No pictures this weekend :(   Had a productive weekend,  got the final engine mount made, this took a good bit of time as space was really limited and several prototype need to be tacked before find suitable. Biggest problem was getting he mount in once the mount was bolted to the engine.

Move the lifiting gear out of the way and had a quick tidy up.

Moved on today to trying to sort out cables and etc, to the block, spent time re-routing all the wiring that came with the engine and trying to ascertain what wiring did what on the 101.    The wires that went to the 101 starter are all cracked so I will need to cut them back and re terminate.

Found that the 101 top has will fit straight to the 300 tdi with a little trimming

Made up a bracket for holding the throttle cable so that it fit onto the 300tdi engine mounts.

Back to the Plan

Ok had a small bit of trouble over the last day or two, converted my MIG welder to run off of Fire Extinguisher (CO2) gas but, the other night the regulator froze up and the relief valve popped.  

When I tried on Monday night to weld again I found that the relief valve hadn't reset and I was loosing gas.  So gave up.

Looking further on the net I found that the CO2 extinguishers have a tube to the bottom so they eject liquid instead of gas. So because I want gas I need to invert the extinguisher. :D

Last night - Disassembled the relief valve and cleaned and re-set it, now working again so I could start welding.

Just a quick note:   Grinding discs  - are you all aware that these have a shelf life and the Best before date is printed or stamped on the disc :

Best Before Date of a Cutting Disc

Started welding up the Drivers side engine mount for "Tiny" first of all it was tacked into position and checked to make sure that it had not moved.

As you can see from the photo above this mount is the old tdi 300 mount with out lugs for the void bush removed and a 45 Deg angle made of 10mm steel mounted so that it lines up with the 101 chassis mounts.

Once checked if was fully welded up and braced in several places.

 From the photos to the left you can seen the mount being welded up. The welding is not pretty but it has full penetration and is 100 x better than the original conversion mounts that came with the engine

Finally the mount is painted and left to dry, fitting tomorrow and then start on the next and final engine mount.

Paint Right hand engine

Making mounts

Getting the engine into place has taken quite a bit of jiggling eventually working out where to position it in relation to the propshafts..

Getting it right means that the original propshafts can be used without modifications., and this means height and position of gearbox is really critical. From experience the sweet spot seems to be that the 101 that the gearbox month on the box are about 2" forward of that on the 101 chassis.
Once engine was hanging in position the first of the gearbox month was made up this was the passenger side one.. To do this the square pattern that mount to the gar box was welded to a length of 10mm bar and drilled to fit the block mounts of the 101 gearbox.

The drivers side was similar a plate was made to fit the gearbox and then bar was used to lineup to the chassis mount.
Tomorrow I will hopefully tackle then engine mounts from what I am seeing I think I can make mounts from the old tdi engine mounts.. We'll see how we get on

(Posted from my HTC) 

New Engine into Load Bay

Moved the engine out of the garage to the side of Tiny, this was done by picking up engine with engine crane and lowering on the the old trailer and then using this to move the engine to the side of the vehicle. It became apparent that there was no way that the engine and gear box would lift into the 101 from the side, partly due to the real wheel arch and partly due to it being bloody heavy.  I also don't think the hood sticks could take the weight. 

Engine Lifted onto Loadbay

The gear box was split for the engine, and the chainfall was used to lift the engine onto the load bay, using a bit of 2" box between the roll bar and the 2nd hood sick. I have a 2"x4" post cut and this supports the 2nd hood stick against the floor.

Picture of the 2" box siting on top of the sticks and rollbar

The gear box was then lifted in the same manner onto the loadbay and the whole lot was reassembled to give a engine and gearbox.  

To the right :photo of the engine and gearbox sitting in the load bay after the clutch has been mated. But still missing the transfer box.

Transfer box getting cleaned with "Strong oven cleaner"

I spent some time also today swapping over the 1.4 Transfer box that was originally attached to the gear box with a 1.222 that I managed to barter from the local independent land rover garage. I know the 1.222 is not idea would prefer a 1.1  but it will do at the moment until the right one turns up 

Interestingly getting the engine up at working height showed some of the previous owners good bodges. The engine came from a 110 Defender that had had a 300 tdi fitted..... so lets have a look at these:

Bodged engine Mount - complete with old welding rod still visible

Re-worked turbo outlet, Bolts space with washer!