This 1965 Series IIa is well past its useful life. The frame is completely rotted out, the motor is worn out and the brakes don't work. The bulkhead was patched but all this did was cover more serious rust. It is time this Rover gets the rebuild it deserves.
The IIa is ready for the tear down. It was painted a color like british racing green, not a series Rover appropriate color. Plus they painted over all the galvanized cappings.
The seats were reupholstered at one point, they are supposed to be a grey material known as ''elephant hide''
When the fenders were removed structural rot was found that was obviously neglected during the last round of patch work.
The bulkhead is placed on a stand to ease further tear down.
If the ridge at the top of the cylinder is thick enough to catch your finger nail on then the block will need to be bored out and oversized pistons fitted, this is the case here.
Most of the frame consisted of a series of shoddily welded patches added one right over the other throughout the Rover's useful life.
Some longer home made lift shackles and more rust, this vehicle like this should never be driven on the road.
All that's left of the frame and suspension
Rotted out axle truss.
The rear differential had almost no fluid in it and here's the reason why, the previous mechanic used the wrong thread nuts. These are british bsf thread, they tried to strip on 3/8'' 24 nuts, they jammed well before sealing the diff to to the housing. This is why it pays to have a shop work on your Rover that understands british fasteners.
Since they ruined the threads, every single stud had to be replaced. Unlike the later press in studs these are bolts that thread in and are wired together to keep from spinning, we used red loctite instead of the wire.
New pinion drive flange. This is the key to a no leak diff. Since the surface on the old drive flange is grooved and worn, even with a new seal it will still leak oil.
The rear axle is primed and starts to go together. New hub seal races installed, again the key to sealing up leaks isn't just new seal but new seal races too.
The old swivel balls were badly pitted, needless to say there was not much oil in there.
Just about every part of the axle was badly worn.
U joints went bad from lack of oil in the swivel housing.
rear axle has had the rotted truss repaired with 1/8'' steel cut to shape with the plasma cutter and welded on. It is painted in Eastwood's chassis black.
The new galvanized frame.
Swivel assembly rebuilt with proper preload.
New brakes, parabolic springs and Old Man Emu shocks, the best shocks for series land rovers.
Rebuilt Turner 2.25 HO engine.
The bulkhead after it is bead blasted.
If there is any one way to do the most harm to your Rover's bulkhead, it's patching over rust.
Parts ready for sand blasting and then off to galvanizing.
The Rover will be getting a power brake unit just like a late series iia would have so the fender needs to modified to clear the master cylinder. We are modifying it exactly as a fender on a late series iia would be.
Bulkhead having its extensive rust removed and new sections welded in.
The roof needs to be seperated from its steel gutter so that it can be regalvanized and the roof repainted. This means chiseling off 154 rivets!
Self levelling seam sealer is applied to the inside of the roof. It seems like all Series roofs leak but the leak can neverbe traced down. This seam sealler will solve that problem.
New door pillars welded in. This needs to be just right or the rest of the body alignment will get really wacky.
All parts have been painted in single stage Bronze green paint.
Door tops getting reassembled.
All exterior fasteners are the originals with the correct markings.
Rebuilt door hinges.
Finished door top, since only Series III type door tops are available the hole for the window lock will be plugged with a genuine Land Rover blanking plug.
New early series IIa wiring harness designed to work with the series III alternator without modification.
Grill getting assembled with new headlights, buckets and wiring.
The bulkhead is installed.
Galvanized under seat box will last much longer than the painted steel one it replaced.
Rear tub goes on.
After the side panels are painted the glass goes back in with new gaskets, lots of silicon is needed here.
Some 4g battery cables are made up to replace the corroded originals, even the battery terminal is the correct type. All terminals are crimped not soldered.
The starter button was missing and replaced with a a cheap aftermarket solenoid. Now the correct starter button is back in place.
All the steel parts are back from the galvanizer.
Period correct rivets.
Refinished banjo wheel.
The door latches were faulty and one side had a lock, one side did not, now both sides will be lockable. Carefully, we drilled this hole for the door lock.
All the keys match so the ignition key will unlock any of the doors.
New windshield glass goes in with new sealing strips for a leak free windshield.
The roof gutter was galvanized and riveted back to the aluminum roof, a bead of seam sealer was laid down between the two to seal it, then 154 period correct hammer rivets were peaned over to join the two. This is the only was to obtain a roof that does not leak and has a gutter that does not leave rust streaks down the windshield frame.
The station wagon had a vinyl headliner but the hardtop did not. The shiny new paint makes a nice clean interior.
The roof is installed new, genuine weather stripping is used on the top and bottom of the side panels.
A rust free hood frame was sourced, it was bead blasted and galvanized, this one will never rust and crack like the old one.
Here is the completed power brake conversion with all stainless steel brake lines.
Even the wiring clips have been replaced with new correct units.
The bright hammer rivets and galvanizing really set off the bronze green paint. Beautiful color for a Rover!
The engine bay is finished with the same level of detail as the interior and exterior of the Rover.
New taillight lenses.
New parking light and turn signal components getting assembled.
4 good wheels and one replacement wheel painted in limestone.
A new old stock firestone 6.50 16 tire is mounted to a replacement 16x5 wheel. This is a tire of the same type that would have come on the rover new. They look great as a spare but radials are the way to go where the rubber meets the road.
Some new elephant hide seats.
The locking center console is installed. We make our own brackets to install these so there is no drilling extra holes in the seat box. That way it can be put back to original with the middle seat at any time. Another good thing is that if the transmission or overdrive need to be serviced it can be removed in a matter of minutes by one person to get to the access panel. Thats not the case when some installers drill holes and bolt it in place with a nuts and bolts that take two people to undo!