I have managed to get the brakes sorted. The P6 handbrake cable ends are of a similar size to the round fittings of the jag calipers. After a bit of pondering, I drilled out the forward spot weld and prised the jaws open then managed to force the Rover ends in. I then used a small nut and bolt to replace the spot weld, just in case I need to replace the cable at some time. Happily, they fitted exactly with no play at all
Thing is though, handbrake linkage is around 80mm wider than Rover one, so the handbrake inner cable is now 80mm too short
. I had a look at the clevis at the front end of the cable and discovered that it was screwed onto a short threaded piece. I found a short piece of threaded bar the right size and a connector, then put the clevis back and yes, it works
I have bought a pipe flaring kit that actually works and made up the brake pipes, leaving a flexible piece to connect to the original pipework on the car.
I torqued up the bolts on the plate which held the front mount in and managed to crush the crossmember
, twisting the plate at the same time. I then had to make up a puller to get it back to original, then set about it with some panel beating hammers. This was quite a set back to be honest, but it appears that most of this crossmember is made out of an old Chieftan Tank, but the small bit at the front, up to the tunnel is made out of wax
I took the bolts out and using studs instead managed to get a nut each side of the metal top and bottom, so 4 nuts per side to give it some support. I then used a bit of the 5mm box section to remake the plate and put it all back together. That should do it.
Now to try and stop the front of the diff from twist upwards under acceleration, I drilled a couple of 18mm holes into the suspension crossmember. Then cut two short lengths of 18mm OD steel tube and tapped them in. Got them just right and had them welded into place.
These will hold two 14mm studs which can be adjusted for length by just doing up/undoing the nuts.
Back in the car, with a couple of struts I made from some 12mm studding and 15mm tube it is all very solid
Just need to get it all adjusted up, then tighten everything up and hope it works.
Oh, and I added a short piece of 10 x 20mm box section at each side on the front, to complete the cage. I couldn't get them both in same place so they are staggered, but I don't think that will be coming out of there in a hurry - so happy with that.
Richard
PS new propshaft and shortened half shafts have arrived back, so next job is to fit them and hope I have the measurements correct - what could possible go wrong ?