Lightweight (Airportable) Landrover rebuild.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I walked a whole minute out of my way to have a look myself!

#landyselfie
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

And you didn't drop in for a cup of tea?

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Very kind of you to help sir, probably at it next Monday so will let you know.

No pics so far today but decided I will just rebuild the slave cylinders as per Teffers suggestion.

Now these slave cylinders have a very different set up to a motorcycle caliper in that instead of seals around the piston they are at the ends of the pistons and the pistons are opposed like a boxer engine, both push out from the same fluid supply in opposing directions.
As long as you can get one piston out you can remove the seals for both pistons and then knock the opposing one out with a punch.

This is how the slave cylinder looks while mounted to the backplate on the axle.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0654-1.jpg

As you can see the pistons are opposed with a single inlet around the back next to the bleed nipple.

Bru · Trackday Trickster Joined: 01 Feb 2007 Karma :

I have never found drum brakes that clean, on any of my cars, and my cars looked 'far' nicer (not that it would be difficult) than yours. Amazing.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Llama-Farmer · World Chat Champion Joined: 23 Jan 2012 Karma :

Eurgh, drum brakes and slave cylinders still give me nightmares.

Gonna watch this thread with interest Thumbs Up

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Wonko The Sane · World Chat Champion Joined: 20 Jan 2013 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Heres the cleaned up slave cylinder. The pistons are now so smooth that if you remove the dust seat the pistons shoot out due to the spring in the middle.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0658.jpg

map · Mr Calendar Joined: 14 Jun 2004 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Aff · World Chat Champion Joined: 05 May 2011 Karma :

Posting for updates. Thumbs Up

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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Not a real update, just had some bits arrive.

New under wing mudshields for both sides, steering box cover, a seal for between the vent panel and windscreen and some flap discs.

Hopefully I will get to do some more work this week as I have 6 days off, just have to make sure I don't eat too much at pork rib night.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0659.jpg

Need to decide what finish I want on the mudshields and steering box cover. I'm thinking hot metal spray, powder coat and then underseal just so they last another 40 years.

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Good Project more interesting than many run of the mill 'I've just stuck a load of tat on my late 90's sportsbike' projects!

Question to Sickpup.
What engine is in your Wagon? I always assumed that the lightweight's had the Rover V8, for it's lightness and grunt, but out on the battle field wet prone electrics and petrol fuel/fire risk would not be the best option, so were they diesel lumps instead?

I know that I've seen several lightweight's with RV8's so if these were not std fit, I assume some have been converted once in civilian ownership?

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

If a lightweight has a V8, it's a retrofit...

As far as I know (which isn't very far Wink

) they all had the 2.25 petrol.

As for the term 'lightweight', they weigh more than a standard civvy series 3.
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

V8's were never to my knowledge a standard fit in the lightweight, it wouldn't surprise me if the factory tried it at some point but none that I know of were put into production. All of the ones you see in public are retro fits.
The standard engine was the 2286 petrol but the Dutch did have LHD 2286 Diesels that were a bit of a failure, have a read here for details of them.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

No pictures today just an update so I can see that I've done something.

Been off and seen the Blacksmith and after a visual inspection he has agreed to repair the vent panel. We discussed spray hot metal and he agrees its the way forward with an external class powdercoat over the top which will not only give good further protection but stop any Zinc-Aluminium contact so no powdery Aluminium after a year.

Refitted the Rear right slave cylinder so that corner is sorted brake wise, hopefully do more on the brakes tomorrow if I wake early enough.

pdg · World Chat Champion Joined: 15 Sep 2012 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Need to find out costs but it looks like Hot metal spray, powder coat and then Dinitrol internally.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

So the rain has stopped for the moment and to work.

Front right brake time.

Bit muckier in here than the rear, looks like something has seeped in here over time as well but all the seals look intact.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0660.jpg

Had to undo the bleed nipple again to release the pressure on the pads but once that was done the drum came off easily.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0661.jpg

Stripped and cleaned the slave cylinder which seems to be fine, here is how the component parts look.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0662.jpg

These are the shoes, as you can see there's a small amount of what seems to be oil contamination. I'm not bothered by it, if that's all there is since I last took the brakes apart 23 years ago then no problem for now. Quick clean with brake cleaner as well as the drum and it all goes back together.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0665.jpg

So thats another corner done and hopefully by tomorrow I'll have the third corner completed. The Rear left is up against a fence so that ones going to be a bit on the hard side to get to. May have to use a high lift jack and sort of swing the rear over, last time I used one though I shattered my left thumb as Reuben can attest to.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Decided to get the master cylinder and servo off today.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0666.jpg

It's a dual circuit master cylinder, one circuit for the front brakes and one for the rear so has two brake lines going into it as you can see here.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0667.jpg

The servo can't be rebuilt as the four studs that hold it on are badly corroded, luckily a new one is only £65.34 so not too bad. Problem is the master cylinder. The piston is siezed solid so I will be having a chat with a company that reconditions them to see what they can do for me, if they can't re-con it I will have to buy a new one. A cheap no name pattern one is only £60 but I would prefer a genuine Girling as they last well, I suspect the price may run into several hundred for one though.

An empty space where things used to be.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0668.jpg

Shaft · World Chat Champion Joined: 27 Dec 2010 Karma :

Try this lot

https://www.powertrackbrakes.co.uk/wcylinder.html#cylinder
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Had the vent panel back yesterday, good and bad news. The bottom part that had rusted away has been replaced and its been filled with rust proofer.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0675.jpg

but unfortunately more holes have appeared where the metal has been corroded away.

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0676.jpg

https://i945.photobucket.com/albums/ad297/750RK/LandRover/DSCF0677.jpg

The metal here is too thin to weld so will need large sections replaced, as a temporary fix I am going to skim the holes with chemical metal, respray and fill the inside with Dinitrol rust proofer. The metal is simply too thin to Hot zinc spray.
Although these sections are repairable it will be cheaper, and it isn't cheap to buy a new one and get that Hot zinc sprayed.