The Bar…………1963 Land Rover Series 2A 109 Pickup

This has been a huge, no, really huge project. Started out as a basket case right hand drive 109 pickup disintegrating in one of Lanny Clarks’ barns. The plan……..Switch to left hand drive, front and rear Sailsbury axles, military 1-ton frame, Defender 200TDi engine, Ashcroft transmission with hi-ratio transfer case, OME parabolics and shocks, Pangolin 4×4 8274 bumper, Toyota FJ60 power steering, plus a few other surprises. Oh, the name………The Bar…………this truck served as the bar at Lanny Clarks daughters wedding………how’s that for provenance.

This will be a long post…………many projects to cover, stay tuned.

676892a3

wedding 032

IMG_9301

Picking the truck up at Lannys…………what a fall from grace, critical wedding support truck to derelict parts truck

IMG_9303

IMG_9345

Back in the shop and disassembled………..very ugly

IMG_9347

IMG_9348

New “1 Tonne” 109 frame courtesy of Rovers North

IMG_9350

Bed full of parts

IMG_9423

The leftovers……..back to Lannys

IMG_9456

A rare front Salibury found by Mark Letourney / Rovers North. It was butt ugly on the outside, but the guts and swivels were like new!

IMG_0285

IMG_0346

Axles cleaned up and painted, new brakes, bearings, seals installed, OME parabolics hung……..it’s a roller.

IMG_9346

Real bad………should have thrown this bulkhead in the scrap bin, but it was a challenge………..rust sucks. Off to Adam at Finish Solutions in Milton, VT for sand blasting, where what was left of the bulkhead just about disappeared.

IMG_1215

This thing had the rust-bug problem high and low. Lots of cutting and fabricating….tedious work.

IMG_1218

IMG_1219

IMG_1538

Some brazing, some welding………at this point you actually look forward to installing the pre-made toe boxes, posts, and center tunnel.

IMG_1541

Bulkhead operating room

IMG_2837

Looks like a bulkhead again!

IMG_3056

Cleaned up, seam sealed, and primed………..off the jig and onto the frame

IMG_3084

Next up, doors. These too should have been tossed in favor of repops, but, what the hell……………..frame pieces are cheap and easy to make, and the alloy skins were original and in great shape.

IMG_3384

Again, Finish Solutions blasted the frames into oblivion so I knew what I needed to replace. Vertical posts cut to size with hinge bolt sleeves brazed in.

IMG_3387

New door frame.

IMG_3790

Fabricated crossbar and door catch mount.

IMG_3951

Door frame finished and primed.

IMG_3982

Re-skinned!

IMG_4425

IMG_4599

Aside from welders, most of the tools used to repair the doors.

1

Next up, wings. Right front outer is trash, both inners have a good amount of corrosion. The good……..front panels are just ok, left front outer very nice. Another consideration is I’m going with dual circuit power brakes so the left inner needs the cutout for the brake servo. I went on the hunt for another set of wings, maybe Series 3’s with servo cutouts, in the hopes of piecing together one nice set. Good old Craigs……..I found a pair of decent Series 3 wings on Alabama Craigs List………gold!

IMG_4330

The new wings arrived in great shape……..time to disect. First the front panels need to come out and be replaced by the decent originals. I marked all of the spot welds that need to go……. out came the spot-weld cutter. These cutters are handy, but go through aluminum very quickly, so if you try one, be careful or you’ll end up with some pretty large holes to repair.

IMG_4328

Marked and ready to drill.

IMG_4333

Headlight bucket out, I now have clear access to inner panel. These need to be drilled from the inside to preserve the wing exterior.

IMG_4326

And they’re out.

IMG_4325

Original front panels ready to go in.

IMG_4671

IMG_4670

Panel bond and lots of clamps.

IMG_4539

The nice right side Series 3 outer has the marker light holes. I cut a patch panel out of a birmabright seat box scrap and got out the tig welder.

IMG_4541Patch tig welded in.

IMG_4542Screw holes filled.

IMG_4544Good weld penetration.

IMG_4543File the weld down and presto………early 2A outer wing panel.

IMG_4675

All assembled and ready to fit.

IMG_4677

Freshly refurbished wings and bulkhead mounted. Next up, the hood (bonnet?).

IMG_3953

Frame is a little rusty and missing the cross supports for the spare tire plate.

IMG_3954

Fabricated supports.

IMG_3956

Supports in place.

IMG_3957

All cleaned up and POR’d.

IMG_9300

On to the bed.Right side is caved in at rear corner and needs to be replaced. Both rear panel lower sections are gone due to dissimilar corrosion, same for the rear body angle. All of the cross members are toast also.

IMG_7415

IMG_7095

Right side is off.

IMG_7096

Lots of spot welds drilled.

IMG_7641

IMG_7640

NOS side in place and clamped up.

IMG_7931

IMG_7932

Two NOS rear panels courtesy of Pangolin 4×4, along with the new rear angle from the guys at Bits for Landy’s in place. I left the floor in place to keep the bed square and give support. Once I’m happy with the new panels the floor will come out too.

IMG_1388

Floor is out. New cross members made by Vermont Custom Sheet Metal. The cross members will eventually come out and go to the galvanizer.

IMG_5535

Time to set the body work aside and get the 200TDi into place. The Ashcroft transmission is in and mated up to the 200. The only motor mount that needs to change is the right front.  Off it comes, fabricate a new mount (as above), weld to the frame and et the engine hoist out.

IMG_5537

Welded up a few spares.

IMG_5656

Welded to the frame and coated with Clearco Zinc Rich Primer…………expensive and nasty stuff, but incredibly durable and far cheaper than lugging the frame to Boston to be dipped again.

IMG_5657

Ready for the engine.

IMG_5776

IMG_5780

And in………..this was the easy part of the conversion. Now to figure out plumbing, radiator placement, intercooler, power steering, exhaust, intake, fuel lines, and wiring.

3 Replies to “The Bar…………1963 Land Rover Series 2A 109 Pickup”

  1. Wow, I’m in awe of the quality of your work and skills.

    I threw out a bulkhead that was actually in better comdition than that! Fantastic job you did of that and the doors.

    In fact everything about this rebuild oozes quality and skill. I think it must be one of, if not THE best Land Rover rebuilds out on the web. I can’t believe I haven’t found this site before, considering I’ve been searching for Land Rover sites for years looking up information for my own rebuilds but don’t recall ever visiting here before last week. I now need to find a couple of days spare to read through all the posts 🙂

  2. exelente trabajo tengo un land rover del año 62 voy a emprender su restauracion necesito sus consejos, vivo en ecuador

    *excellent work I have a 62 year Land Rover to undertake its restoration I need your advice, I live in Ecuador

Leave a Reply

Your email address will not be published.