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.

[masonater]

Removed soft top and some other small bits, started to see what i was getting my self into.

[masonater]

Started the long fight with rusty old nuts and bolts removing the seats, seat box, and floor boards.

[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...

[masonater]

Then on to the front wings, this is when I found my new friend the cut off wheel.

[masonater]

Rear crossmember in very rough shape

A few years back i removed a beach sticker and with it came some metal revealing how bad it really was.

[masonater]

Front drivers side frame horn, or what was left of it...

More parts coming off

door rot. probably going to scab patch and save up for some new tops this summer.

[masonater]

before and after some time in the bead blaster


Wiper motor rebuild start. not sure why i did this because it worked fine, i guess i just wanted to see its guts.

After powder coating, time to rebuild

[masonater]

Pulled out the motor with no problems at all. Hoist didn't break a sweat.

Lots of oil in bell housing, seemed like a mix of engine and 90w oil

Motor after a steam bath

bell housing after bath

Started coal slag blasting because I thought that was as far as I would go in the disassembly, we all know how that goes...

Cut out rusted frame horn

[masonater]

baking powder coated drive shaft

Removing swivel assembly was a nightmare. All the nuts were caked with undercoat.

Removing military undercoat was the worst. Spent a few days with an air chisel and scraper chipping away...

Got my new used crossmember in the mail (thanks Ike)

Another before and after bead blast of the swivel housing.

Powder coated housing and swivel balls.

[masonater]

Before and after hub blast

OCD taping prep for powder coat

came out great!

Cut the old crossmember off

Dumpster time

Home built frame horn (first time playing with metal so forgive me)

Time to learn how to weld

After a little practice i went for it...

[masonater]

Frame coal slag blast, turned that snow into black gritty mud.

Few hours and 100 pounds of slag later...

Front axel ready for primer

Used eastwood extreme chassis black primer and satin black top coat

Done

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.

my 5 second tape job (should have spent a little more time making it right but i was too excited to paint it)

Duplicolor Detroit Diesel Alpine Green

[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.

New ebrake shoes and springs and naturally, some powder coat

All back together and looking nice

painted the wheel cylinders just because.

replaced the rear main seal and put the flywheel housing back on the motor

Started coming together!

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.

Beat up old bushings

New bushings did not want to go in, press made them

Powder coated table at its peak

[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!