitting the bed properly they just drilled new holes right near the old ones and bolted it down.
http://i1183.photobucket.com/albums/x478/masonater84/P5090122.jpg
2 weeks left until she has to be shipped home to the island, done or not. :eek:

[masonater]

Finally figured out a way to hook up the capillary oil temp gage in a good location. I thought about putting it in the extra hole in oil pan but it was too close to the drive shaft for comfort. I got my spin on adapter in the mail and used the adapter for the original oil filter along with it. It almost looks like it was ment to be in there and no fabricating needed. Still have plenty of room to take off filter for oil changes this way too.
http://i1183.photobucket.com/albums/x478/masonater84/P5100123.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5100126.jpg
Started some wiring the other day. 2 solenoids installed, one for the master switch and one for the starter. I will run a large copper bus bar between them soon. Im not going to have a key just switches to run everything.
http://i1183.photobucket.com/albums/x478/masonater84/P5100124.jpg
Powder coated my brake and clutch lines, last ones!
http://i1183.photobucket.com/albums/x478/masonater84/P5110129.jpg
Trying to figure out what to do about my door tops...bottom 2 are what i had (junk) top red ones and brand new one were junkyard scores but not much better than mine. I am planning on getting RM door tops in the fall so i think ill see if i can make 2 semi good ones out of what i have to hold me over.
http://i1183.photobucket.com/albums/x478/masonater84/P5110132.jpg
Drilled out the rivets and removed the runner strips in the bed. I will paint the whole thing tan except galvy stuff which ill try to bring back to life a little. Im going to get a sheet of 1/4 inch oak to stain and varnish then put that down as the floor of my bed. I will screw the runner strips to the wood and hope i dont get splinters.
http://i1183.photobucket.com/albums/x478/masonater84/P5110134.jpg
Did work on dash and gages. Bead blasted and then primed the panels this morning and will put tan on later today. Painted the gage trim rings and got them as clean as i could. I put them back together and am pretty happy with the results.
http://i1183.photobucket.com/albums/x478/masonater84/P5120136.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5120135.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5120139.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5120137.jpg
A gasket on one of the gages was dried up and showing on inside of glass. I took some gasket sheet i had and cut out a new ring to seal it. Worked pretty well after i painted it black to i couldn't see it.
http://i1183.photobucket.com/albums/x478/masonater84/P5120141.jpg

[Terrys]

What is the extra solenoid for?

[masonater]

What is the extra solenoid for?

I'm starting from scratch with wiring and have some help from folks who build planes. It will be to bring power to the circuit breakers and will be on its own main switch, separate from ignition. The lower solenoid is for the starter that will also have a main switch to power the ignition system.

[masonater]

Started putting dash back together. I think i need to make a thicker gasket for one because the glass is not tight and can spin around. I also noticed some finger prints on the inside, oops!
http://i1183.photobucket.com/albums/x478/masonater84/P5130143.jpg
Got a piece of oak veneer plywood that i stained to make a new floor for the truck bed. After many coats of polyurethane i will attach the metal strips and have a cool looking floor. If i ever need to load stuff that would beat it up, i can just slide it out.
http://i1183.photobucket.com/albums/x478/masonater84/P5140149.jpg
Got the seat box parts back on.
http://i1183.photobucket.com/albums/x478/masonater84/P5140148.jpg
Also filled all fluids yesterday, i really hope i dont see any puddles on the ground when i wake up...

[stomper]

maybe you meant to do this, but your speedometer and auxillary gauges are reversed from the original set-up.:o

[masonater]

maybe you meant to do this, but your speedometer and auxillary gauges are reversed from the original set-up.:o

I did mean to do it, thinking it would be nice to have the speedo on my side since the truck used to be RHD. But after i put them in realized i need the smaller hole on far right center for the trip knob. I already switched them back but forgot to take a picture. Still thinking of something to put where the old 2 pin 12v plugs were.

[Terrys]

Also filled all fluids yesterday, i really hope i dont see any puddles on the ground when i wake up...
Whenever I pull out from a parking spot, I check to see if I 'marked my territory'. If I don't see a fresh spot, I check my fluids to see if I even have any.

Why not just put the red and black connectors back in? They can be pretty useful, and to me it's one of those iconic land rover things, like the scuttle vents in the bulkhead. Maybe my memory is playing tricks with me, but didn't early MGBs also have those? Was you dash panel originally tan? I've had a couple exmods, and along with every other later truck I've had, they have all had black panels. The change was made when they went to Negative Ground, and purportedly was done so the truck wads immediately recognized as 'negative earth'. The last positive ground truck I had still had it's body colored panel, and I never could get used to looking at it. I converted the truck to negative earth, but did'nt get around to 'converting' the panel.

[masonater]

Terrys,

I dont mind my rovers marking their territory but after replacing every gasket and seal on the truck, it would be nice to see the floor dry for once. If it is dry, i'm sure it wont last for long.

I probably will put the red and black connectors back in, though i cant think was can be used in them these days. I think i have a plug somewhere that fits in the the holes, maybe i can wire a phone charger or something to it.

Dash panels were black when i started, im still not sold on the tan yet. I thought i would really like it but it may be too much tan with everything else. I may strip and powder coat them satin black.

[Terrys]

I had a bunch of those plugs at one time, but gave them away one by one till I nneded one, to find them all gone. It makes plugging in a trickle charger handy. I saw a couple of those nice genuine trouble lights at Metal Dah last year, but couldn't pull the trigger. I can buy a few good maglites for $85.
Every time I visit this thread makes me regret selling my last ExMod.
Forgot to mention earlier; your extra solenoid to feed the circuit breakers is a good idea. One thought though; put your battery charger on it on the bench for a while to see if it gets hot. 'Continuous Duty' isn't what it used to be.

[masonater]

One thought though; put your battery charger on it on the bench for a while to see if it gets hot. 'Continuous Duty' isn't what it used to be.

Good idea, i had it on a charger for about half hour while i was figuring out what prongs do what. Being a beginner, i wanted to see how it worked too. Ill do that again for longer and see if it heats up.

[masonater]

Ive been attacking the wiring on and off for the last couple days, along with a bunch of other smaller things. Got the floors, seat box, and tunnel covers put on.
http://i1183.photobucket.com/albums/x478/masonater84/P5170169.jpg
Got my used fluid reservoir in the mail (thanks Pete!) powder coated and installed it then took on the fun task of bleeding everything.
http://i1183.photobucket.com/albums/x478/masonater84/P5180172.jpg
After painting the dash tan, felt it was too much of one color and changed it back to the original black color.
http://i1183.photobucket.com/albums/x478/masonater84/P5150157.jpg
Found a mystery leak on the transmission housing. It looks like there was a repair done at some point in its life. Hard to see in picture but pretty much in center there is a small amount of fluid seeping out. Not really sure what is going on here...
http://i1183.photobucket.com/albums/x478/masonater84/P5150160.jpg
Also tried to fire her up today, with no luck. Set points at TDC, have spark coming from the coil but nothing going to the plugs. Will check to see how strong the coil spark is tomorrow. 5 days and its going on a trailer back to the island! :eek:

[badvibes]

Also tried to fire her up today, with no luck. Set points at TDC, have spark coming from the coil but nothing going to the plugs. Will check to see how strong the coil spark is tomorrow. 5 days and its going on a trailer back to the island! :eek:


Looks like from the pics you have the dome topped distributor, I think its a 25D. Check the low tension lead from the dizzy "deck" to the body of the distributor. If the ground isn't good that's what you get. I had one that looked intact but wasn't. Was a real head scratcher to diagnose.

Jeff

[masonater]

after almost the entire day head scratching...found my issue and she started right up after 3 years in 2 cranks! I couldn't see it when it was installed but the condensor had a break in insulation that was grounding. Had a new one handy. Let her run for a little to make sure there were no leaks and took it for a spin around the airport. Got some weird looks and had one of the best days yet! Those 255/85/16 BFG muds are sure harder to turn than my old baby tires. Now i have to focus on the wiring mess...

[Momo]

Hey what type of fasteners do you have there on the dash? Dome head machine screws? I can't tell from the pic.

[masonater]

Hey what type of fasteners do you have there on the dash? Dome head machine screws? I can't tell from the pic.

yup, #10 stainless. First had AN3-4A aircraft bolts but was not a fan of hex head/dash combo. Used #10 nuts on back with exception of insanely hard to find (local) acme bolts for the vent screen nut plates already in there.

[Momo]

Did you consider rivnuts? The PO of my 109 SW installed them on the dash and they are terrific. I'll be using them on my project 88.

[masonater]

Did you consider rivnuts? The PO of my 109 SW installed them on the dash and they are terrific. I'll be using them on my project 88.

Wow, no i did not until you just said it. Great idea. Will be doing that for sure. I love rivnuts....

[Cutter]

very cool connector, I didn't know about those!

[masonater]

Did some more bleeding today and got a little better pedal. Brakes are all new but seems like there is still some air in there somewhere. I adjusted the 4 wheels to they were dragging and then backed off a little. Then bled each wheel until i got just fluid. Still have to pump about 2 times to get anything to work. Clutch still needs some attention as well, works but only almost against the floor. Let the engine run for about 15 minutes to let the thermostat open so i can fill up the coolant to proper capacity. Only got about 2 gallons in before it was full, bible says about 2.75 gallons i think...
Pretty neat having it outside and running for first time in years...
http://i1183.photobucket.com/albums/x478/masonater84/P5200177.jpg
Did some work on the truck bed. First gave it a steam bath to get the crud off and old oil and grease that had been thrown all over it for years.
http://i1183.photobucket.com/albums/x478/masonater84/P5210178.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5210179.jpg
After a bath
http://i1183.photobucket.com/albums/x478/masonater84/P5210181.jpg
And a coat of Waxoyl i got from RN last year to finish the bottom off. Man that stuff is messy! Probably should have worn gloves.
http://i1183.photobucket.com/albums/x478/masonater84/P5210184.jpg
Left the 109 out in the sun for a while to warm things up as prep for the cavity waxoyl. Didnt make it to that today, huge thunderstorms rolled through
http://i1183.photobucket.com/albums/x478/masonater84/P5210183.jpg

[Momo]

You can modify the front brake configuration so that the cylinder with the bleed screw is on top. Search the forum, it's been discussed before. I will sheepishly admit I have never gotten a system with the CB mast cyl to be pump-free. Early on in LR ownership I got so fed up I took my 109 to a mechanic and he couldn't even get it dialed in. I've since converted to a boosted system, and using a power bleeder, it's now a ten minute job. It might be worth it for you at this stage to take that plunge...

[masonater]

Spent a while taping off the door tops then painted them. Didn't try too hard as after the summer is over im going to buy some RM ones. Mine are pretty rusty and not worth much effort. Also masked off the bed and had planned on painting it tonight, again more thunderstorms. Too big to fit where i have been painting everything else and i really dont feel like setting up a ghetto paint booth in the hangar. Going to try early this morning when the wind is calm and see what i can do.
http://i1183.photobucket.com/albums/x478/masonater84/P5220185.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5220186.jpg
Too much fun driving it like this. Although i wouldn't mind if it was together...thats for tuesday.
http://i1183.photobucket.com/albums/x478/masonater84/P5220191_2.jpg

[SafeAirOne]

http://i1183.photobucket.com/albums/x478/masonater84/P5220191_2.jpg


Coming right along and looking pretty good :thumb-up:. Just be careful on the test driving:

KCFkOwx-KwQ



:D

[masonater]

Well it has been a long time since I have done anything rover. I had to be back East for Memorial Day weekend and still had a body-less rover. Then i took over a restaurant and my computer crashed, so i was off the grid. Posting was put on hold while I worked straight for 3 days and nights so I could put it on a trailer and make my ferry boat home.

Anyway here is a recap of how my build came to a finish (almost)

Painted old beat up door tops with rattle can. I plan on buying RM door tops pretty soon to replace.
http://i1183.photobucket.com/albums/x478/masonater84/P5230207.jpg
Got a little wild and stained a sheet of oak plywood a bunch of times. Im going to attach the metal strips i painted on top of this and see how i like it. Always loved the look of old American pickups with wooden beds.
http://i1183.photobucket.com/albums/x478/masonater84/P5240208.jpg

[masonater]

Took me and a buddy 2 solid 5am nights to wire the entire truck from scratch. I am so happy and shocked at how well it all came out. Very simple, safe, and no key. Just what i wanted, and it looks pretty cool i think too. I was in such a panic to get this done and leave i didnt take many pictures which im not that happy about. Here is a shot of the finished dash. No more fuses, I used aircraft breakers and 2 bomb switches to arm the car. One switch lights up everything but ignition. The second charges the ignition system and the button starts. I have 2 accessory plugs, one on either side (still need a driver side one).
http://i1183.photobucket.com/albums/x478/masonater84/P5240209.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5240213.jpg

During wiring i still was putting stuff together as paint dried. Got the bed painted outside hanging from the fork lift around 3am just as a thunder storm rolled in which was pretty intense. But it came out great. Put doors on and lined up pretty well considering i had everything apart.
http://i1183.photobucket.com/albums/x478/masonater84/P5240212.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5240214.jpg
Hoops back on! Started looking like a rover again.
http://i1183.photobucket.com/albums/x478/masonater84/P5250216.jpg
Windshield and door tops. I think I had about 36 hours until I needed to be 1000 miles away on a ferry at this point.
http://i1183.photobucket.com/albums/x478/masonater84/P5250217.jpg

[masonater]

I just realized i dont have any pictures of wiring. Ill take some in the next few days now that i have a life back (restaurant closed sunday) I used close to 450 feet of wire with 4 extra ones for future fun stuff that i ran through the frame as well. Like i said i was racing to finish so pictures are not as good as they had been throughout the build.

After 10 total months, roughly 5,000 hours of labor, and a countless amount of help from folks on this board she is ready for the journey home.
Still a lot of little things to take care of but its time in Kentucky has ended.
http://i1183.photobucket.com/albums/x478/masonater84/P5250218.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5250219.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5250220.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5250221.jpg

With no time to sit back and drool i had to pack it full of all the crap i now realize i have and load it on the trailer.
http://i1183.photobucket.com/albums/x478/masonater84/P5250222.jpg
http://i1183.photobucket.com/albums/x478/masonater84/P5250223.jpg
One way to beat up your jeep
http://i1183.photobucket.com/albums/x478/masonater84/P5250224.jpg
just before the worst road trip i could have imagined
http://i1183.photobucket.com/albums/x478/masonater84/P5250226.jpg

[jac04]

Looks great!
10 months & 5,000 hours of labor = 16 hours a day average. :eek:
I thought I was crazy at 1,000 hours over 18 months.

[masonater]

I rented the heavy duty auto transport from Uhaul. Heavy being the key word there.
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0793.jpg
Took this picture with my cell somwhere on I-80 in PA as the gas station employees were shouting for everyone to get inside to the showers because a monster tornado was on its way. No way was i going to stay there and have a gas station fall on my baby. The storm was west of me moving 30 mph, i was going east at 60mph. I booked it out of there as soon as i fueled up.
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0786.jpg

20 hours of nothing but fuel stops and coffee I made it to the ferry.
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0788.jpg

Reunited again...
http://i1183.photobucket.com/albums/x478/masonater84/IMG_0792.jpg

[masonater]

Looks great!
10 months & 5,000 hours of labor = 16 hours a day average. :eek:
I thought I was crazy at 1,000 hours over 18 months.

That is crazy, dont know what i was thinking this morning. All day for 10 or 11 months over 2 winters. However many hours that is...

And you were not kidding about all those sanding hours!

[cedryck]

Nice work mate.
I love the sand color, and large bfg's. Curious though, why the no key entry?
Jeff

[siii8873]

Mason, did you get your computer back working?
soft top??? Don't think you sent that out next day nothing received.
Truck looks great. My 1971 IIA exmod's instrument panel is body color not black?

[scatterling]

:thumb-up: Truck looks great, congrats!!

[masonater]

cedryck,
keyless for a few reasons. didn't feel like moving it to another spot from right side of dash. Passenger knees would always smash the key and it has broken a few times. The main reason for no key, i think its fun flipping switches and pressing buttons to start her.

My never ending project saw some milestones this past weekend. Installed the PU cab and some new door seals. Also bit the bullet and purchased RM door tops and installed them. They are great, so much better than my old ones.
http://i1183.photobucket.com/albums/x478/masonater84/Image.jpg
Now to figure out why it is stuck in 4x4 all the time...

[scatterling]

aaahhhhh.... now it's perfect. Nothing better than a 109" with a pick up cab :thumb-up:

[masonater]

High 5 to that!


aaahhhhh.... now it's perfect. Nothing better than a 109" with a pick up cab :thumb-up:

[rickv100]

Agreed on the pickup cab on the 109. Are those WoodenBoat calendar images on the garage door?

Rick

[masonater]

Agreed on the pickup cab on the 109. Are those WoodenBoat calendar images on the garage door?

Rick

Yup, my dad has had those calendars for as long as i can remember. I dont think he has thrown a single one away. A few sundays a year we go wild with the staple gun.

I want a rover calendar....

[masonater]

Today was the first day I drove the 109 on a road in almost 5 years. Put 45 miles on it today, mostly dirt and the island is only 14x6 :D
the weather is suposed to be very nice with record breaking highs tomorrow, may have to ditch the top
http://i1183.photobucket.com/albums/x478/masonater84/Image-Version2.jpg

[achtung]

WOW Thanks a lot for taking the time to make such a great thread! I will be using a lot of the pictures here as a reference for my truck.

[lincoln lass]

Looks gorgeous, good work.

[scatterling]

Awesome :thumb-up: :thumb-up: :thumb-up:

[siii8873]

see you have that soft top on it, good to see it getting used

[masonater]

Thanks to all. It really is a great feeling after all the hard work and dollars spent to finally drive it. My jeep is already tucked away in the bushes. Time to enjoy my new daily driver! Its almost 50 degrees already so today i may have to test out the 4x4 on some sand :thumb-up:
my PS headlight burnt out so ill fix that at some point today so i can get her inspected. I never really did figure out how to replace a headlight on the military tucks...seems to be a lot going on in those assemblies.

[masonater]

see you have that soft top on it, good to see it getting used

Yes, and thank you once again! My old lady neighbor does sail and canvas repair. Im going to see if she can beef up the stitching and replace the plastic windows. Also bringing her my old windowless beat up canvas to build some sort of bikini top.

[LaneRover]

Very nice and congratulations on being able to drive it after all of that work!

[l.a. rover]

just ran into this post and all i can say is AWESOME!!! A true labor of love!

[ca_surveyor]

Headlights are easy. Just push in on the lens and turn it, and the whole assemby will come off. Remove the plug. You still have to deal with getting the screws undone (rusty?) for housing removal, but that is done on the bench.

[Les Parker]

Just a quick comment on this stellar rebuild, it might be worth while turning the canvas wrapping towards the vehicle, so when it rains (??) it does not gather in the side curtains - soaking you when you go to fasten the sides/rear flaps.

Well done on the job and the continued postings.

[masonater]

Just a quick comment on this stellar rebuild, it might be worth while turning the canvas wrapping towards the vehicle, so when it rains (??) it does not gather in the side curtains - soaking you when you go to fasten the sides/rear flaps.

Well done on the job and the continued postings.


Thanks Les,

I agree, i just picked up this top from a board member and it was different than my old windowless one. I used holes i poked and zip ties to roll those sides up the other way. It has straps and buckles that seem to be designed to roll up the way i have it, no? Im having my local sail repair lady beef the new top up and maybe add some marine zippers front to back to i can just zip the sides off and have the top secured with snaps or something the like. She is also taking my original top and converting it to a bikini style one.

mason

[jimsshuman]

I have to go ahead and put out there that I am very envious of you!! You live on the cape, spend about half your time at a well equipped airport, have an amazing truck (although seems you worked very hard for it, well I imagine you worked hard for all the rest of this stuff, also), sail maker neighbor customizing your tops, stumble upon hellova deal on an 8274, and the list probably goes on and on!!

Nice work man, enjoyed following your build, awesome truck.

[masonater]

I put new seats, floor mats and 2 rear benches on the 109 today, i will post pics of that soon. In the mean time, burned some gas on the beach this afternoon and had a great Easter sunset.

Im really loving live with a pickup cab.

camera+ app shot
http://i1183.photobucket.com/albums/x478/masonater84/Image-3.jpg

[scatterling]

:thumb-up::thumb-up::thumb-up: very nice!!