Sunday, 15 January 2017

Sliding window rattle

The rear windows of the cab in the Defender made a disconcerting clack noise when going over bumps. It was a bit of a worry that the glass might crack.


I replaced the broken lock and the banging has gone.


Fairly easy job. The only tricky bit is removing the old lock. There's not enough headroom to bash it directly so I used a screwdriver horizontally and bashed the shaft of that.


The amount of force needed was a bit worrying but the lock did give way before any damage to the window.


Refitting was a case of bashing the new lock on to the slide rails, in my case, with a rubber mallet.

The rattle has gone.

Saturday, 14 January 2017

Indicator cancelled too soon

When indicating right in the Defender the switch was very sensitive and the slightest twitch of the wheel would trip it back to the centre off position. I think I have found a fix.

A search on the Internet found quite a few people with the exact same problem, always indicating right. Like ours the left direction worked perfectly. None of the reports I read had a fix.

Indicate right

While fitting some electrics in the dash today I noticed that in the left position the grommet round the indicator column was loose but when selecting right, the grommet was taught and pulling on the stem of the switch arm.

Indicate left

The grommet appeared to be fitted correctly so the best idea I could come up with was to push the part of the grommet that covers the long stem back towards the steering column to give it some slack. I did this and exposed about a 1cm length of chromed metal.


We have driven a good few miles since making the change and both direction indicators performed as they should. It's not conclusive yet and I don't know if the grommet sleeve will work back along the stem but so far so good.


Sunday, 8 January 2017

Defender headlining replacement

Shelley spent Friday recovering the headlining that was still attached to the cab when we picked it up.


We had watched a couple of videos but dealing with the contact adhesive and all the curves was harder than it looked. The finished result however looks very good.


We fitted it to Fender today.


The headlining, like the cab was in a poor way when we got it. We didn't expect to re-use it, the main roof piece had the centre of the fabric cut out and several of the other bits had bends and breaks. It was all a bit damp.

A wipe over with something to get rid of the mould and a few days in doors to dry and it looked a bit more acceptable.  I ordered some foam backed fabric and 20 black trim clips from Segal Motor Trimmings and some spray adhesive from Amazon. the whole lot to do the job cost less than £50. I ordered the fabric late on Tuesday afternoon and it arrived on Thursday.

The fabric is:
ID: HL 365
Desc: 63" Black Woven Nylon Foam Backed Headlining
2m was just enough.


I got the spray adhesive from Amazon. Shelley used just over one can.
https://www.amazon.co.uk/dp/B00E98FVTY/

To get the shape of the fabric, for the smaller bits where they still had a covering on, Shelley pulled the original fabric off and used that as a pattern for the new material.






It was fairly easy to refit in to the car. It did have to be done in the right order so that they overlapped correctly.




Finding the screw holes through the fabric for the sun visors was a bit tricky but a bradawl helped.

The metal retaining strip over the back window had been held on by self taping screws driven though to the outside of the cab. I filled those holes with sealant from the outside. There were some pre-existing holes that lined up with the holes in the metal strip so I assumed they were intended for holding that on. I found some more suitable screws for use with those holes that did not penetrate the outer frame.




Again the bradawl helped find the holes. Once the first screw was in the other holes lined up easily.


The mirror is a pain to get back in. The top clip is sprung, but it is very strong. I found that if I hooked in the top first then grabbed the stem tightly, pushed upwards, with quite a bit of effort the bottom snapped in.



The alarm sensor just clips in and the light is fairly easy to attach.



The end result is very nice.

Window winders

Today's Land Rover job was replacing both front window regulators in Junior, our Discovery 2. The windows were dropping at an angle and struggling to lower properly.


I've replaced window regulators before, many years ago on Fords. The job has not changed much, if any. I did watch a good video specific to the Discovery 2.


Worth watching, it has some good tips to make the job easier. One tip is that lifting the weather strip before removing the door panel makes it easier to refit the panel afterwards.


On mine I found an 8mm socket someone else had left behind the plastic cover.




One of the screw mountings was broken so I glued it back together. I fixed the end on with superglue then attached a washer with lots of Araldite, just to be sure it would hold.

The roll of scrap paper shown in the photos is to make it easier to drill out the hole after the glue has set.






If you cut the plastic in the middle of a metal panel or right at the edge and not across the holes, it is much easier to tape back up afterwards. You can press the duct tape down firmly against the panel.

Once the plastic sheet on the doors were peeled back I could see the problems. The passenger side was just worn but the drivers side was properly broken.



All back together and both working properly.

Saturday, 7 January 2017

Local parts supply

I ordered some parts for Fender yesterday off of e-bay and they were delivered by hand this morning by Calvin in his Discovery 300TDi.


He runs MuddyBoots4x4 and is just a few miles away in Heybridge. Being local that will be very handy. I can pick them up or he can drop them off much quicker than waiting for the post. Even a mobile number to call: 07883 388499 for those parts not obvious on the web site.

Wednesday, 4 January 2017

Now it's a pickup

Today's job was to swap the hard top for a cab. Lots of people have said it's an easy job and it is. It is easier with a few hands so we called in Andy to help.


We picked up the cab on New Years day. It was in a sad looking way. Before we started the swap Shelley cleaned it up very nicely.



The roof came with a big dent in the middle. I wasn't expecting to get rid of it completely but just to reduce it a bit so the headlining fitted properly. We balanced it upside down on some blocks of wood to control where we applied pressure then stood on the areas that looked like they were kinks we might be able to reverse.

We worked entirely from the inside and, well, much to our surprise after a few attempts with increased pressure and working along different areas the dent popped out.


When we flipped it back over we found out why it had taken more pressure than we originally expected. There was now a big crack in a large patch of filler. The filler was almost certainly what had been holding it in the wrong shape. I've chiseled out as much of the filler as I can and will refill and sand it back to shape.

The whole job of swapping the roof is fairly easy.

Inside there's a few simple bits of wire to remove and the washer tube can be separated at a non-return valve near the front windscreen on the left side. It was cold, so I used a hot air gun to make the tube pliable. I reversed the non-return valve to seal it off.

The headlining comes out by removing the trim clips, mirror and the sun visors. The alarm sensor un-clips and the interior light unbolts from the headlining.



The rear door is the pain to remove. The usual problem of rusted in bolts. We were lucky that we were eventually able to undo the nuts. A lot of WD40, a breaker bar and some good thinking by Andy sorted out most of them. One of the door stay bolts snapped off.




Once the door has been removed, the rest of the bolts are fairly easy to remove. The corner bolts are left on the upper panels and the lower nut is removed.





It's quite a fun job to see it go through its changes.



In warmer weather topless would be fun.


Putting the cab on is very easy.



Andy had the good sense to loosen the rear brackets so that once bolted in they can be pulled back down on to the seal. For some reason the rear centre four bolt holes were pre-drilled but the outer four needed to be drilled.



Nuts and bolts all in place and a bit of sealant squeezed along the top of the front screen. The door seals fitted better after we removed all the old sealant that had been pumped in to some gaps. Once assembled we added our own sealant where we could see daylight round the door seals in the corners.


All back together and looking very nice. We didn't think we would get Shelley out of there :-)





A job for another day will be fitting the tailgate.