Got My Lightweight!! Stay Tuned for Project Updates and Plenty of Questions!

[jac04]

Well, after asking quite a few questions on this Forum, I finally got a Lightweight. I've always liked them, so when I sold my restored 63 IIA, I started looking for one.

This one is a 1973 SIII LHD 12V with 67,000 kilometers on it.

The bad:
- The rear section of the chassis is toast.
- The bulkhead footwell areas have some small rust holes - not too bad.
- The bottom of the radiator support is a little tender - again, not bad at all.
- One door top frame has a very small rust hole.
- The engine taps (only when on the throttle) and seems a little down on power (maybe just a valve and timing adjustment needed).
- The water temp gauge pegs to full hot (hopefully just a sending unit needed). The owner says that the temperature taken with a thermometer at the radiator looks good.

The good:
- The door frames seem solid.
- The upper bulkhead looks really good.
- The body itself is in great condition with only 3-4 small dents - I've never seen such a straight body on a military vehicle.
- Everything seems to be there and in decent shape with the exception of the rear lifting rings.

The plan:
- Install galvanized chassis & new brake lines.
- Install parabolic springs & OME shocks.
- New stainless exhaust.
- Tune up engine & adjust valves.
- All new seals - hubs, trans, swivel balls, diffs, etc.
- Clean & paint all drivetrain bits.
- Repair bulkhead & radiator support.
- New Michelin XZL tires (an early X-Mas present to myself).
- Waxoyl the inside of the door frames and bulkhead areas.
- Brush-on a fresh coat of camo paint.
- Enjoy

The goal is to have a vehicle that is mechanically excellent while retaining it 'character', and will last a long, long time.

Any and all comments/suggestions are welcomed!!

Here are a few pictures:
http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/IMG_1027.jpg

http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/100_1846.jpg

http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/IMG_1033.jpg

Pretty straight, isn't it?:
http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/100_1845.jpg

http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/100_1841.jpg

http://i79.photobucket.com/albums/j126/jac04/Land%20Rover/100_1844.jpg

[CLIFF]

nice:thumb-up:

[BirdNerd]

Jac,

Nice Lightweight---where are you located. There are a couple of Lightweights on the South Shore (Plymouth area)

drop me a line on the side

rovr66atgmaildaughtcom

BN

[jac04]

I'm actually in East Granby, CT. I bought it from a guy who lived in Rutland, MA.

[Tim Smith]

Welcome to the club! :thumb-up:

I'm surprised at the rust on the leading edge of your bulkhead. Looks like it's trapping sand up there but I'm not sure how... maybe I'm missing a plate on mine. :confused:

[jac04]

^^Yes, it is definitely trapping stuff between the splash guard and the bulkhead. It actually looks like someone bent the bulkhead sheet metal a little to allow for drainage. Luckily, they didn't cut anything and I should be able to straighten it out.

I may end up bringing the bulkhead to my body guy for a 'correct' restoration & re-spray. It's probably better to do it right the first time than to just slap some patches on it and have to fix it again in the future.

[Tim Smith]

^^Yes, it is definitely trapping stuff between the splash guard and the bulkhead. It actually looks like someone bent the bulkhead sheet metal a little to allow for drainage. Luckily, they didn't cut anything and I should be able to straighten it out.

I may end up bringing the bulkhead to my body guy for a 'correct' restoration & re-spray. It's probably better to do it right the first time than to just slap some patches on it and have to fix it again in the future.
I agree with you on that one. Not sure where you could source a bulkhead for these things any more...

[greenmeanie]

I agree with you on that one. Not sure where you could source a bulkhead for these things any more...

PABlanchard. Source of all things good for Rovers in cabbage and black. Not cheap though.

[Jim-ME]

Atleast you can find parts which aren't here for all of us.
Jim

[derekchace]

Looks Great! I almost bought that rover but found another light weight i liked more in PA! i think we are going to have to start a pure light weight club and get some drives together next year

[jac04]

Silly question, but how the heck do you tighten the straps that hold the spare tire to the hood? (I know, it's should be the least of my worries). There is a hinged buckle on the front strap, but it only allows you to adjust the length if there is no tension on the straps. There must be some way to hook the front strap, then cinch it down tight.

[Tim Smith]

Silly question, but how the heck do you tighten the straps that hold the spare tire to the hood? (I know, it's should be the least of my worries). There is a hinged buckle on the front strap, but it only allows you to adjust the length if there is no tension on the straps. There must be some way to hook the front strap, then cinch it down tight.
Mine was loose for years. The best I could manage was to pull the tentioning side under the holding strap side and then cinch it down with the clamp. If I did it right, I'd get a few weeks of tight tire. Then it would just bounce around again.

Kind of scary with a 33" tire.
:confused:

[jac04]

Tim how do you "cinch it down with the clamp"? The way the strap goes through the clamp on mine, it isn't possible - and this is a brand new assembly. I'll try to take a few pictures and post them.

Otherwise, I started the tear-down, and confirmed that I have 109 2.25 liter 11" front brakes and normal 88" rears (1" diameter cylinders and 10" drums).

It also looks like I may have a few pin holes in the rear diff cover, D'Oh!! I wasn't planning on that! I'll have to sand blast the rear axle casing and evaluate.

[Tim Smith]

Your set up might be different than mine but I'll also try to get a picture or two.

[Jim-ME]

This is our 3rd batch of 20 new lightweight bulkheads (MRC 3227) and are proving very popular. There are four available from this batch priced at £695 + Vat. Our fourth batch are due to be manufactured in Jan 2004. (PA Blanchard in the UK)
http://www.pablanchard.co.uk/photos/web%20lightweight%20bulkhead.jpg

[jac04]

Your set up might be different than mine but I'll also try to get a picture or two.
Here's mine. As you can see, when the hinged buckle is closed, it effectively lengthens the front strap. I am thinking that if routed differently throught the buckle, the strap would tighten when the buckle is closed.

http://i79.photobucket.com/albums/j126/jac04/000_1058.jpg

Buckle "open":
http://i79.photobucket.com/albums/j126/jac04/000_1061.jpg

Buckle "closed":
http://i79.photobucket.com/albums/j126/jac04/000_1060.jpg

[Moose]

They are tricky little buggers so set up correctly. When I got mine I had to find one to look at.

Semi open

http://farm4.static.flickr.com/3025/2963105104_9a81597c23.jpg?v=0

Fully closed

http://farm4.static.flickr.com/3167/2963105110_f749485c0f.jpg?v=0

Mine usually stays tight. When it gets wet it seems to stretch and loosen up a bit though.

Brett

[jac04]

I worked on the Lightweight for a few hours and here's where I'm at:
http://i79.photobucket.com/albums/j126/jac04/000_1062.jpg

#4 was about 50 psi low on compression. No evidence of a head gasket problem, but the cylinder has a distinct wear ledge compared to the others. Oh well.

Other than that, I'll pick away at it each night for a few hours until all I'm left with is the chassis, then I'll refurbish/replace everything and start the whole process in reverse. What have I gotten myself into??:)

[Les Parker]

Nice touch with the Fire Extinguisher !

:thumb-up:

[SafeAirOne]

It's amazing how far you can get in just a few hours. I've had my wings and radiator support off so often in the past few years that I'm considering installing quick-disconnects for the wiring harness between the wings and rad support.

[jac04]

Progressing...slowly but surely...

http://i79.photobucket.com/albums/j126/jac04/000_1080.jpg

[jac04]

Well, Arthur from Rovers North just dropped off a little shipment of parts for me. This should gets things started:

http://i79.photobucket.com/albums/j126/jac04/000_1091a.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1093.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1094a.jpg

[Moose]

This should gets things started:

WOW, I'll say. :thumb-up: Looks like Christmas came early this year at your house.

So what do you figure, about a week or so? :D

Brett

[SafeAirOne]

Well, Arthur from Rovers North just dropped off a little shipment of parts for me.

Where's the "little" shipment of parts? Behind the new chassis, new engine, new wheels and tires?:D

You're making my 109 jealous...

[jac04]

...don't forget about the new stainless exhaust, new radiator, and transmission ass'y..

Yeah, I figure a few weeks and I'll have it all together....just kidding. I have a lot of sandblasting/priming/painting to do so I may have to wait until Spring for re-assembly. I really don't feel like paying to keep the garage at 65-70 degrees all winter just so I can paint. I'll try to finish the tear-down this winter and get some of the mechanicals squared-away.

[greenmeanie]

...don't forget about the new stainless exhaust, new radiator, and transmission ass'y..


So waht are you keeping from the original - The LR badge from the grill?

That little lot is a bunch of money. Have fun.

[jac04]

So waht are you keeping from the original - The LR badge from the grill?

The funny thing is that I actually had to buy one of those - the original was missing.

[78LtWt]

Looks like you have your weekends booked up.... What kind of tires are those?

[Eric W S]

They look like Michelin XZL tires in 750x16.

Nice choice.

[jac04]

^ Yes, XZLs in 7.50x16.:thumb-up:

[Eric W S]

Nice! :thumb-up:

I am going with the Michelin XPS Tractions myself!

EwS

[jac04]

The floors & seat box are out and the tops of the rear tub are off. So far, so good. The roll bar and lower part of the rear tub will hopefully be coming off this weekend.

http://i79.photobucket.com/albums/j126/jac04/000_1125.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1126.jpg

[jac04]

Rear tub is off and pressure-washed. Man, I really want to start putting something back together......just tearing stuff apart is getting depressing. I have a lot of work ahead and the days are getting shorter & colder, so any time anyone wants to start offering some words of encouragement..........
http://i79.photobucket.com/albums/j126/jac04/000_1136.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1137.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1131.jpg

[SafeAirOne]

...any time anyone wants to start offering some words of encouragement..........

Nice job! It's looking more apart than ever! :thumb-up:


EDIT: I couldn't leave it like that. We've seen the pile of brand new parts you bought and we all know that when you get it back together, It'll be be a better machine that 80% of ours (if not more). We're all waiting and wondering why it's taking you so long. Sheesh--It's been 3 weeks, after all! :)

[rwollschlager]

yea whats the hold up that thing still looks almost like a land rover? it only took my dad 14 years to rebuild his 109. What you did in three weeks would have taken myself or him a year to do

[jac04]

^^ Thanks, that helps! :)

[ivarra]

For those who dont know, I'm the one who bought this mans 1963 S11 88 after he did a magnificent restoration. I think its in better condition than when it came off the assembly line, and it was restored at least 10 years back. I got mud on it once and nearly panicked!

So expect this restoration to be on the meticulous, attention-to-the smallest-detail level. Read: perfection.

I also just cant understand why its taking so long?? Put a heater in your garage so we can see progress! Cold cant be an excuse when you live in CT.

PS, my check book is waiting.:D

Ivar

[jac04]

Ivar - don't set the bar too high for this one! Yes, the mechanicals will be done right, but I think that I'm going to leave the body a bit rough around the edges. Well, at least that's what I'm saying for now.

With the '63, it was so nice that I was worried about really using it. I'm glad to see that it went to a loving home and that you & your family are really enjoying it. You should post a few pictures for everyone to see.

[jac04]

Does anyone want my old frame? If so, please claim it within 24 hours. Otherwise, I'm taking the sawzall to it. The rear crossmember is almost non-existant and the bulkhead outriggers are very tender - otherwise it doesn't look too bad.

[teechizpet]

I got $40 at the scrap yard for mine.

[jac04]

Well, I lopped off the back half of the chassis to free up some garage space. It's amazing how quickly a 36' x 36' garage fills up with stuff.

By the way, my old springs are in fairly decent shape - if anyone needs a set for cheap, please let me know. Also, I'll eventually be getting rid of the set of 5 wheels & tires. The tires are 235/85/16 General Grabber AT II that are practically new. The spare has never touched the ground, but I think that the wheel is bent judging from the amount of balancing weight on it.

Half a Rover (Well, maybe it's more like 1/3):
http://i79.photobucket.com/albums/j126/jac04/000_1146.jpg

Checking a few critical dimensions:
http://i79.photobucket.com/albums/j126/jac04/000_1151.jpg

Finally, a few things actually put back together (even if only temporarily, it makes me feel like I'm making progress):
http://i79.photobucket.com/albums/j126/jac04/000_1147.jpg

[rwollschlager]

are you still looking to get rid of the general grabbers? would the rims come with them?

[jac04]

^ Yes, and Yes. Send me a PM if you are interested.

[jac04]

... a few more parts taken off... I just ordered a bench top sandblast cabinet, so I will be starting restoration of all those small rusty pieces fairly soon. For the big stuff, I will wait until spring and use my regular sandblaster in my outside makeshift 'booth'.

http://i79.photobucket.com/albums/j126/jac04/000_1161.jpg

[jac04]

The bulkhead coming off:
http://i79.photobucket.com/albums/j126/jac04/000_1182.jpg
Not much left. Hopefully I can find some time to pull the engine & trans tomorrow:
http://i79.photobucket.com/albums/j126/jac04/000_1184.jpg

[jac04]

I had a few more hours to work on the tear-down.

Here is the engine & transmission coming up....
http://i79.photobucket.com/albums/j126/jac04/000_1191.jpg

... and out.....
http://i79.photobucket.com/albums/j126/jac04/000_1192.jpg

...and into its new home, which is on 6 swivel casters to make it easy to move around the garage...
http://i79.photobucket.com/albums/j126/jac04/000_1193.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1194.jpg

Almost gone:
http://i79.photobucket.com/albums/j126/jac04/000_1196.jpg

[telwyn]

Great buy! I'm new to this forum (never noticed it before on RoversNorth), but glad I found it. Heck of a project you have going. Look forward to following your progress.

Lots of Rover folks over on www.ExpeditionPortal.com with a great forum there as well you may want to poke around.

I have a 1982 Land Rover Lightweight - here's a site with my pics and modifications. Lots of ongoing work as well.

http://web.mac.com/eelwyn/Pokey/Home_Page.html

Good luck!

[jac04]

The front axle ass'y out from under the old chassis:
http://i79.photobucket.com/albums/j126/jac04/000_1208.jpg
A little surgery required to get the steering relay out of the chassis:
http://i79.photobucket.com/albums/j126/jac04/000_1209.jpg
The old rusty chassis finally out of my garage:
http://i79.photobucket.com/albums/j126/jac04/000_1211.jpg
Now, the long, tedious task of restoring every little piece and slowly re-building this vehicle from the frame up.

[SafeAirOne]

Hmmm.....You've been working on this for what....a month or month-and-a-half now and you've disassembled a lightweight so that there's no original part left that's bigger than a bread box. You've ordered and received tons of new parts. I'm presuming that you've gone to your regular job during this period...

I'm really curious--how the heck did you find the time to put up Christmas lights on your house? :D

[jac04]

I'm presuming that you've gone to your regular job during this period... :D
I knew I was forgetting something!! ;)

In reality, most of my time spent working on the Rover is between 8:30pm and 1am. We have a 3-year-old daughter and a 2.5-month-old son, so that's the only time I have.

[rwollschlager]

In reality, most of my time spent working on the Rover is between 8:30pm and 1am. We have a 3-year-old daughter and a 2.5-month-old son, so that's the only time I have.

hmmm so while the rest of us are dreaming of rebuilding a land rover, at that time you actually are! :thumb-up:

[jac04]

Yes indeed. Like right now (10:20 pm) I just finished the first coat of paint on my engine & trans mount brackets. Between coats I will be sandblasting various other parts and prepping them for primer.

[jac04]

I got the benchtop sand blast cabinet fired up. Here are a few pieces that were heavily rusted. They have been blasted with a fairly coarse media. I will switch to a fine abrasive for final clean-up before painting.

http://i79.photobucket.com/albums/j126/jac04/000_1280.jpg

Here are my finished engine & trans mount brackets:

http://i79.photobucket.com/albums/j126/jac04/000_1281.jpg

[jac04]

I finally unpacked the rebuilt transmission and got it installed.

Now THIS is what a rebuilt assembly should look like. Everything has been cleaned & painted as required and all hardware/covers have been re-plated.
http://i79.photobucket.com/albums/j126/jac04/000_1290.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1291.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1292.jpg

At home in the chassis:
http://i79.photobucket.com/albums/j126/jac04/000_1293.jpg

[BackInA88]

WOW that is looking sweet!!!:thumb-up:



Steve

[Tim Smith]

A thing of beauty!

[SafeAirOne]

Very nice---You'll be done in no time! :thumb-up:

It's your project, so you can, of course, do anything you want, but I secretly hope you don't restore it to the point that it'll never see dirt under its tires again. As you know, a rover yearns to be on trails and in the woods and fields, and fording streams and climbing hills...

[jac04]

It's 12:15am Saturday morning, which means I just finished up a few things on the Lightweight and I'm getting ready for a solid 4.5 hours of sleep. After sandblasting the steering relay, I installed new seals and primed & painted it. I also did the steering relay arms and a few pieces of the e-brake linkage. I plan to send a bunch of the little stuff & hardware out to be cadmium plated, so it got the blast treatment as well.

http://i79.photobucket.com/albums/j126/jac04/000_1298.jpg

The drying room:
http://i79.photobucket.com/albums/j126/jac04/000_1297.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1296.jpg


SafeAirOne- I hear you. Well, the plan was originally to give everything a quick "once-over". I must have some addiction to restoring things, because I just can't seem to put a part back on the vehicle without really doing it "right". I just want to make sure that all this hard work will look good & perform well for years & years.
I promise that the body will not be getting a real restoration. It will most likely get stripped before paint (only because the paint is flaking badly), but I don't think that I will bother with any real body work. I certainly don't want this one to get to the point of my 63.

[jac04]

Here are a few pics of the pintle hitch broken down and partially cleaned-up. The pins, clips and hardware will be sent out for plating:
http://i79.photobucket.com/albums/j126/jac04/100_2086.jpg

http://i79.photobucket.com/albums/j126/jac04/100_2088.jpg

[Tim Smith]

Something tells me that you won't be needing a hammer to open and close your pintle, like some of us do.
:o

[BackInA88]

Doesn't the lower end of the steering relay fit pretty tight to the hole in the frame?
That paint on the bottom may be coming back off?:(

And that trans looks to nice to but in a rig.
Hell even the frame looks to nice to put in a rig!!


Steve

[jac04]

Actually, the steering relay is a fairly loose fit in the hole in the frame. The retainer plate on the bottom (held to the chassis with 4 bolts) is a snug fit with the very bottom of the relay.

[ktom300]

Where did you source those tires? Man I wish I had the funds and time to do the same thing to my 74 Lightweight.

Thanks!

[Leslie]

Where did you source those tires?

Our hosts have them.

http://www.roversnorth.com/store/p-11066-tire-michelin-xzl-750-x-16.aspx

[jac04]

I bought the Rover a nice little NOS gift for x-mas:
http://i79.photobucket.com/albums/j126/jac04/000_1303.jpg

[Jeff Aronson]

I once replaced a loose distributor with a new one like yours. It made all the difference in tuning the car. Once the points were adjusted and it was timed, it rarely required timing again - even with new points. It's amazing what a new distributor will accomplish in terms of running.

Good work!

[jac04]

I think that I will go ahead and convert this to a Pertronix electronic ignition before I install it. I had a Pertronix in my old '63 and I loved it.

[Daurie]

I think that I will go ahead and convert this to a Pertronix electronic ignition before I install it. I had a Pertronix in my old '63 and I loved it.

I just took out my Pertronix. I found it was the source of a few issues I was having. Now I'm back running points and smoth as ever. I hear Lumenition has a electronic setup for the 45d and it supposedy is smoother running. FWIW.

Daurie

[Eric W S]

MSD universal 4 Cylinder system. Timing off the crank shaft, proven pointless pick up in the dizzy, and second spark system as well. :thumb-up:

Oh and Santa Singing Camel and his brown uniformed elves dropped off two pristine early 60's inner wings. Thanks Marc - Singing Camel! :thumb-up:

[jac04]

^^ Well, maybe I'll give the points a shot before getting too ahead of myself. I probably won't drive this thing more than 1500 miles per year, so once the points are set up properly I can forget about them for 10 years.

I'm now in the fairly boring stage of sandblasting & painting a lot of little stuff, but I'll keep posting some pictures for everyone. Here are the painted parts of the pintle hitch:
http://i79.photobucket.com/albums/j126/jac04/000_1305.jpg

[kevin-ct]

Jac 04.

I love reading this thread. It brings back memories of my restoration of my Series 3.

Question, What type of paint are you using for the mounts and hitch and stuff on the under side?

For the points, stick with them (thats what I did) You dont need to adjust them for years for the amount of driving these things do.

Thanks and keep on posting pics!

Kevin

[jac04]

Kevin-
I'm using RustOleum semi-gloss black. So far, I have only been using spray cans, but I may use brush-on for the axle housings. The pictures make the parts look a little more glossy than they really are. I chose semi-gloss because every place that I found original black paint it had a semi-gloss finish. I just hope that things don't look too glossy in contrast to the dead-flat paint job that this vehicle is going to get. I guess we'll eventually find out.

Now, this is my first time using RustOleum for a restoration project. For my 63 Rover and my 68 Camaro I used Tru-Test (True Value Hardware store brand) satin black, which is definitely more flat than the RO semi-gloss. For the money, the Tru-Test paints can't be beat.

I switched to RO for this project because of the positive feedback their paint gets for durability. I have been very happy with the RO products so far - they go on easy, cover well, and dry fairly fast. Also, you can buy the RO paints at WalMart for a decent price (although I buy local to support the family-owned hardware stores - they give me a 10% discount if I buy by the case.). We'll have to see how the paint holds up over the long term.

Let me know if you have any questions.
-Jeff

[scott]

^^... pintle hitch:
http://i79.photobucket.com/albums/j126/jac04/000_1305.jpg where'd you get tht haitch. all the swivel ones i've seen don't mount flat. i was thinking i'd have to cut and sleave a hole in my rear cross member to accomidate a swiveling pintle

[jac04]

^^ It was on the vehicle when I bought it. Per the military manual that I have, it appears to be the original hitch.

I'm not sure what you mean by mouting flat. The hitch mounts to a flat surface on the rear crossmember, but the bolts are about 8" long and go through sleeved holes, then there is a reinforcing plate that goes on before the nuts. You can kind of see it in this 'before' picture:
http://i79.photobucket.com/albums/j126/jac04/000_1131.jpg

[scott]

^^...I'm not sure what you mean by mouting flat...

by flat i mean there's no center axle. all the swiveling hitches i've see have a center axle that extends towards the front that's about 2" in dia and 6-8" long such that you need a 2.5" hole through the cross mbr centered between the 4 bolts

[jac04]

Oh, interesting.

[yorker]

by flat i mean there's no center axle. all the swiveling hitches i've see have a center axle that extends towards the front that's about 2" in dia and 6-8" long such that you need a 2.5" hole through the cross mbr centered between the 4 bolts

Sounds like you are talking about the US swivel type pintle hooks, they protrude through a rear crossmember and don't mount flush like the Dixon Bate or whoever makes the Brit army ones. The Brit ones are pricey, once in a while you might score one for a song though if you ask around or keep a close eye on ebay.

[xsbowes]

I can't see your photos from work but if your hitch is like this one below it was used on vehicles with the military rear crossmember. The lightweights (at least mine has them) and 101s have holes for mounting in the front also.

http://www.lrseries.com/resources/user/f9a2fcd131fa05df35abf1db1d6ead0f32a49224/NRC2051-ROTATING-TOWING-HOOK-FV.jpg

you can get them here but they're pricey:

http://www.lrseries.com/shop/product/listing/8742/4304/1/NRC2051-NATO-HOOK-ASSEMBLY.html

[yorker]

scott here is one, shipping might be a bitch though:
http://cgi.ebay.co.uk/Ex-Army-Landrover-NATO-Towing-Hook_W0QQitemZ120353674361QQcmdZViewItemQQptZUK_Ca rsParts_Vehicles_CarParts_SM?hash=item120353674361&_trksid=p3286.c0.m14&_trkparms=72%3A1301%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318

for comparison's sake here is the US swivel type:
http://cgi.ebay.com/ebaymotors/military-pintle-hitch_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c66Q3 a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318Q7c301Q3a1Q7c293 Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec0Q2em14QQhashZit em150318145000QQitemZ150318145000QQptZMotorsQ5fCar Q5fTruckQ5fPartsQ5fAccessories

http://www.thehollandgroupinc.com/NR/rdonlyres/7BDEC8A2-B370-4AF9-BDA8-6003A6644DD3/0/PHT60AOSL8_lrg.jpg

http://www.thehollandgroupinc.com/NR/rdonlyres/BABCAE61-5AB5-498F-91A4-FF9E793C91D3/0/PH775SL11_lrg.jpg

I think US trailers- at least the smaller ones have always had lunettes that swiveled so the smaller pintles didn't require that capability, larger lpintle hooks on US Army vehicles had that ability, some were spring loaded too I think.

http://www.thehollandgroupinc.com/NR/rdonlyres/9F26985D-CC8D-4113-A03A-4AF4291E2ACA/0/PHT100A_lrg.jpg

[scott]

scott ...for comparison's sake here is the US swivel type:
http://cgi.ebay.com/ebaymotors/military-pintle-hitch_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c66Q3 a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318Q7c301Q3a1Q7c293 Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec0Q2em14QQhashZit em150318145000QQitemZ150318145000QQptZMotorsQ5fCar Q5fTruckQ5fPartsQ5fAccessories

http://www.thehollandgroupinc.com/NR/rdonlyres/7BDEC8A2-B370-4AF9-BDA8-6003A6644DD3/0/PHT60AOSL8_lrg.jpg

... (http://www.thehollandgroupinc.com/NR/rdonlyres/BABCAE61-5AB5-498F-91A4-FF9E793C91D3/0/PH775SL11_lrg.jpg)
even this one would require cutt'n the cross member

[yorker]

even this one would require cutt'n the cross member Yes that was why I posted it for illustrative purposes for those who didn't know what you were talking about in regard to the US swivel type pintle hooks, the ebay.uk link was one for you to potentially purchase.

[jac04]

I have been busy with other things due to the Holidays, but...

...my collection of restored and ready-to-go bits & pieces is getting larger:
http://i79.photobucket.com/albums/j126/jac04/000_1309.jpg

...and I was missing a seat bracket, so I made a new one:
http://i79.photobucket.com/albums/j126/jac04/000_1308.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1307.jpg

[jac04]

My seat box is now all set to go back on the vehicle, although who knows when that will be. Originally, I was going to just use the seat box ass'y as-is, but I decided to remove the seat rails, sandblast them, prime & paint them, then install with all new Grade 5 hardware.

http://i79.photobucket.com/albums/j126/jac04/000_1315.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1316.jpg

[TSR53]

I see you've taken over the house, nice :thumb-up:

[Tim Smith]

I'd love to see how you reattach the lower sides. Mine are a combo of bolts, rivets and I think some tig work... Nothing lines up the way it should.

[jac04]

^^ The lower sides of the rear tub, right in front of the rear tires? If so, I'm not planning on removing them from the tub. They are riveted, bolted, spot welded and welded - so I'm not touching them.

By the way, a few nice Lightweight parts arrived today from TLR:
http://i79.photobucket.com/albums/j126/jac04/000_1319.jpg

[Tim Smith]

By the way, a few nice Lightweight parts arrived today from TLR:
<sigh> So that is what the tunnel cover is supposed to look like... before you bend it around the shin burner four or five times.
:o

[CliftonRover]

when you reinstall the inner fenders or mud/splash guards, use a nut or some washers to space the bottom of the shield out 1/4 of and inch from the bulk head, this allows anything trapped in there to escape and still protects the bulkhead. I just saw the picture on the first page or so of the bulkhead. the project looks great, keep up the good work.

[jac04]

^^Sure will - I've used the splash guard spacers on all my past rovers.:thumb-up:

[jac04]

The fuel valve is all rebuilt & ready to go. I have all new fuel lines as well.

Before:
http://i79.photobucket.com/albums/j126/jac04/000_1322.jpg

After:
http://i79.photobucket.com/albums/j126/jac04/000_1324.jpg

[SafeAirOne]

The fuel valve is all rebuilt & ready to go. I have all new fuel lines as well.

Is it just me or is the valve installed upside down compared to the before photo?

[jac04]

^^ Nope, it's not you, it is installed the other way. All the reference info I have shows the valve installed the way it is in the "after" photo. It's hard to tell if the valve was ever removed before, so I don't know if it was installed correctly in the "before" photo. Maybe someone else with a military vehicle can take a look at their valve and see how it is.

[Terrys]

The valve ports on my 109 GP are one up, two down. I don't know why a LW and a 109 GP would be different, but you know Land Rover.

[jac04]

Where are your electrical switches, top or bottom? Mine were originally on the bottom, but are now on top. I may not be able to make the elec connections (too close to the seat box), so I may end up flipping the valve back the way it was.

[jac04]

OK, I ended up with the valve back in its original position - turns out it was correct after all. :o Now I'm just waiting for the fuel line from the valve to the pump and the "LH Fuel tanks RH" sticker.
Here it is installed:
http://i79.photobucket.com/albums/j126/jac04/000_1326.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1325.jpg

[BirdNerd]

Jac,

The fuel tap on my lightweight is on the right side passenger footwell, I've never seen one mounted on the seat box--is your truck RHD? 24V?

If you need a pic let me know.

rovr66atgmailcom (don't forget the dot!)

[jac04]

Weird - I thought that they were all on the seat box. The manuals only show it in this spot. Mine is a LHD 12V.

[telwyn]

My RHD 12v Lightweight has it on the right seat box.

[jac04]

All the clips & wiring installed:
http://i79.photobucket.com/albums/j126/jac04/000_1329.jpg

[Tim Smith]

All the clips & wiring installed:Where do you find all of those clips? Is this something our hosts carry?

Looking good by the way!

[Eric W S]

Where do you find all of those clips? Is this something our hosts carry?

Looking good by the way!

Most UK car parts specialists have them by the bag for under a tenner. Our host should have them as well.

EwS

[teechizpet]

Jac, Looks like you are doing it right. I check in regularly on your progress. I am in the final stages of a frame replacement on my Lightweight. Drop me an E-Mail if you have any questions. jamet07@hotmail.com

[jac04]

^^What did you do about the shims used between the rear tub and the chassis? Mine had shims, but they basically disintegrated when I took the rear tub off. I was going to make some up if needed, but I'm wondering what to expect as far as alignment issues.

[teechizpet]

The ones that I had were in decent shape so I cleaned them up and painted them w/POR 15. I haven't done a final fit on the tub yet because my doors arent quite finished so I havent used them yet. As far as yours disintegrating I don't think they would be too hard to make. If you need one for a pattern I can send you one. I would definitely use a differant material though.

[BirdNerd]

Tim,

West Marine has those clips (in stainless no less!!)

if you need a Part Number shoot me an email at my gmail.com acct

byrdnyrd@......

BN

[jac04]

Well, I just ordered a new front bumper, front bumperettes, and seat back cushions from PA Blanchard. I'll let everyone know when they arrive.

[jac04]

I received a few Mil-Spec goodies from Saturn Surplus.

0-Gauge battery cables, battery terminals & covers, and a nice ground strap (all for really cheap!!):
http://i79.photobucket.com/albums/j126/jac04/000_1330.jpg

NATO trailer plug cover (exactly the same as what came on the vehicle):
http://i79.photobucket.com/albums/j126/jac04/000_1332.jpg

[jac04]

...started rebuilding the rear driveshaft...

Before:
http://i79.photobucket.com/albums/j126/jac04/000_1337.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1335.jpg

During:
http://i79.photobucket.com/albums/j126/jac04/000_1338.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1340.jpg

'After' pictures to follow.

[jac04]

My shipment of goodies from PA Blanchard arrived. New Old Stock bumper, bumperettes, and seat back cushions:
http://i79.photobucket.com/albums/j126/jac04/000_1348.jpg

[jac04]

Both halves of the rear driveshaft are all rebuilt & ready for reassembly...just waiting for the paint to fully dry. I'm probably spending way too much time on detailing all this stuff, but:
http://i79.photobucket.com/albums/j126/jac04/000_1354.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1356.jpg

[jac04]

Here is an update. I have been spending a lot of time just trying to figure out exactly what I've gotten myself into. The vehicle appears to be 1980 or newer. Unfortunately, this means a metric brake system (MC, lines and junctions are all metric threads). It also looks like I have the newer style stub axles (which take different oil seals). On the plus side, I guess, this thing should have 24 spline axles.

The rear drive shaft is completely assembled, greased & ready to go:
http://i79.photobucket.com/albums/j126/jac04/000_1391.jpg


I restored the e-brake mechanism and got it put back onto the chassis:
http://i79.photobucket.com/albums/j126/jac04/000_1389.jpg

BEFORE:
http://i79.photobucket.com/albums/j126/jac04/000_1285.jpg

AFTER:
http://i79.photobucket.com/albums/j126/jac04/000_1380.jpg

A few more parts sandblasted/primed/painted and ready to go. I also completely disassembled & restored the brake pedal box. I'll finish it off with a new master cylinder.
http://i79.photobucket.com/albums/j126/jac04/000_1386.jpg

[MerlynIIa]

Hi, nice lightweight and great job on the rebuild!

Did not know where you were in relation to the bulkhead. yours looked repairable. In case you are interested. TLR, in Tennessee, has a lightweight bulkhead

www.tntlr.com (http://www.tntlr.com)

At the home page, click on "parts"

then click on "bodypanels"

scroll down "ltwt bulkhead, used"

its $500.00, has a pic.

I don't know much about lightweights, so it may not be the right one, but thought I would pass it on.

[jac04]

Yes, I saw the Lightweight parts that he has, but thanks for the heads-up. My bulkhead is definitely save-able. My hood has a few big shallow dents in it - I would love to get that hood that he has, but shipping would be $$. Oh well, but I guess the dead-flat paint job will hide a lot of stuff.:)

[jac04]

Here are a few more pictures. I'm having a tough time trying to get decent pictures of a lot of stuff - I suppose because they are black and I have a basic digital camera. I lightened up these pictures to try to show some detail - let me know if they look better than my other pics.
Rifle holders:
http://i79.photobucket.com/albums/j126/jac04/000_1393.jpg

Clutch pedal box components:
http://i79.photobucket.com/albums/j126/jac04/000_1395.jpg

Clutch pedal box assembled:
http://i79.photobucket.com/albums/j126/jac04/000_1397.jpg

[rwollschlager]

the rifle holders look different? did you use a matt or satin finish?
As for the other pictures they look about as good as the rest of them....awesome!! At this rate is your truck gonna be done for british by the sea '09??

[jac04]

^^Yes, the rifle holders were painted flat black when I got the vehicle, and looked to be fairly original paint. So I repainted them with flat black. The roll bar/seat belt anchor hoop is also flat black.
BBTS 09 may be pushing it - I'm realistically thinking September or October.

[rwollschlager]

BBTS 09 may be pushing it - I'm realistically thinking September or October.

All metal dash?

[ktom300]

I'm in the process of restoring my tailgate and pioneer brackets. It looks like your's are intact so I was hoping you could give me a measurement from the bottom rivet center to the end of the strap? I need this measurement to install the new straps I just picked up off ebay.
Thanks!

[jac04]

^^ My tailgate is stashed away in the attic above my garage. The problem is that the Rover is parked under the pull-down stairs so I can't get to it. If you PM me your e-mail, I have a hi-res picture of the back of the vehicle that should gove you a good idea of the strap mounting.

[thixon]

That is the cleanest gearbox I have ever seen....bar none.

[Tim Smith]

That is the cleanest gearbox I have ever seen....bar none.I agree. I wonder if that is the result of that aluminum paint stuff. Heard of it but never used it. If that is the case then sign me up! :thumb-up:

[jac04]

^^ You know, at first I thought that it was just a bead-blasted case in natural aluminum. However, when assembling the e-brake mechanism, I noticed that the studs were the same color. Turns out that the case IS painted with some type of aluminum-looking paint. At first I was upset, but the stuff seems very tough and should keep the box looking great.

[Tim Smith]

I once bead blasted a transmission and made the mistake of leaving it without any protection. It started to erode on me in the first 1000 miles and looked like junk in no time.

The paint would have been a much nicer way to go if you ask me.

[jac04]

Clutch pedal box assembly all ready to go:
http://i79.photobucket.com/albums/j126/jac04/000_1400.jpg

[ktom300]

Tried to reply to your PM you but it says your box is full. Popular guy!

[JackIIA]

Boy oh boy, looking good! Appreciate you taking the time to snap all the shots as you go. Inspiring. I'm surprised you're getting such good quality with the spray cans. Looks very pro. Makes me think my HVLP is overkill. Keep up the updates!!!

[jac04]

Tried to reply to your PM you but it says your box is full. Popular guy!
All clear now! Sorry.

[jac04]

I'm surprised you're getting such good quality with the spray cans. Looks very pro. Makes me think my HVLP is overkill. Keep up the updates!!!
Thanks for noticing, I really spend a lot of time on prep work, so that obviously helps. I blast using DuPont Biasil sand, then sand smooth with 320 or 400 wet-or-dry paper. Then it's time for a laquer thinner wipe down followed by a tack cloth. Finally I get to prime & paint. My trick is to keep everything warm, especially the spray cans. I keep my 'paint room' at about 80-90F, and the paint cans I estimate at about 100F. It really helps.

[greenmeanie]

Clutch pedal box assembly all ready to go:
http://i79.photobucket.com/albums/j126/jac04/000_1400.jpg

Can anyone tell me the part number for the metal shim that shows quite nicely in the work above? It is the piece that goes between the master cylinder mounting feet and the pedal box. My 109 does not have it and I feel it will lead to wet toes.

[jac04]

Certainly:
http://www.roversnorth.com/store/p-8221-spacer-plate-clutch-mstr-series-iiiia-iii.aspx

[greenmeanie]

Thank you sir.

[jac04]

I got the brake master mounted:
http://i79.photobucket.com/albums/j126/jac04/000_1409.jpg

[ktom300]

I got the brake master mounted:
http://i79.photobucket.com/albums/j126/jac04/000_1409.jpg

Wow! I hope she doesn't spring a leak and get GTLMA all over the place!

[jac04]

Look what arrived from PA Blanchard in the UK today:thumb-up: :
http://i79.photobucket.com/albums/j126/jac04/000_1431.jpg

[kevin-ct]

With a new part, why do I think that the housing will be stripped and repainted?
Question, Will the body look as nice as the underside? :rolleyes:

[jac04]

^^ Yeah, it will. It just isn't up to my standards.:D
Funny, I keep telling the guys at work that I won't be going overboard on the body and that this project is just a refurbishment. They keep telling me that I don't have the ability to do anything half way and I'm into a real restoration. I'm in denial, but at least I know it.

[jac04]

I think the forum is having some issues. I posted these last night, but the posts disappeared.

New rear axle casing partially stripped in preparation for new paint:
http://i79.photobucket.com/albums/j126/jac04/000_1439.jpg

Starting the tear-down of the rear axle assembly:
http://i79.photobucket.com/albums/j126/jac04/000_1434.jpg

[jac04]

Sandblasting of diff housing and hubs is complete.
Confirmed that I have 24 spline axles :thumb-up: :

http://i79.photobucket.com/albums/j126/jac04/000_1440.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1441.jpg

[jac04]

I got the diff mounted in the new rear axle case. I ended up installing a new input flange and oil seal on the diff. The rear hubs are set up with new bearings and seals. The backing plates cleaned up nicely with the sandblaster. I have a new set of rear axle shafts and new rear stub axles on their way from PA Blanchard. The late style stub axles don't have separate oil seal wear sleeves, so replacement is the only way to repair the seal area. :mad: Man, this project is starting to get expensive.
I'll post pictures once everything is assembled & painted.

http://i79.photobucket.com/albums/j126/jac04/000_1475.jpg

[JackIIA]

Finally...!

I've been waiting for my jac04 picture updates for like a week or more!!!:)

Looks good as always.

[jac04]

I got the stub axles and brake backing plates installed on the new rear axle case. The original bolts were in great shape so I cleaned & re-used them, but the nuts were rusted beyond recognition, so I replaced them with new Genuine nuts (BSF).

Here it is after priming & painting:

http://i79.photobucket.com/albums/j126/jac04/000_1481.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1482.jpg

[Drain Rovers2]

i thought that the axles that I just rebuilt and put 3 coats of paint on looked really good, but this one just put them to shame!!
Nice work hope to see more pictures soon!!!!

[IIA Lightweight]

IIA Lightweight in Wisconsin

[jac04]

The rear axle assembly is coming together:
http://i79.photobucket.com/albums/j126/jac04/000_1486.jpg

I also started working on my gauges. I ordered a new MPH speedo for 7.50x16 tires to replace the KM/H unit for 6.00x16 tires. It arrived with a broken lens, so I ordered 2 new lenses and gasket sets from Nisonger Instruments. Here I have fit the new lenses to both gauges and am getting ready to install the re-painted bezels:
http://i79.photobucket.com/albums/j126/jac04/000_1483.jpg

[rwollschlager]

Did you sandblast and repaint the parabolics??

[jac04]

^^No, I just put on a few coats of brush-on semi-gloss paint. I used a pipe cleaner to get between the leafs:p .

[jac04]

Gauges are done:
http://i79.photobucket.com/albums/j126/jac04/000_1488.jpg

I got the brake cylinders and lines installed, as well as the LH hub assembly. So far, so good. I'm waiting on an axle to get the other side finished up:
http://i79.photobucket.com/albums/j126/jac04/000_1490.jpg

[xsbowes]

Have you thought about using the blank spot for another fuel gauge. I did this and it sure makes it convenient not to have to use the tank transfer switch just to check your fuel level. Just a thought!:)

[jac04]

^^ I did, actually. I also wouldn't mind having an oil temp gauge in this spot. However, I have so many other things to do I figured I wouldn't worry about it until later.

[jac04]

Making some progress.....
http://i79.photobucket.com/albums/j126/jac04/000_1500.jpg

[jac04]

U-Bolts torqued, OME shocks installed, check straps on, and new brakes installed:
http://i79.photobucket.com/albums/j126/jac04/000_1501.jpg

Test-fitting drums before painting them:
http://i79.photobucket.com/albums/j126/jac04/000_1502.jpg

Next on the schedule:
http://i79.photobucket.com/albums/j126/jac04/000_1503.jpg

[jac04]

Teardown of the front axle assembly is almost complete:
http://i79.photobucket.com/albums/j126/jac04/000_1519.jpg

...also picked up a little something for under the hood:
http://i79.photobucket.com/albums/j126/jac04/000_1520.jpg

[jac04]

One of the rear hubs all cleaned up & painted (new bearing races installed along with complete inner bearing & seal):
http://i79.photobucket.com/albums/j126/jac04/000_1521.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1522.jpg

[jac04]

Front axle housing/diff is all cleaned up and ready for paint. I installed a new diff gasket and input oil seal.

http://i79.photobucket.com/albums/j126/jac04/100_2258.jpg

Here's what it looked like 'before':
http://i79.photobucket.com/albums/j126/jac04/000_1514.jpg

[Tim Smith]

Looking great!

Are you just bead blasting to get the parts cleaned up?

[jac04]

I'm actually blasting with either Black Beauty (fine) for the heavily rusted stuff or Biasil sand for everything else.

[Tim Smith]

Like I said, looks great.

I've got a few parts to clean up and am planing on using black beauty for most of it. The only thing I'd note is that you want to be darned sure you get all of the residue out of your parts before reassembly. It would wreak havoc on the internals if any were left floating around.

I'm sure you knew this. Just thought I'd mention it. ;)

[jac04]

^^Oh yeah, I know what you mean. Even if you try to mask off the internals of a part before blasting, that stuff always seems to gets inside. Luckily, none got in my axle case becasue that really would have been a PITA to clean out.

I just finished blasting & cleaning my second swivel pin housing. I spent almost as much time cleaning afterwards as I did blasting. I'm having sooo much fun. :thumb-up:

[jac04]

I re-installed the swivel balls after fitting new Railco bushes & lower bearings. Here it is in the "paint booth":
http://i79.photobucket.com/albums/j126/jac04/100_2271.jpg

Brake backing plates are being assembled with new steady posts, wheel cylinders & lines:
http://i79.photobucket.com/albums/j126/jac04/100_2269.jpg

The front swivels housings are now ready for re-assembly:
http://i79.photobucket.com/albums/j126/jac04/100_2268.jpg

[ktom300]

I'm amazed at your progress. For those of us contemplating ground up restorations, what do you estimate your total $ spend to be when you're finished with this project?

[NickDawson]

to echo ktom300's sentiments, I am also really impressed! whith hopes that you don't mind, I've snipped your pic above from spraying the axel b/c we are day dreaming about what it would take to spray parts ourslevs... great work, looking forward to seeing more!

[jac04]

I'm amazed at your progress. For those of us contemplating ground up restorations, what do you estimate your total $ spend to be when you're finished with this project?
Well, keep in mind that I ended up buying A LOT of parts for this vehicle. Things that I planned on re-using ended up needing replacement (like the engine - that was over $5k alone). Or I decided to replace parts instead of repairing them (like the rear axle case and wheels, for example) . I also bought a rebuilt transmission ($1800) instead of dealing with mine, and I splurged on almost $2k worth of XZL tires.

I have a few more things to buy, but in the end I will have roughly $25k into this vehicle.

[jac04]

Front axle assembly is now installed. U-bolts still need to be torqued & trimmed. It's starting to look more like a vehicle now:
http://i79.photobucket.com/albums/j126/jac04/100_2285.jpg

http://i79.photobucket.com/albums/j126/jac04/100_2282.jpg

http://i79.photobucket.com/albums/j126/jac04/100_2281.jpg

[roverlandpark]

...also picked up a little something for under the hood:


What happened to your engine from Rover's North in November?

(Page 3 of this thread)

Just curious... BTW, this is probably the only thread I've read start to finish more than once; and it's not over yet!

[The one behind the mask]

Hey, I want to say that I'm really impressed with all the effort you're putting into restoring this Lightweight of yours. I've also been busy with a Lightweight for the past six months or so. I can't really afford a chalvanised chassis, so I decided to get the original into shape. It wasn't that bad for its age, the year of built is '69. Also I didn't pay too much attention to the engine, gearbox and axes, aside from the necessary bearrings and gaskets, because it's all running quite nicely. My main concern is that it's going to be a reliable operational vehicle. I'm running towards the end of this project. Waiting for some parts that are being chalvanised at the moment, and it has a charging problem. Other than that it's almost finished.

If I didn't need to drive it within short time and if I had a few more k to invest I would have done pretty much the same as you are doing right now. Maybe in ten years or so I might do it anyway. Hopefully I won't face too many difficulties until then.

Good luck with your project! Greetings from a dutch guy.

[jac04]

What happened to your engine from Rover's North in November?
Good catch. :) There were a few issues with it evident upon inspection and they ended up picking it back up from me. I'll leave it at that.

[jac04]

Good luck with your project! Greetings from a dutch guy.
Thanks and welcome to the forum. I'd love to see some pictures of your project.

[The one behind the mask]

Alright, here are some before pictures. I'm gonna do this in a few posts, because I can only add three pics.

[The one behind the mask]

Creating the new rearbumper is one of the most intense things I had to do. Trying to make it fit perfectly, after mounting everything finding out not everything fits perfectly... Getting it right after all.

[The one behind the mask]

Have to skip some photo's here due to exeeding limits, but this was the testdrive the other week. Right now I'm having a charging-problem. I thing my regulator is busted. I'm also waiting for some parts being chalvanised and arriving this tuesday. The headlight-switch is being revised and when that's all complete I can finally drive legally. I had the bulkhead all blasted and powdercoated. I decided to leave the outside as it was. You can count the years in the layers of paint blistering off, which I think is kind of unique. Maybe some day I'll paint the whole thing, I don't know. For now I just want to drive it, that's all.

[jac04]

^^ Nice looking project.

I got the swivel housings installed, but I still need to set the pre-load and install the seals:
http://i79.photobucket.com/albums/j126/jac04/100_2298.jpg

I noticed that the new 'normal' bump stops that I installed did not match the originals. The originals are almost 1" taller (they sit on a boxed-in steel section). I removed them from the original chassis, then sandblasted & painted them. Here they are:
http://i79.photobucket.com/albums/j126/jac04/100_2299.jpg

As you can see, I had to get a little creative when mounting the original front bump stops on the new chassis. The mounts on the new chassis are much too high for some reason. Compare the above picture to the original chassis and you'll see what I mean:
http://i79.photobucket.com/albums/j126/jac04/100_2302.jpg

[jac04]

Got my air cleaner support back from the powder coater:
http://i79.photobucket.com/albums/j126/jac04/000_1537.jpg

I also just received about 15 pounds of hardware back from being cadmium plated. I was finally able to re-assemble the pintle hitch and get it installed:
http://i79.photobucket.com/albums/j126/jac04/000_1542.jpg

[Tim Smith]

Looking good as usual. :thumb-up:

I assume the locking bolt for the lower part of the pintle was there to begin with. Mine is missing and I don't think that is a part I could find separate. Just curious really.

[jac04]

Thanks.
Yes, the locking pin & 'R' clip were there to begin with. They are available:
http://www.lrseries.com/shop/product/listing/16367/STC3430-NATO-HOOK-LOCKING-PIN.html?search=nato%20pin&page=1

http://www.lrseries.com/shop/product/listing/16627/STC3431-NATO-HITCH-R-CLIP.html?search=nato%20pin&page=1

[Tim Smith]

Thanks!

[The one behind the mask]

Hey what's taking you so long? I'm already driving around in mine! I'm kinda curious for your latest progression. I'm probably going to start on my dads
Lightweight some time this year, and we're gonna tear it apart and rebuild it somewhat like you're doing right now.

[jac04]

Yeah, yeah, yeah - I'm working on it. :)

[Drain Rovers2]

we need more pictures!!! please:thumb-up::D

[jac04]

All rust repairs on the bulkhead are now done. I test fit the bulkhead on the new chassis and it fit! Now I'll temporarily mount the pedal boxes, run the new brake & clutch lines, then take it all apart for final sandblast & paint.

http://i79.photobucket.com/albums/j126/jac04/000_1557.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1556.jpg

[Mike_S]

I just got to say WOW, you are doing some excellent work....so much that I am embarrassed at the condition of my exMOD Series III :(

anyways, keep up the great work! :thumb-up:

[jac04]

Leftover parts...someone had substituted regular military bumperettes for the lightweight-specific ones:
http://i79.photobucket.com/albums/j126/jac04/000_1545.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1546.jpg

[Moose]

If you are looking to get rid of those bumperettes and will ship them, I would be interested. I've been looking for a set.

Brett

[jac04]

I temporarily mounted the pedal boxes so I could get the final brake lines bent. Everything will now come back apart for final sandblasting & paint.
http://i79.photobucket.com/albums/j126/jac04/100_2509.jpg

[jac04]

I also finally got around to unpacking the Turner rebuilt longblock:
http://i79.photobucket.com/albums/j126/jac04/000_1566.jpg

I have also started cleaning up everything that needs to be swapped from the old engine to the new one. Here's the intake manifold:
http://i79.photobucket.com/albums/j126/jac04/000_1579.jpg

[4flattires]

Is that Bill Nye hanging on your wall, looking over your shoulder and sneering at your every move, commenting in his squeeky voice about the benefits of BSF thread patterns?

Would it not be more appropriate to display the iconic (circa 1976) Farrah Fawcett poster in her red swimsuit?

Lets get that man-cave back in order!

:thumb-up:

Jeff

[jac04]

Yeah, but "Science is Way Cool!"

[jac04]

Engine in the 'paint booth' for a nice single-color paint job:
http://i79.photobucket.com/albums/j126/jac04/000_1580.jpg

[NickDawson]

i mean... I guess I recognize the shape...but can't imagine an engine that clean.
ever.

joking aside - the pics are looking great - keep up the good work

[ktom300]

With every update, I can just see how you're going to leave the body in "rough condition". You don't still believe that do you? :p
Seriously, I'll be shocked if this lightweight ever gets started let alone drives down the road. Belongs in a museum.:D

[ivarra]

Funny, but good point!

I bought a 63 11A from Jac03 two years ago. It had been restored 12 years prior, but still looked like a museum piece (and still does). I even wax it periodically :o, and continually get asked 'so are you ever going to use this as was intended?' Well, maybe it was intended to drive kids around the neighborhood!

Anyway, every club needs one to remind the other owners what their vehicle once looked like.

Ivar

[jac04]

...got the NOS distributor installed along with the oil filter assembly and manifolds, rebuilt the original AC fuel pump, had the flywheel resurfaced, installed a new clutch, and the engine is finally in:

http://i79.photobucket.com/albums/j126/jac04/000_1586.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1587.jpg

[jac04]

engine assembly continues....waiting for parts for a really neat filter set-up utilizing an AEM Dryflow air filter
...rear driveshaft installed...

http://i79.photobucket.com/albums/j126/jac04/000_1588.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1589.jpg

[Tim Smith]

It is looking great as usual. :thumb-up:

Who made that chassis? I just noticed the front cross member and what looks like rear body mounts made out of box steel. I've never seen a bunch of those things before.

[jcasteel]

Nice work!

[greenmeanie]

The front cross member is a feature of the lightweight chassis. IIRC it is to provide a mount for a NATO hitch to allow the truck to push trailers onto aircraft and the mud. I don't know about the rest.

[jac04]

It's a Marsland chassis. greenmeanie is correct about the x-member behind the front bumper (and the bumper is also reinforced). The rear body mounts are specific to the Lightweight since the rear tub mounts to the chassis differently than the civilian models.

[Tim Smith]

Interesting. I just took a look and I do have those box frame bits for the rear tub. Just never noticed them before. I don't have the front cross member though and I also don't have the battery box plate.

Mine came from out of Canada as an ex-BATUS truck. At least that is the story I got. Makes me wonder if they had a different spec chassis than your average lightweight.

[jac04]

Tim - Do you have a civilian chassis under your ltwt? I believe that the S3 civvy chassis may have had the 'box steel' body mounts as well.

[Tim Smith]

To be honest, I'm not sure. I have the military rear cross member (square ends) and I don't see signs of that being modified so my guess is it's military. I had found the original owner of the truck after the MOD but that was years ago. As I remember it, he had built this truck up out two that were retired from BATUS.

[xsbowes]

Tim-Check to see if the crossmember for the tranny is removable. the military frames had this feature to allow for quicker servicing/replacing of the gearbox. On my frame you can see where the front crossmember has been removed and re-welded. more than likely to replace the fron horns.

[Tim Smith]

Tim-Check to see if the crossmember for the tranny is removable. the military frames had this feature to allow for quicker servicing/replacing of the gearbox. On my frame you can see where the front crossmember has been removed and re-welded. more than likely to replace the fron horns.
Oops. Missed your message.

Yes I do have the removable transmission bar.

[jac04]

I never much cared for the oil bath air cleaner, so I installed my own filter set-up using an AEM Dryflow air filter:

http://i79.photobucket.com/albums/j126/jac04/000_1591.jpg

[jac04]

I installed a new old stock double groove crank pulley and installed a Delco 10SI alternator:
http://i79.photobucket.com/albums/j126/jac04/000_1594.jpg

[Dino]

I installed a new old stock double groove crank pulley and installed a Delco 10SI alternator:
http://i79.photobucket.com/albums/j126/jac04/000_1594.jpg

Thats a beautiful engine

[jac04]

I can almost see the light at the end of the tunnel.....

The fuel tanks are now installed (after being blasted, etch-primed & painted):
http://i79.photobucket.com/albums/j126/jac04/000_1602.jpg

The bulkhead is almost ready for primer:
http://i79.photobucket.com/albums/j126/jac04/000_1601.jpg

The radiator support is ready for final paint:
http://i79.photobucket.com/albums/j126/jac04/000_1600.jpg

[xsbowes]

Are you going for the original color? Were you able to find any of the original under the camoflauge? Mine was bronze green before someone decided it should have a NATO green paint job. The original color was still visible under the door seals once they were removed.

Great job! All your work keeps me motivated to work on mine.

[jac04]

I have decided to paint the vehicle flat desert tan, as if it were prepped for Desert Storm. The interior will stay green.

Actually, the original paint is is fairly good shape. I found that Citri-Strip will remove all layers of paint except for the factory finish. My vehicle was factory painted flat green. It then appears to have received one sprayed-on flat green paint job followed by several brushed-on black/green camo paint jobs.

So, my 2 choices right now are:
1) Remove all loose paint, hit it with the DA sander, then spray/roll on a few layers of desert tan.
2) Strip all the body panels to the original finish, do body work, then spray it desert tan. This is probably the better way to go, but it will end up being a ton of work for a vehicle that was never intended to look all that nice.

We'll have to see what I decide.

[jac04]

...bulkhead is now in primer:
http://i79.photobucket.com/albums/j126/jac04/000_1603.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1604.jpg

[thixon]

I'm glad to see I'm not the only one hanging parts on an engine hoist for paint outside his garage.:thumb-up:

When I do this, it drives my neighbors nucking futs!

[ktom300]

Looks like the dash might need a skim coat of bondo to smooth over the rivets and other dents.:D

[jac04]

^^ Yeah, I'll take care of those when I fill in all the spot welds.;)

[Eric W S]

Looks like the dash might need a skim coat of bondo to smooth over the rivets and other dents.:D

Why? You're supposed to see those.

[jac04]

Paint stripping continues........all I have left is the rear tub and tailgate. My CARC substitute Desert Tan paint arrived today and I can't wait to get rolling...or brushing or spraying.....

Here are the door skins after sitting overnight with a layer of Citristrip on them:
http://i79.photobucket.com/albums/j126/jac04/000_1613.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1614.jpg

[JayGoss]

Please spray the car!!!! It's so beautiful a brushed on paint job just won't match the quality of the rest of the Rover. Guess it would be in keeping with what the MOD would have done but they could never eat dinner off of their transmissions! Thanks for letting us live vicariously through you- and keep those pics coming!!!:thumb-up:

[jac04]

Well, the radiator support, lower bulkhead and upper bulkhead have been sprayed. What a fiasco.

I purchased several Spra-Tools from Eastwood along with a bunch of extra propellant packs. Each of these things is supposed to be able to spray enough paint to cover about 10 square feet. I initially figured that I would use them on my wheels, but then decided to use them to spray the entire vehicle. Well, that plan has changed.

I thinned the paint (Gillespie 686 Tan CARC substitute), loaded it into the cup, and test-sprayed some cardboard. The spray pattern was a little smaller than I expected - they say it is supposed to spray like a real paint gun, but the pattern is smaller than a regular spray can in reality. However, it seemed to work great, so I started sparying the radiator support. After about 30 seconds of spraying, the Spra-Tool basically stopped working because the temperature of the propellant can dropped significantly.

So, I set up an "oven" made out of a cardboard box and a small ceramic heater, into which I put a bunch of the propellant cans. I had to swap them out every minute or two of spraying. I finally got through the parts I needed to get painted, but I will either be rolling the rest of the vehicle or purchasing a HVLP set-up for the remainder of my painting. I'm probably just going to go the HVLP route since I still need to paint all 5 of my wheels, which would be almost impossible to do with a roller.

Here are the best pictures I could get. The flash with the flat tan color produces lots of glare, but you can't see much without the flash. The parts came out very nice:
Radiator Support
http://i79.photobucket.com/albums/j126/jac04/000_1623.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1625.jpg

Bulkhead (lower):
http://i79.photobucket.com/albums/j126/jac04/000_1627.jpg

Bulkhead (upper):
http://i79.photobucket.com/albums/j126/jac04/000_1628.jpg

I also sandblasted the door frames and sprayed them with multiple coats of Eastwood Rust Encapsulator paint:
http://i79.photobucket.com/albums/j126/jac04/000_1624.jpg

[jac04]

So it's been about a year now. I am finally seeing the light at the end of the tunnel. Every part of the vehicle is now ready for final paint. I thoroughly cleaned the under side of the rear tub, coated it with several layers of 3M rubberized undercoating, then installed new tub supports.
I test fit the rear body and...............everything lined up perfectly. Things are good.

New supports:
http://i79.photobucket.com/albums/j126/jac04/000_1651.jpg

Rear body test-fit. The springs seem to make the vehicle sit very high. I never noticed it until the body was put on. I hope it settles down a little, otherwise I may be looking at military front shackles to even everything out:
http://i79.photobucket.com/albums/j126/jac04/000_1653.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1654.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1655.jpg

The badge is back on, so it's officially a Land Rover again:
http://i79.photobucket.com/albums/j126/jac04/000_1652.jpg

[gphiver]

This is fantastic!

Thanks for sharing... so much to look forward to.

[xsbowes]

Mine rides that high also with the parabolics. Even with the Tropical Roof (not on in this picture) that I have now.

http://pic80.picturetrail.com/VOL2073/10249131/18498171/292145282.jpg

[jac04]

^^Stacy-
What parabolics are you running, and how many leaf rears?

[xsbowes]

2 front and rear. Not sure of the brand, RM by the looks with Emu shocks.

[jac04]

I took yesterday off from work and painted the vehicle entirely in pieces along with all 5 wheels. It was a lot more work than I thought. It took me from 10am until 8pm to paint everything. Every piece was masked and painted. I used a Campbell Hausfeld HVLP system and it worked GREAT! If you are painting with a flat or satin paint, and you are looking for an economic painting system - definitely check it out at:
http://www.gleempaint.com/ch-hv1001-hvlp-system.html

Here are the finished pieces:
http://i79.photobucket.com/albums/j126/jac04/000_1663.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1657.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1658.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1659.jpg
http://i79.photobucket.com/albums/j126/jac04/000_1662.jpg

[NickDawson]

great work jac04 - really enjoying watching your truck come together

[Nium]

Those panels and wheel look good. Damn fine looking work. Minimum to no craters? I hope.

Love the spray both very MacGiverish! The garage door opening change color? :D

[jac04]

I'm not sure what you mean by craters - do you mean fish-eyes? Either way, the paint went on very well and covered excellent. I didn't have any significant issues or problems at all with laying on the paint. I did get some runs on one door, but sanded them out and hit the door with another coat and everything was OK. I used about 1.25 gallons to paint everything.
For spray booths - I actually had 2 set up like you see in 2 of my 3 garage bays. I made sure to cover the closed garage doors in plastic as well. I made the mistake of not covering the floor completely on the 2nd spray booth, which is the one I did most of the spraying in. The result is a floor covered in paint, but what the heck, people go through a lot of trouble to paint their garage floors, right?

[LaneRover]

The result is a floor covered in paint, but what the heck, people go through a lot of trouble to paint their garage floors, right?

Sounds to me like that is a good 'ecological' way to paint your garage floor too! Otherwise the paint would just be wasted!

[jac04]

...things are starting to come together....
http://i79.photobucket.com/albums/j126/jac04/000_1665.jpg

http://i79.photobucket.com/albums/j126/jac04/000_1670.jpg

[Tim Smith]

It's amazing. Looking at your tub, now I know why there are two big spots of bondo on mine. The PO must have been trying to hide the rivets on the front lower section where the bottom of the door meets up.

At least I hope that's why. :(

Looking good as always! :thumb-up:

[jac04]

It's starting to take shape........
http://i79.photobucket.com/albums/j126/jac04/000_1673.jpg

[xsbowes]

I see you are not using the rear military lights. What country was your lightweight from? Mines a '72 SIII LHD Ex-MOD from Canada but I only have 1 red light on each side.

[jac04]

No military lights, maybe later, but my lenses were in rough shape and replacements were going to be very expensive. So I decided to use the Defender lights. I don't know what country mine is from. The second red light on each side is a rear fog light.

[JackIIA]

Jac -

Nice. Perfection, as always. What about curing issues, if any? As I remember, you're using Rustoleum products for the bits in black. I've been getting a fair amount of scratches on this paint when reassembling. But, I know you paint while keeping temp around 70 or higher, which I have not necessarily done. However, I have let cure times run well into the weeks before reassembly. Curious if the temps, then, have made a big difference.

Also, did you use hardeners for the desert storm paint? These shots are huge motivators. Thanks as always.

[jac04]

The Rustoleum black paint will stay soft for quite a while - like over a month, even keeping the parts warm. Most parts that I am reassembling were painted several months ago, so I haven't had too many paint issues, although don't expect powder coat durability out of the Rustoleum paint.

I didn't use any hardener in the Gillespie tan paint because it tends to add too much gloss (or so I am told). I have been very pleased with how well the paint has cured, even though it has only been in the 60s here. I painted on Friday, and now the paint seems fully cured (can't dent it with a fingernail).

[sailtech]

Outstanding work! Did you have the galvanized bits re-galvanized?

[jac04]

^^No, they had quite a few layers of military paint on them , so they were very well preserved.

[jac04]

The bulkhead is now on the chassis, complete with the wiring harness and brake & clutch systems. All hydraulics are full of GTLMA fluid and completely bled.

http://i79.photobucket.com/albums/j126/jac04/000_1674.jpg

[TJR]

Very Nice work... It looks great...
Does the Mower ever have a chance to get used? LOL

[jac04]

...one front hub is back together. The drum isn't on yet, obviouslysure it's machined correctly. I'll start a new thread to ask the question.

http://i79.photobucket.com/albums/j126/jac04/000_1679.jpg

[Moose]

It's starting to take shape........
http://i79.photobucket.com/albums/j126/jac04/000_1673.jpg
Interesting the way your license plate light is mounted upside down. I've not seen one done that way before. All the Ltwt's around here (and 101's) have the light on the tailgate (the lower half) with the plate mounted on a swinging metal bracket so the plate still hangs properly when the tailgate is open. To remove the tailgate, a single wire to the light also needs to be unplugged.

Brett

[Nium]

What are you running in that wall of the garage that you need 3 "High Voltage" warning signs. Must be one heck of an arc welder you are using.:D

The rebuild is looking good. It's just so odd to see a clean and shiny Land Rover kinda hard for me to wrap my head around at times.:p

[ktom300]

Interesting the way your license plate light is mounted upside down. I've not seen one done that way before. All the Ltwt's around here (and 101's) have the light on the tailgate (the lower half) with the plate mounted on a swinging metal bracket so the plate still hangs properly when the tailgate is open. To remove the tailgate, a single wire to the light also needs to be unplugged.

Brett

Like mine. Funny, I didn't know why the plate had a hinge unitl I read your post.

http://i364.photobucket.com/albums/oo89/ktom300/IMG_6405-2.jpg

[Moose]

Glad you posted that pic ktom300. Wasn't sure I described very well the way the plate was mounted.

Brett

[jac04]

Mine has the hole on the inside of the tailgate for the center plate light wiring, but that's it - no signs at all of a center plate mount. The holes on the body for the side plate light appear to be factory. Keep in mind that mine may be a very late body, like 1983 vintage.

[ktom300]

Mine has the hole on the inside of the tailgate for the center plate light wiring, but that's it - no signs at all of a center plate mount. The holes on the body for the side plate light appear to be factory. Keep in mind that mine may be a very late body, like 1983 vintage.

If your's was meant to have the center plate, you'd have two brackets or at least four rivet holes for the hinge mounts. You'd also have a square punched hole for the plastic bushing that allows you to swing the plate down and lock it back into place.
Seems like there were a a lot of variations with these vehicles. Especially with the marker lights and interior guages.

[JayGoss]

Jac,

Was looking at the pic of the painted tub mounted on the frame (looks great by the way). I noticed that the rivets were left unpainted- my Series II is was finished the same way by someone else & I like the look. I was wondering how you did that- did you mask each rivet prior to paint or did you remove the paint after spraying?

[LaneRover]

I am going to guess that painting was done before riveting.

[jac04]

Yes, I drilled out the rivets on the rear body before painting. I did this so I could prep & paint in between the panels in the areas where they were riveted - I didn't want to risk the paint peeling over time. However, I ended up using #10 stainless phillips head screws and stainless nylock nuts to put these areas back together. I tried the rivets, but had a tough time getting the panels to come together. I did rivet all the galvanized trim.

[jac04]

The tailgate is now complete:
http://i79.photobucket.com/albums/j126/jac04/000_1690.jpg

The front hub assemblies and brakes are done:
http://i79.photobucket.com/albums/j126/jac04/000_1691.jpg

[ktom300]

Looking good. I noticed your axels have cone shaped center caps.
How are these different from the flat style like mine?

[jac04]

Mine are the late style axles, so they use 24 spline axles and hub caps that are the same as the civilian version. Your axles are a special shorter length for use with the flat caps.

[jac04]

Gauges and heater are installed:
http://i79.photobucket.com/albums/j126/jac04/000_1692.jpg

Got my XZLs mounted & balanced today:
http://i79.photobucket.com/albums/j126/jac04/000_1693.jpg