Building the perfect 90

erover82

Well-known member
After this build I can't even look at my project the same anymore. I do some cool upgrade, then I read your latest post & I go to the garage to apologize. The crazy thing is, when we meet up, you seem so... normal.

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Seriously though, guys sharing cool upgrades and adventures (of all sizes) is what makes the forums great. Spent much of my 20s on the sidelines watching others, gathering ideas, and dreaming of doing similar things one day.
 

Siia109

Well-known member
First off - thanks for the level of documentation. My mind is so singularly focused on the task at hand that I will finish it and then step back and after I get done with the "Yeah I fucking built that" self patronizing congratulations that we all go through to different degrees - the reality of the fact that I didn't take any progress photos hits me - let along the time to post them up and give a great write up!

So I ask this singular request with the most humble and subservient hearts - do you have a listing (something you can post or on a website) of the products you like to use (paint to lubes to abrasive bits / pads etc.) as well as the larger tool purchases that you have found to a great bang for the buck? Such as purchasing a sand blasting cabinet vs a 30L ultrasonic cleaner vs a 20T press vs 6T press vs a good spray gun etc - A simple parts washer from HF worked wonders for my rebuild - but what you are doing is about 8 levels higher and its not only the talent of doing the work but the tools that help. If that makes sense.

Thank you very much for doing this.
Matt
 

erover82

Well-known member
First off - thanks for the level of documentation. My mind is so singularly focused on the task at hand that I will finish it and then step back and after I get done with the "Yeah I fucking built that" self patronizing congratulations that we all go through to different degrees - the reality of the fact that I didn't take any progress photos hits me - let along the time to post them up and give a great write up!

So I ask this singular request with the most humble and subservient hearts - do you have a listing (something you can post or on a website) of the products you like to use (paint to lubes to abrasive bits / pads etc.) as well as the larger tool purchases that you have found to a great bang for the buck? Such as purchasing a sand blasting cabinet vs a 30L ultrasonic cleaner vs a 20T press vs 6T press vs a good spray gun etc - A simple parts washer from HF worked wonders for my rebuild - but what you are doing is about 8 levels higher and its not only the talent of doing the work but the tools that help. If that makes sense.

Thank you very much for doing this.
Matt

It helps that the majority of us carry a high quality camera in our pocket at all times, but I've run into those situations as well, usually when frustration is high or time is tight, where I wish I'd taken more photos to document how something came together.

We all have tools and products that we've come to rely on or despise and I think it's a great idea to share a summary list of those. I'll probably post on a separate thread for this as it would be interesting to see what others are using (or used and now avoid) as well. With exception to the tools I've used through industrial connections, my list would be for the guy who wants good results, but on a budget and with limited space.
 

erover82

Well-known member

Filling was easy, but if it were ever to function it would need to be reunited with its shifter assembly.

Like most of this age, it was worn and missing several flange bushings on the LT230 linkage.

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Disassemble, clean, media blast, Alodine, epoxy, and enamel the castings.

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Linkage was either re-zinc plated or Cerakoted (in previous batches)
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Reassembling transmission end. Realized I was missing the shaft pin and ended up waiting weeks for one.

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Reassembling shift lever end with new bushings, o-rings, and rebuilt reverse plunger.

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Old gear lever turret was worn beyond repair. Not my pic, but you can see how the vertical slot wears due to being softer metal than the lever, and due to grit mixing with minimal lubricant.

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Obtained a new one, but was again disappointed with the rough casting in the slots. However, this gave me an idea...

I started by machining out the slots to 8mm.

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This gave a larger and smoother surface for the lever to slide against.

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Coated the housing with the same dry film lubricant used on the pistons and other parts.

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Obtained 8mm Oilite sleeve bushings and pressed them on to the new lever.

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To be continued..
 

erover82

Well-known member
No offense, but you should be doing vintage Ferraris or at least Porsches or something. 🤣

Hey, I agree! I have an address - send as many vintage Ferraris as you'd like. However, as I don't actually have a proper shop, I can't guarantee two curious little boys wont discover them. Perhaps after this project wraps up, I can get back to business on things that could one day afford such indulgences.

Anyways, I guess this is all a bit much for an old farm truck.
 

LRNAD90

Well-known member
Hey, I agree! I have an address - send as many vintage Ferraris as you'd like. However, as I don't actually have a proper shop, I can't guarantee two curious little boys wont discover them. Perhaps after this project wraps up, I can get back to business on things that could one day afford such indulgences.

Anyways, I guess this is all a bit much for an old farm truck.

Passion is passion, if it for an old farm truck, or an old sports car. You're work blows me away..
 

erover82

Well-known member
Moving on to the LT230 linkage, I wanted to give the shifting more precise and positive feedback by reducing slop and flex. The linkage pivot points utilize several flange bushings, which while a good idea in principal, tend to degrade and give a spongy feel due to being plastic.

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To accomplish this I spent hours researching possible alternative flange bushings and finally settled on a set of steel-backed PTFE lined bushings from National Bronze (part # LBF 0805)

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While as close to the original part's dimensions as I could find, they were still too long. To remedy this, each one had to be machined to length. This required placing each bushing inside a large thick washer for workholding of such small parts.

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Test fitting the shortened bushings.
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Another strategy employed to reduce slop was using large-gap retaining compound around bushings on their non-friction sides. In this case the new LT230 lever ball bushing (white plastic) sits snugly in its cross shaft.

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LT230 shift lever assembly completed. The additional surface thickness from the low-friction coating also helped to reduce tolerances between components, but too much in some cases where considerable surface polishing was required get proper fit.

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Final assembly

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erover82

Well-known member
Stainless steel performance exhaust system from RN - a nice bit of kit.

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The boys testing it out in a game of "yell loudest and blow the other's eardrums out best".

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Test fitting. How close are we?

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Way off, even after making all sorts of small adjustments at both ends. Wants to be about 1/2" longer and 3" closer laterally. In other words, normal for a Land Rover.

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We're going to solve another problem too, this one inherent to the 200Tdi exhaust design. The down pipe is mounted very rigidly to the engine, which being an old diesel, shakes like mad and transmits that down the entire length of the exhaust. It's a wonder these things don't leak at the joints more than they do.

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Measure, cut, add flexible coupling.

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Weld, fit, curse, measure, remove, cut, weld again, fit, revel.

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MountainD

Technical Excellence Contributor
First, the shifter bushing. Jesus man, really? You make me want to disassemble my newly assembled shit. Stop it.

however, and this is my only critique… ditch those horrible slit compression bands and go v-band clamps on exhaust. You’ll never go back. And it always should have had the vibration sleeve…all mine did…
 
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