jims-terrano Project

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Inner Wing Continues

Hi Guys, well my son did a little more today whilst I was out at work. The NS inner wing is fixed!! it's solid!!!.





We've now cut the repair panel for the wheel arch round to the floor but we got rained off.

We did manage to get the rear and centre sections of the exhaust off. Got prices for the garage to replace complete system is £240 for a budget and £288 for a quality exhaust. Get this a stainless custom exhaust would be £500 with lifetime warranty. So so tempting I must say.
 
With your sons welding skills why not make your own.
Get down to Kwik fit and salvage some large section OE pipe with bends as its usually the joints that rot out.
Stick a straight through box in for a bit of back pressure and straight out the side or back as you fancy:thumb2
 
Just a quick update.

We've finished the welding on the ns :clap need to paint and seam seal it and then we can refit the air filter, fuel filter and abs pump along with their brackets. Will post some photos this weekend.

My son has had a look at the front pipe and has managed to remove one of the bolts but the other two will not budge.

Replacement pads and anti roll bar links arrived today.

Can't wait to get the interior put back together on the ns. Really feels like we are seeing the light at the end of the tunnel at last.
 
NS Is Finished!!!

Well a step or two nearer and a step backwards:doh but main thing is the project is moving forward and we are having a blast:thumbs

So the ns wheel arch is sorted now, the last patch to go on was the bottom of the arch and floor to the body mounting. didn't get a pic before painting so it's covered in a hammerite.




How cool, real progress the interior fitted back on the NS. This feels like a real achievement to have got this far.


The headlamps had some poor quality Chinese bulbs in that had stuck into the holders so the holders were damaged when I removed them. Bought myself some ceramic holders off ebay along with a pair of Osram Night Breakers and also fitted a pair of LED sidelight bulbs I got off Sweety last year. I soldered the wires for the headlamps and covered in heat shrink.




Had to reconnect the battery for a minute or two to test they all worked, just one sidelight bulb needed changing around due to the polarity for the LED's.

Sadly had a slight set back, decided to remove the ns caliper seen as the brakes would need bleeding anyway so. Disconnected from the flexi pipe without much drama but unfortunately one of the pistons is seized. Got another thread running but unless I can pick up a known good second hand I'll have to go for a recon from Milners. Even if I don't keep the car once finished I need to know the brakes are in good order.

That's All Folks, will post some more when I've got the brakes sorted and ABS pump fitted back along with the filters and brackets.
 
No pictures tonight Im afraid.

Bought a new exhaust and trackrod from Milner which arrived today. Decided for the moment the front pipe will be fitted by the garage that will be doing the MOT. We've fitted the centre box but couldn't fit the tail section due to it being slot together and clamp but no exhaust paste:doh another trip to the factors tomorrow.
Last night I managed to get the track rod released, cut the nuts off and bashed with a hammer thanks for the tip Fez:thumbs. Cleaned all the chassis and suspension at the passenger side and treated with Fertan. A coat of hammerite tomorrow to clean it up properly.
Had to cut the anti roll bar link off as that was well and truly rusted and the ball joint fell apart yesterday when my son tried removing it.

So tomorrow when I get home from work I'll have a paint brush in my hand and hopefully exhaust paste to attach the rear section.

Will try and get a few pics uploaded at the weekend but not much time for the car this weekend, teaching Saturday and a Risk Assessment course on Sunday oh what fun!
 
Well as you can tell from my previous post and various threads this week has been a bit up and down really. After last weekends feeling of good progress being able to put the interior back together on the passenger side this week seems to of been one step forward and two back.
So firstly the passenger side brake caliper was seized, one of the pistons must have taken on board water and rusted inside the bore so had to order a recon from a local motor factors. The good news was it was cheaper than Milners and came with the rubbers for the brake sliders, usually cheaper at Milners.
Also the passenger side track rod failed test on a loose lock nut, a bit of a joke really. One of the lock nuts on the adjuster had a gap only just big enough for a finger nail between adjuster and nut. The nut was actually rusted solid so that I might as well get a new track rod as the tracking will need doing. So new one ordered from Milners I decided to cut the nuts off with the grinder but then the remaining shaft wouldn't drop out of the drag link end and the hub. Took a lot of heavy blows from a lump hammer before it finally gave up the fight.
Also as expected the anti roll bar link needed replacing too so ended up cutting that off too.
With all this removed thought I'd take the wire brush to the suspension and chassis and treat with the rust killer and then paint with hammerite.
The new exhaust also came from Milners this week so the centre section and rear section is now replaced. Just the front pipe to replace but due to location and condition of the studs I think it's probably sensible to let the garage that will be testing replace this part rather than risk snapping something.
Whilst under the car I looked up and noticed carpet! yep the boot floor below the rear seat has ventilation!
Today after work I built up the brake caliper and fitted the new pads. Fitted the wheel and then noticed movement with my hands top and bottom. With a bit of luck Solarman will be correct and it's just the wheel bearing that needs nipping up but the thought of those fiddly circlips is making me flinch. Not quite sure when I'll get chance to do this job as I'm busy for a few days.

So here's the latest batch of pic's:thumb2

OOHHH Shiney!!!!

Sneaky Polly Bushes on the ARB Link:clap

Starting to get her face back :)

None standard ventilation, where did that come from :doh


And finally it's been an exhausting week:lol


I did tell my son that if I'd of seen that hole in the rear floor a few weeks ago we would of been breaking it. He turned around and said "it's not a problem Dad, we can fix it for nowt" So proud of him :bow
 
Nice to see another father and son team getting down and dirty :D
My lad has been doing as yours and fine tuning his welding skills on my truck over the years. So much so that early repairs he did, he's cut out and done them again. He couldn't bare it if someone saw them lol
Loving your detail work guys, keep it up and then keep it .
Skills rule :clap
 
There is nothing like a Father-Son team for getting jobs done, even if it's just gardening, painting, or working on cars.
However... friction can sometimes break through, and you sometimes have to back off a little, after all, you don't have to prove anything.
The main point is to give them encouragement and praise, rather than say, "that is a stupid idea," it might be better to say..."Do you think this will be better,?" and explain why ...

Teenagers are the most difficult to motivate, but it looks like you have a great relationship Jim, that will last a lifetime.:thumb2
 
Cheers guys, we also work together/instruct at a youth organisation and people from there have often passed comment how a like we are.

Also this project has captured his interest which helps a great deal.
 
Fantastic work Jim & by the time you have finished it it'll be like a new truck:thumbs As for the scuffs in your leather seats shoe polish works very well to fade them
 
Cheers Sweety, glad you like it. It's become a toy now and I'm adding things to it. Notice the bulbs still going strong that I got last year:thumbs

There will be an update to the thread in the next day or so. So keep an eye open.
 
I just gave this a rating of 5 stars, as it shows perseverance , with a strong will to succeed.
It is also well documented, and makes you want to look at the next instalment.

In my opinion, it is the best Terrano based thread live at this time.:thumb2
Keep up the good work. :thumb2

Rustic
 
I just gave this a rating of 5 stars, as it shows perseverance , with a strong will to succeed.
It is also well documented, and makes you want to look at the next instalment.

In my opinion, it is the best Terrano based thread live at this time.:thumb2
Keep up the good work. :thumb2

Rustic

Could not have said it better, Rick
 
Thanks friends, I'm humbled by your words. To tell you the truth this project has become much more than simply doing a car up. It's become father and son bonding, we really have become much closer. I really can honestly say that this has been an amazing experience that I'll never forget. I truly appreciate what this car has done for us.

Back to the project! Not sure how much I'll get done tomorrow as I've just got in from helping out at a local hospice pyjama walk, been hard work but good fun. So I've got a few photos building up ready to edit and upload so I'll try and get these sorted out and an update in the next day or two.

Cheers guys
 
Yup,i 3rd that.I have followed this thread with a great deal of interest. 1st class work Jim..
 
well done jim , its a great when you really bond with your son , its even better when he helps you in ways that you cant .:thumb2:clap
 
Update 20th September

Well guys, you have spurred me on to get the latest update on here. Thanks for the kind words and encouragement, I've told my son about this too.

Well as you've all read this week been doing a few jobs and gaining confidence in my abilities all the time. Firstly found that the NS wheel bearing needed adjusting so with the usual great advice from this site I nipped the bearing up no problem. Then got the wheel back on and moved the truck so that I could work on the OS and first check was indeed the wheel bearing and sure enough it needed nipping up. Got this to a fine art now, around 15 mins:clap Mind you it's helped me having my trolley jack fixed thanks to my son for repairing it.

Found the OS Calliper outer dust seals ripped to shreds. Messed about ordering a hardware kit from local factors but this turned out to have bits missing so bit the bullet and ordered a complete calliper from Andrew Pages. Thought it's better this way so that both sides are the same and I don't want to mess about with brakes.

Wire brushed all the OS Suspension, brake components and the inner wing. Then treated with Fertan and today gave them all a second coat of Hammerite. All looking nice and clean ready for reassembly this week but I've got loads to do so not sure how much I'll be doing.

Decided that the track rod was seized so as I had replaced the NS thought I might as well do the OS too. Also found the ARB Link was duff which was no surprise so cut them both off which gave me more room to clean components.

So this weekend I was at a loose end waiting for Fertan and Paint to dry so decided that I would modify the brake lights into Stop and Tail Lights and I'll be working by myself this weekend as my son was busy. I had ordered some bulb holders from eBay last week so has the parts at hand.

First of all removed the brake lights from the car. Tried the new bulb holder and soon realised I need to cut a new bayonet notch for the bulb holder so out came the dremmel.







Needed to trim down the edge of the bulb holder so that it would sit into the recess in the lamp unit



Fits just nice and twists into position too.



I'm a bit concerned about the quality of the bulb holders so left the old stop light holders on the wiring just in case. Will keep the actual holders in the glove box or somewhere handy. All the joints are soldered and then covered in heat shrink rather than tape as tape deteriorates with time.



Fitted back in place, the brake lights work but not connected the side lights so will have to post a photo of that later.



The alarm horn had been disconnected due to not having a working key fob. Now I've got a working fob I decided to connect it up. Knew it was behind the side panel but never seen it before.



Next project is a pair of Work Lights mounted on the roof above the tailgate. Decided that I will use relays so that they will be connected to the reverse lights and also an over ride switch in the boot. Will be fitting a second battery later so these will run from the second battery. Looked around for a few weeks and decided to buy a pair of LED Work Lights from Milners, talked them into extra discount so result I think.
First job was to drill the holes, covered the two sections of roof in masking tape. Then marked where I wanted the lamps and measured and then measured again until I was satisfied I had the correct areas marked for the holes. I chose to use a pair of IP68 rated cable glands, not sure who it was but someone on here posted about using them for power to roof lights. Drilled the holes yesterday and then gave the bare metal a lick of hammerite. Then fitted them today but thought I'd use Tiger seal to water proof the lamp fixings and glands. I also bought some Stainless Steel bolts to replace the bolts supplied with the lamps. Can you tell I'm paranoid about bolts going rusty and water ingress.



Didn't think there would be enough heat to require such a big heat sink.





Tiger seal is a bit messy but all being well water proof and hey who will notice underneath those lamps.









Looking good :thumbs







Time to tidy up a bit. You can see the cables drooping down too. Again soldered all the joints and covered in heat shrink.



WHAT NEXT

Well I need to fit the new suspension and steering parts and the brakes too. Once this is done we are going to look at the welding on the OS floor and body mounting. Trouble is I don't have a lot of time this week so may end up being next Sunday before I do a great deal more.

Once again thanks for the great advice and support from the members of this truly great club. Can't wait to get the car back on the road and attend a few meets.
 

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