SANDYS REBUILD
For more photos click on any photo to go to album.
Sandy when we set off 17th April 2009.
When Sandy arrives back home we intend to strip her down to the chassis and rebuild while extending the wheelbase out to a 130. This will give more room on the back as we intend to build a motor home type body. Not with all the fancy panels, but lots more robust and solid to take the knocks that we expect to get en route to Aus.
The initial brief spec is 3.1mtr long x 2.03 wide with an elevating roof. Height (We must fit into a std ISO container). Solar panels, Fridge, freezer, shower, cooking facilities, heater, sleeping for two and stowage. We will use specially made small wheels for containerising to assist with the height problem.
Lots of research to do before starting the build but we hope to start strip down about end of April.
19-03-10
Sandy is back now so the planning work has started. First job was to find chassis drawings. Now that is a lot easier said than done. But we have managed eventually, although they are not as detailed as I would have liked but they will suffice
In view of how hard it is to obtain them I am going to post all the drawings on the web so that others may use them. Land Rover is so o o o helpful, it made me think about buying a Toyota. (Wash my mouth out with carbolic soap, ugh!!!).
The basic plans, wheelbase extension and box for the rear are drawn but it will be subject to change as I go along dependent upon what fittings and materials I can get. The main construction should GRP sides with 25 to 30mm of insulation and then an interior lining. It is hoped to take most of the interior fittings, i.e., cooker, fridge, shower units etc out of a crashed caravan to help keep the cost down.
TO SEE BETTER PHOTOS OR TO LOOK AT THE CHASSIS DRAWINGS CLICK ON THE PHOTO BELOW.
From outside
Rough interior plan.
More as we go. (If anybody sees a boo boo, anytime don’t be afraid to let me know. A word wise is a fortune saved.)
We will update as we go.
26-04-10
Work has now started; Sandy is in the garage with the top removed along with the front inner and outer wings, bumper, winch, seats and all the auxiliary electrics. She is starting to look a sorry state.
I have kept the entire engine in one piece at the moment as I need start up to find a power steering fault before I progress any further as once the engine is dead locating the noise will be a no no.
The white stuff on the rad etc is the mud from Meremi National park in Namibia.
06-05-10
The engine and gear box are out, fuel tank, brake lines and all electrics removed. All that is left is the chassis and two axles, just! So easy to take apart. I just hope it is so easy to put back together. Some hope. Ever so easy to move the chassis without anything on it. Just roll it where you want it. Blasted the chassis off with the pressure washer and I am pleased to say that only two small bits of rust to deal with. The rear cross member is a bit bad, but that will be going anyway.
 The engine is on the bench and having removed the head I can see why we were getting intermittent over heating. The head gasket was weeping from no 2 to the water way under pressure. I.e. going up hills. The vacuum, lift and power steering pump are to be replaced along with the cam belt, idler and tensioner bearings. The sump has been removed and the two bolts that sheered in Namibia when we cured and oil leak are now being removed and the bolts will all be replaced. They are 8mm thread but 10mm heads which ring off ever so easy. I will replace with high tensile 8mm with 13mm heads to facilitate better removal in the future as I very much doubt that if I have to take it off again I will have workshop facilities...
Next job after the engine will be to strip all the under seal off the chassis for final inspection before a firm decision is made to cut and extend or buy a new 130 galvanised chassis. A hard call as a new chassis is close to £1800.00 but galvanised and preferred. I can extend this for about £300.00. So if it is all solid it will have to be extended. If not I have to find another £1800.00. Ouch!
18th June.
Chassis is sorted as you can see. All cleaned and painted.
Ready to start the rebuild. I have managed to re register Sandy on the original registration number. so I have very little paperwork to sort out with the DVLA. The engine , gear box, transfer box and both axles are checked over and ready to be fitted. So as soon as I can start things will happen very quickly.
28th June.
I have a chassis that can be moved on wheels. What a milestone. I thought it would never come.
Now for the engine and gear box, we will see how we get on.
03-07-10
Engine and gear box all fitted and bolted down, we are now starting to look like getting a Land rover back. Ther bulkhead is now being preped for painting and checking over. So as soon as that is fitted the electrics and breaks should follow shortly.
15-07-10
The bulkhead is now fitted, simple. Just 6 bolts and it looks like you have done lots of work. But in truth the work is done before fitting. Found small bit of rust in the passenger foot well that had to be patched but otherwise solid as a rock.
Fully striped and painted inside and out. Electrics are fitted and the loom only needed small repairs. Connector ends, new sheathing. Would like to spend more time on the job but with now working full time its getting hard to do what you want to do in the time you have. Anty roll bar is fitted. But I have noticed that all the ball joints, i.e. track rod ends are loosing the grease. So much for being sealed for life. What is life? Not long enough for me so I am ordering a load of grease nipples and I will drill and tap so that all ball joints etc become greased. Another tedious job but one that in the long term should pay dividends.
7-8-10
Drilled all the ball joints and fitted grease nipples so now I should be able to grease them all on a regular basis. One of the front wings is now fitted, washer system, and all the electrics on that side. Most of the air ducting is mounted but until the steering box is fitted that side is on hold.
We have purchased two front wing spats from M+M that are 2” wider than normal to take into account the 30mm wheel spacers that will be fitted and keep the mud from hitting the side of the car so much with the mud tyres. The spats aren’t bad but they would leave a gap at the inner wing to the outer wing if just fitted as they only screw to the outer wing. Not wanting a hole in the wing I have trimmed the outer part of the spat from the inner and will fit the inner to seal the hole.
Starting to prep all the water system and the seat box. Mine is corroded quite badly on the driver’s side so I have obtained another one that has some corrosion on the passenger side so two into one will make one good one. Additionally I need to modify it to take two 90 fuel tanks fitted under the seats. By doing this I get the additional fuel I need and don’t have to lift the seats up to access the storage boxes so I can fit better seats. The Defender seats are not too bad but comfort is good.
18-08
Just fitted the last of the air intake system and the front os inner and outer wing. Now ready to fit the intercooler, rad, fan etc. Next will be test the electrics, front lights, and so forth. Not able to do the rears as the loom has been cut to extend it for the additanal length that will be needed.
24-08
Things are starting to get close to start up. It will be with the fuel tank sitting on the chassis for now, but it is very close. Intercooler and rad all fitted and piped up, just the antifreeze to fit.
28-08
WE HAVE LIFT OFF. Well the engine runs anyway. No more black smoke on start up. When we came home every time we started Sandy up a huge cloud of black smoke came out of the exhaust. It was quite embarrassing at times. But no more. She ran sweet as anyhing, no leaks, no rattles. So so pleased. It was a big moment for us. the tank and battery are ballanced on the chassis on a plank of wood, but who cares!
New prop shafts are arriving next week so then she will be driveable. The cab has been undercoated and the first top coat applied in readyness for fitting. Still held up by lack of fuel tanks. We need two Defender 90 fuel tanks and brackets. Short of paying about £400.00 out it is a waiting game. Next item on the ajenda is to tidy up the dash and refit everything after checking it over. More later, this happy bunny is going for a pint or 4.
4-9-10
All the lights are sorted, well the front ones. Had an electrical problem with the pre heat not working. Took two nights to find the problem. In the end it was the relay that had a terminal bent over so neatly that I thought is was supposed to be like that. Once it was straightened out everything worked fine. It’s always little things that seem to take the most time to sort out. But they have to be done its no good leaving them until later as it is always harder to come back and fix it later on. Cab is repaired and painted with the first top coat. I am painting most things before they are fitted so that everything has a coat of paint. When fully assembled I will repaint with the final coat. The tub has been cut and trimmed to form the base of the back of the cab.
Had a test fit and it all goes together quite well. The rest of the tub I will keep for now as it is a good source of alloy sheet for modifications. The cab has been striped back down to finish off and trim the base section before painting. We intend to cut the back of the cab to give access into the body but I am not sure if I want to cut it now or when the body is ready. Have to think about that for a while.
New prop shafts ready to fit. Purchased from Bailey Morris at Eton Socon. Best props going and not over expensive especially as they have 30d angle on the flanges.
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