Pulling to the left

The Land Rover has been pulling to the left under braking recently, last Thursday it become bad enough that I thought I’d take a look, as it could no longer be written off as being dirt in the drum or something. Sure enough I have leaking wheel cylinder on the right front drum.

Dripping oil from the dust cover on the wheel cylinder
Wet with oil, no wonder the right wheel wasn’t braking much.

I also painted some of the more white parts and bare aluminium.

Super shiny, in parts..

Dash must now be at about 90% complete

I reckon the aluminium dash is almost done, it’s not perfect, but who cares. Not me. I’ve installed two USB power ports, they’ll put out up to 10 amps from the PSU, so that’s future proofed for a few years yet. Still need to install a few more switches to do other stuff and make the bit for the right of the dash similar to the bit on the left of the dash.

CB radio mounted where the centre console used to be. Those switches have moved to a new part of the dash right next to the dash itself.
Need to workout what I’m going to do to hid and protect those wires, two USB power ports stashed away out of sight.
Two spare holes for starter switch and something else.. I have yet to dream that up.

Next is to fit better LED illumination for the dash. Shouldn’t be too hard.

Blown Fuse

I blew a fuse in the Land Rover, entirely my fault. A terminal broke off the back of the voltage regulator, so I replaced the feed to the instrument cluster by running a cable from my 12V stabilised power supply to the instruments instead. Unfortunately, this was all I did. I lift the existing supply cable behind the dash, still with broken terminal protruding from the insulated crimp. I imagine that this had touched something that was grounded/earthed and shorted out, blowing the fuse. At least I hope this is why the fuse blew.

Interesting how the wire has melted back where I guess it arced across the gap as the gap formed. Also interesting how it burned a line into the paper.

Air Duct

Finally I have all of the air duct in.

I have not yet sorted the air into cabin, and I think I will likely need to get the two printed parts re-printed, I will alter the right hand part to have an angle on the cabin discharge port. The left hand one needs a lot of work..

Stuck the print in

Today I have Sikaflex’d in the 3D printed “heart valve” component.

There is a bit of a gap at the bottom and given that both the base of the print and the bulk head are a little convex the two don’t fit together very well. Luckily I have plenty of Sikaflex and no fear of using it!

Air ducting behind the dash

I have designed and a friend is printing for me some components for the air duct work that supplies hot air to the windscreen and cabin of the Land Rover.

This is actually going to be 3 parts glued together to reduce the complexity of the print.
The half size test pint

And then inside will split up the air flow unevenly so that the driver side has far more air flow than the passenger side.

The small top left aperture will feed the passenger side windscreen and the small lower right aperture the passenger foot well.

Heater blower fitted

At long last I can have hot air in the cab again. Not that it helps anyone other than the passenger at the moment as there is no dash or duct to direct the air my way or onto the windscreen for that matter. That’s the next job.

In situ
You’d barely know that I’d done the job really.
From the outside end things, minus the grill covers the hole.

Heater blower completed

Today I assembled the bits, had to re-solder the wires to the resistor, they broke off at some point. Found some new nuts and bolts, but also used old stuff where I suspected it was imperial.

Should have hot air into the cab again soon!

Black heater blower

I have painted the heater blower now, not done a great job, but it’ll do, it’s far better than it was. At least now it’s build some pressure and move some more air. Reassembly is next, re-fix the resistor to the side of the housing and re-solder the wires to the fan motor.

Nice and black.

I phoned Flag, who’s paint I used, to find out how it was going to do covering the Sika Flex brand sealant I had used to fill some of the gaps. The nice person I spoke with didn’t seem to understand the question very well, and given that the worse case seemed to be that the paint wont take to the polyurethane, I just went ahead and gave it a coat. Whats the worst that’ll happen?

Volvo Alternator

After the voltage regulator failed I purchased second hand alternator for £30. I fitted this and it turns out that it works perfectly.

One new “old” alternator.
Looks like it’s always been there..

I also swapped out the Land Rover starter motor for a new one. It’s made a hell of a difference, I think in part because the old one was rusting from the inside out because of water ingress over 9 years.

New and Old.