Bugger me what an exhausting two weeks since my last post.
Got the head back on Thursday the 10th. Old mate sheetmetal worker took half a week longer than promise to modify the shroud but came through with the goods and I'm over the moon with the finished piece.
On re-assembly we discovered that the elbow the radiator shop had brazed onto the HDJ79 radiator fouled on the steering damper, so it had to go back for another round of mods, sits a lot closer now and all sorted.
Biggest headache of all was the gearbox and transfer case. Managed to lose (despite being pretty OCD) a pin and a ball (from thrust washers), then discovered that I needed a 90mm input shaft bearing, not 92mm. Then discovered that I had the wrong mark's crawler gears (I had ordered the kit without the shoulder for the gearbox to transfer seal shoulder on the transfer input bearing. Got the right part express freighted overnight.
New gear was out of spec for the major diameter of the spline, tried pulling it on regardless, destroyed my puller, was then stuck with it half on, half off. Spent half a day making some custom press tooling, juuust managed to get it to press off, then had to linish down the major diameter of my (in spec) shaft to suit the (out of spec) input gear.
Was meant to leave for a 3 week 4wding holiday on Saturday morning at 8:30am, at 11:45pm on Saturday night we finally finished assembling the gearbox and transfer. Spent today installing it and reassembling the rest of the car. Will leave 7am tomorrow, two days behind schedule.
But, it means I've now got:
Rear drawers in and working
Rear locker in and working
Rebuilt gearbox (3rd gear synchro/synchro sleeve had eaten themselves on my original box)
Rebuilt (manual instead of vacuum) transfer with marks 3.05:1 gears.
New headgasket, water pump, bunch of coolant lines, lower thermostat housing
New HDJ79 radiator with modified shroud
New washer bottle, pump and lines (first time it has worked in a couple of years...)
Oh and the version 3 prototype of my DIN slot switch panel arrived from the 3d printer.
So now it is nearly 11pm and we're halfway through packing to depart in 8 hours time.
Plan is to re-torque the head bolts and change from straight water to glycol coolant during a rest day at camp some time this week.
Wish me luck and merry christmas!
-Adam.