Project 1989 90 (Bruce)

Defender-Sam · Aug 30, 2012

How do people, thought i would start a thread for my 90 project, it was brought around this time last year and i have been working on it in my spare time. it turned out to be a fairly big project requiring a new chassis (richards) due monday and fairly extensive work mechanical wise and body.... I will start with a few posts of the work i have done so far

299905_10150281535853403_710748402_7962174_6272264_n-2.jpg

doesn't look to bad?

294606_10150281535563403_710748402_7962171_1034165_n-1.jpg

oops spoke too soon!

thanks for looking. Sam

kato Disco · Aug 30, 2012

Just out of interest how bad was the chassis? Any pics of the old one?

Cheers.

Rawly86 · Aug 31, 2012

I have a feeling my Bulkhead on my 1988 90 is getting like that!

MrPDude · Aug 31, 2012

Ooh can't wait to see how this progresses. One thing I was grateful for on my project was the solid bulkhead.

Should have gone the same route as you though and got a whole new chassis.

defender11069 · Aug 31, 2012

have fun be good when its finished

wangie46 · Aug 31, 2012

Good start

get plenty of pics as you go we all like pics.
Plenty of help here if ya get stuck with anything just ask.
Good luck

Defender-Sam · Aug 31, 2012

Hi guys thanks for showing some interest, regarding the chassis it probably could have been repaired but i think i would have been chasing my tail so to speak keeping it treated and patched so bit the bullet and decided a new one was the way forward. pics

Defender-Sam · Aug 31, 2012

Well i think i will make the most of a quiet night in and add some more progress, as you can see by the pictures so far, apart from the chassis the bulkhead is in probably the worse condition. So i got the required panels ordered and set about replacing the rot starting one side at a time to try and minimise warpage as much as possible. the worse side was the passenger side needing a footwell, hinge panel, mounting whotsit along with the regular top repair panel along with small extensions and mods made to these standard "repair" panels because mine is quite bad.

312053_10150281539468403_710748402_7962220_7859402_n-1.jpg

the foot well has had its fair share or patches and repair work in the past

On with the fabrication

couldn't find any of the drivers side during the work but took some once finished,

appologies still trying to get this pictures and writing set up looking "presentable" cheers Sam

Defender-Sam · Aug 31, 2012

Right on with the doors, both the drivers and the passenger side doors were in quite a bad way as with most landys but the previous owners of this particular one didn't seem to quite grasp vehicle maintenance, so as with the general vehicle condition they were especially bad. now i will admit beforehand that I'm not particularly proud of this bodge but it is the best i could do with what was left, the plan is to source some better condition doors once he's up and running, pictures are meant to paint a thousand words so here they are-

its hard to see i know but its just possible to make out how much has rotted of the bottom door frames in the above pic so to be clearer

new section on the left and old on the right

the aluminium skin has corroded pretty badly as mentioned

repair section fabricated which was welded to the rest of the remaining frame, the skin bent back around and a skim of filler

the same process was used on both doors but the rear door was beyond repair having sustained serious corrosion to both aluminium skin and steel frame, and the weight of the door mounted spair wheel cracking all the welds, rendering the door useless so a new one will be sourced later in the project along with a swing away wheel holder to help carry the hefty weight of the wolf wheel (more info later on them) thanks Sam

gse1986 · Aug 31, 2012

Good call on new chassis!

top drive · Aug 31, 2012

Looking good so far , doing all the right things , mines heading this way , just got an engine and going to do the bulkhead and engine and stick it back on the road and get the v5 changed to reflect the new engine. Then do the chassis with the engine mounts to suit the new engine

Defender-Sam · Aug 31, 2012

thanks for the positive comments, I'm going to be keeping the engine standard for insurance reasons really being only 19 its going to be a nightmare with the standard engine so no doubt they wouldn't be happy with an upgrade but thats something ill worry about nearer the time. got a call of richards today whilst at work the chassis is coming tuesday now not monday but no major worries, ill be updating the thread tomorrow with axles and suspension maybe some work on the rear tub and engine but i need to capture so pictures of them so we will see. thanks guys sam :hippie:

bluehaze · Sep 1, 2012

Put mine on a Richards chassis - excellent quality.

top drive · Sep 1, 2012

Yeah richards will make me very poor

they do chassis and cage combos.

PembsLandy · Sep 1, 2012

Looking forward to the next installment. My doors could do with the same repairs you've done. Another item on my to do list

Defender-Sam · Sep 1, 2012

Right then this time its axles, both had similar treatment stripped down de rusted, primed, painted then reassembled using i mix of new, re used and reconditioned parts. I have/will be fitting all new brake components when assembling the 90, the front had new disks and will eventually have new callipers still deciding on genuine or non genuine so if anyone has an opinion then please let me know thanks, both front and rear have since be fitted with ashcrofts reconed diffs as they were showing signs of wear, the rear had been fitted with a range rover diff not sure why just what was available i guess. on with pics not many during the work but i take it most people know what goes into an axle anyway.
rear stripped awaiting paint

front swivel housing and hubs drying,

front axle awaiting assembly

finished rear fitted with my newly purchased wolf type wheels (set of 5 fitted with brand new tyres) they won't be staying nato green but unsure whether black or white to go with the final vehicle colour of pennine grey. sorry don't seem to have and pics of the finished front axle.

cheers Sam

Jason2 · Sep 2, 2012

Wicked

Would love to do this to my 110 but just don't have the time and it's a daily drive.

Keep up the good work

Bede · Sep 2, 2012

I'm in the same boat, can sneak it off the road for a weekend at most. really frustrating.

Would love a 90 as a plaything to strip and rebuild but also want to buy a Sankey and convert for camping. Need a lottery win.

Defender-Sam · Sep 2, 2012

right people, i can't get a lot done this weekend kind of waiting for the chassis to arrive. so instead i will update you with some suspension progress. all the suspension components such as radius arms, trailing arms, panard rod, a frame assembly, shock mounts, diesel tank mount, engine and gearbox mounts along with the propshafts have been cleaned up and painted, the bushes have been replaced with polyurethane ones and the rolling chassis will be assembled using new springs all round along with the terrafrima shocks. i will be replacing the standard type axle breathers with extended ones routed to somewhere around bulkhead level or up to the snorkel if i decide to fit one. pictures-
as removed

painted and new bushes fitted

new suspension components

brake pipes and breather bits

Defender-Sam · Sep 2, 2012

right people onto some bodywork, as you can see its in good condition apart from the bit between the headlights and tail lights but i guess that my fault for starting with a bad one..... too late now anyway, i have had to replace a couple of panels including both front wing skins due to the drivers side had a fair sized dent streching from the front panel to the wheel arch and the ns had been filled in areas with body filler to a depth of about 3 inches so replacements were sourced (paddocks abs skins) which are of varied fits one side needed every hole extending to fit the bolts and the other one fitted perfectly first time, the rear tub needed a fair amount of work as the rear panels had been torn somehow then filled again with a decent amount of filler so new panels were sourced and fitted along with new corner and top cappings, underneath the floor supports running the length of the floor have been replaced along with the floor itself as it had rotted through with the supports and a new section which secures the assembly to the rear
crossmember.

the seatbox has been fitted with one of yrms aluminium battery trays and there replacement side panels which had corroded through were they mount to the sill members.

definitely my record for the most rivets set in a day there.

just to throw in a pic of the finished bulkhead the clutch pipe bracket and the support brackets will be fitted once its mocked up on the chassis

and to show the wing dent and its just about possible to make out the rear capping rust,

along with this repair work i have been rubbing down the rest of the panels to help speed the project up a little i prefer to do the sanding outside as the garage gets filthy enough as it is, all thats left is the roof to flat back and probably some final tweaking of the other bits. :tea:

Project 1989 90 (Bruce)

New Member

Well-Known Member

Active Member

Active Member

AKA Mr cool...

Active Member

New Member

New Member

New Member

Active Member

Well-Known Member

New Member

Well-Known Member

Well-Known Member

Active Member

New Member

Well-Known Member

Active Member

New Member

New Member

Similar threads