1993 Defender 90 Rebuild

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Just a quick update to celebrate actually doing something in the time I ancipated. The heater and wiring loom are both out.

The circular foam that sits between the heater and the air intake has seen better days and now has the consistency of those sponge fingers you get in trifles. Unfortunately not the flavour though.
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In fact foam doesn't seem to last very well anywhere. For some reason replacements are silly money (about £20 for this rectangular one and £8 for the circle) so I think I'll be making my own when the time comes.
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Predictably, the heater box was hiding more rust. At this point I think the bulkhead is either scrap or a very large project for someone with too much time on their hands. The replacement one can be seem lurking off to the right.
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And this is what a Defender wiring loom looks like. Tiny in comparison with the miles of wiring inside more modern cars. I've taken lots of photos pre-removal and tried to label some of the bits in the hope of making reassembly a bit easier, but I'm sure it's going to be a right ball-ache.
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And finally, a Defender looking more like a Series. Who needs all that wiring and plastic stuff?!
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And the engine bay looks that little bit emptier.
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Not sure what's for next time. Probably propshafts and draining various fluids. Stay tuned if that sort of thing floats your boat.
 
This week has been mostly bulkhead related. The brake pedal and servo come out haemorrhaging fluid all over the place despite my best efforts.
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And the accelerator and clutch part company with the bulkhead in less dramatic style.
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For some reason I then decided to do something different so removed the transmission brake.
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Oh yes, now I remember. I realised that to remove the steering column I needed to drill out the steering lock shear bolts and couldn't summon the enthusiasm.
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And finally after dropping the ignition switch on the floor and bending all the contacts, the steering column could be pulled out and I finally find out why the hole is a teardrop shape - so the sticky outy bit welded on to the steering column can fit through.
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I then set about tackling the bolts holding the bulkhead to what remains of the outriggers (see later photos) with a huge bar, and after lots of swearing they finally came undone. Don't get me started on those flat-headed machine screws holding the bulkhead to the chassis through the footwells. Mole grips, a wire brush, WD40 and more swearing were required.
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And then, possibly the most difficult bolt (well, nut) I've yet had to undo on the Land Rover, holding the clutch pipe to the bulkhead. With hindsight I should have just cut the hose and bought a new one, but after undoing it halfway I wasn't prepared to admit defeat.
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But finally, out comes the bulkhead, which is a bit tricky on your own and involves balancing precariously on the chassis rails.
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I suspect the outriggers have gone beyond the point of no return.
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But in more positive news, something shiny has arrived! Not the one-piece cappings I ideally wanted, but beggars can't be choosers.
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Next time, off with the rear tub (if I can drum up some assistance) or failing that I'll unbolt some other stuff.
 

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Dont scrap that bulkhead, wont take much to fettle that when you have time and will put a fair chunk of money back in your pot...
That's a thought. It is a bit crispy around the edges, but actually it's not too bad in the middle. Maybe when my non-existant welding skills have got to a certain point I could give it a go.
 
I'm starting to wonder if I should flog the TD5 bulkhead and use the proceeds towards a galvanised one, particularly if I can get a bit back for the old one as well. How much does a mint condition TD5 bulkhead go for these days?
 
I would suggest a figure of £500 and maybe ad best offer...
OK, I did wonder if I might get a bit more than that but it's food for thought. There are a few chancers on eBay trying to get that much for bulkheads that look more like the one I'm taking off!
 
Yes, if it really is mint then maybe ask £600, is it the green one ? it looks to be military before a darker green respray...
 
Yes, if it really is mint then maybe ask £600, is it the green one ? it looks to be military before a darker green respray...
Yes, it's the green one lurking in the background of some of the photos. It's a standard LR colour, maybe Coniston Green or something similar.
 
A guy in Manchester has a unit and probably only does 6 a year besides other things.
Cant remember his name unless i see him advertise again, i went to see the bulkhead first and picked fault as you do so eventually he relented...
 
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