More Pictures from the 109 / 110 chassie build

[safarirover]

Here are some more lessons learned the hard way.....

A Defender Hood is appx 4 inches wider than a Series Bonnet. Therefore a brake Servo and master from a 2004 Defender will not allow the bonnet to close as it hits on the 11 inch Servo. A Servo and master from a 1989 Defender is 8 inches and will allow the smaller bonnet proper clearnace to close. This will not effect the disc in the front and drum in the rear 110 brake system.

Sheet metal fabrication (to allow the Defender Tunnel Cover to matt to the Series Seat Base) is a royal pain in the arse.

A defender steering shaft must have some cosmetic alterations to allow the Series Slip ring to properly fit, thus allowing the center push button for the Lucas Horn.

Exmoor Seats do not come with instructions and when a call is placed to Exmoor some one says use your better judgement while mounting.

 

[Leslie]

Couple of questions.....

a) If you've galvanized the breakfast (radiator support panel), why not the bulkhead?

b) If you've changed over so many bits on this 109 to 110 parts, then why not use a 110 heater, or even a Series III heater, instead of the shinroaster?

c) Why install the wings before you have the engine in?


Looks good, though. Hope to have mine looking somewhat as complete at some point....


-L

 

[ISUZUROVER]

Exmoor Seats do not come with instructions

Why are instructions needed? Aren't they direct replacements for the stock items?

I was also wondering why you haven't galvanised the bulkhead (or maybe you have but you painted over it???). It isn't too late - galvanise or you will regret it later.

 

[safarirover]

Couple of questions.....

a) If you've galvanized the breakfast (radiator support panel), why not the bulkhead?

The bulkhead is not galvanized as it exceeded the weight and cost allowed in the owners budget. I sand blasted and repaired the bulkhead, new foot wells and door post. Using a tukey baster from the kitchen, (damn good thing I am not married) I injected the bulkhead with Wurth Rust Guard. On the outside the lower pannels ( areas not visable above the hood and fenders received rust guard and an additional coat of Wurth Stone Guard coating and Wurth Rust Guard Primer and Paint. This will not only reduce nosie, but effectivly prevent rust.

b) If you've changed over so many bits on this 109 to 110 parts, then why not use a 110 heater, or even a Series III heater, instead of the shinroaster?

Again budget constraints- We are considerably over budget. An upgraded heater was suggested and may be added down the road.

c) Why install the wings before you have the engine in?

The wings are on only to test the fit of the radiator and breakfast. The wings are back in storage until the engine is in and tested. To help protect the paint I expect the wings to be one of the last items installed.

 

[safarirover]

Exmoor Seats

Seats are supposed to be drop in direct replacements, however

The rear bench seat (top cushions) do not have any mounting tabs on them. Spoke with exmoor and they suggested self tapping screws. I see two issues with this.
1. Going into particle board and I don't have a rear love for that stuff. It tends to crumble and therefor the screws will have nothing to hold.
2. Even with short screws, I fear as the form ages the screws will stab someone in the back.

Middle Row
there where very few Series 109s in the UK with single folding bench seats. The replacement seats are a grouping of three. To make it the cleanest install one should order the frames also. Works out to be appx an additional 600.00 for seat frames. I stripped the old frame and reused it for the seats and they seem OK, but I don't like the way it all looks. Some seats have Riv-nuts in the bases and some don't. Some are there and covered. seems like poor quality control.

Front Seats
Same with the front. These appear to be drop ins, yet some of the 6 pieces do not have Riv-nu0ts and some do. Some are covered and some are not. Will not have a final report on the seats until the very end. Hate to install the seat base and then have to remove it again to work on the gear box or what ever.