90 defender rebuild

The next job I tackled was the rear windows , I had not planned on doing anything to them but cleaning them , but when offered up next to the new paint I realised they needed doing .
This is how a restoration gets out of control when you are paying someone to do it - If the paint is shiny then everything has to match or it sticks out like a sore thumb .

The windows were masked inside and out and the same treatment was given , etch , primer , base and clear - im sure you are bored of the stages by now so Ill spare you the photo's of the early stages

Base coat , again Mercedes Metallic black



Clear coat going on



Masking removed to allow paint to settle whilst baking



Window fitted and much better than before



I also got around to refitting some stuff under the bonnet that had been removed - Washer bottle was cleaned and replaced



Heater air intake cleaned up and fitted



New air filter fitted and housing replaced

OMG!
Is that a 19J engine?

Looking great

Are you leaving the existing 19j engine in it? Whats it like ? Smokey ? Low power ?

joeyb said:

Are you leaving the existing 19j engine in it? Whats it like ? Smokey ? Low power ?

Click to expand...

Hi Joey ,
I have still got the 19j in it , It starts every time , no smoke at all , not even on startup . It has a little oil leek but I guess they all do .
Power is a little low but I have 205 tyres on at the moment , new wheels and tyres as part of build might help a bit .

If I decide to keep it I will do a 200 tdi conversion but I keep getting people ask if I will sell it , if the offers get high enough it can go and I have already lined up another one or 2 to replace it ;-)

Nearly there now and I am beginning to see the concept as a whole , looking good so far and really looking forward to getting it on the road .

Hopefully this is the last bit of welding / repairs and then its build up time proper !!

So , The 90 is lacking a couple of fairly vital bits , namely the doors ....

I seem to have been putting this off as I really dislike repairing VW doors and presumed they would be as bigger PITA .

Anyway it would seem as if I was wrong .

This is the drivers door , The better of the 2 - but still rotten



Bottom section was beyond just welding up



The lower section was cut out and the new bit cut to size ( sort of ) then painted and put into place - Tiger seal was used on all surfaces to get a good adhesion



Corner wasnt quite cut perfect but I can sort this out with the welder



Lots of clamps were then used to close the bottom gap whilst the seal went off - I used a piece of wood along the outer lower edge to prevent damage to the skin



The corners could then be welded , a bit untidy but still lots of rust on surface so it splattered a bit - it will clean up well



The skin is also nicely stuck down at the top and follows the outer skin well



Originally the doors had the return for mounting the inner trim so I replicated that from a bit of scrap steel .



Cut to size and drilled for plug welding



Plug welded along the bottom - seamed in the corners



This can then be cleaned up .



Then it was dollied and hammered to close the gaps at the bottom properly and treated to a paint coating in KBS rust stop .



Passenger door was alot worse



This also got the same treatment



All done and dusted



I just need to strip them now and get them painted .

Might be worth mentioning not to forget to drill some drain holes, or she'll fill with muddy then stinky stagnant water.
nice repair though, really like how this build has come along!

Top work fella!!!!

4x4madness said:

Might be worth mentioning not to forget to drill some drain holes, or she'll fill with muddy then stinky stagnant water.
nice repair though, really like how this build has come along!

Click to expand...

Thanks - mental note made - drill holes in the morning

some more progress , getting very close now !!!!

The doors get etch , then primer , You know the drill by now and I cant use the focus on my camera LOL


Next to go on was the front window



The wiper arms and wipers could then go on - You may have noticed its a heated front screen ;-)


Rear glass also fitted - Heated rear screen and wiper at the rear


Hinges fitted

Door fitted



Just before doors went on I trimmed the front - The seat boxes were done in a hard wearing but flexible fabric


Floor wells done in nice thick black carpet


The rear tub is also trimmed in the same black carpet - bulkhead is left at this time as may change this yet , depending on seating position.


Next up were the seats - The fronts were done by welding a box section on the back of the runners to get a fixing point and the fronts were attached using the original MGF mounting holes - This was basically copied from another thread on here so thanks for that !!

The rear I wanted to do something that looked factory but wasnt the stupid money that late forward facing seats go for .
So I got another pair of MGF seat and modified them .
I wanted front facing seats as I have 2 small boys and wanted 3 point belts for them .

Just in case it helps anyone I have done a bit of a step by step .

First purchase seats - £5.03 from e bay
Remove the seat belt mounts , they are ugly submarine type ones and will be in the centre of the vehicle .

Then cut the rear most ends off the sliding rail and pull the lever up and slide off the runner - Rubber mallet helps .
You are left with this -



In the section at the back of each runner is a small raised section



You need to grind this out to give a flat surface


Once flat you can fit in some steal box section - For MGF 15 x 30 is perfect and requires a light tap in to get in place


You can then get sone 20 x 20 box and use it to create a square frame - In this picture I have also added the inner stand - that is the same height as the top of the tub from the floor - a brace is also welded between those 2 legs


Then get a measurement from the outer legs to the side of the tubs and weld in the same legs and brace at that point


Just tacked in place here - Weld in place properly after checking they fit well


Having checked they fit they were bolted into place - using 2 inch washers bellow the tub


Once in there is enough room for an adult as well as a child to get between the rear seats and more importantly there is space for the golf bag ;-)

Whilst we are here - more progress .
Seat belt mounts this time .

Box section again - 50 x 20 3mm walls


After some careful measurements and putting the correct angle on the top section to match the roof section I could weld tabs in the correct place on the top and bottom


You should end up with 2 of these


Mount at the bottom buts up to the corner brace


The same should happen at the top


These were then drilled with 3 mounting points top and bottom and fixed with high tensile bolts .

Anyway , I also ended up doing a few little jobs like fitting new handles and locks all round , top up fluids , Fit new master cylinder as the brakes failed when I first tried to drive it out the workshop .
Once it was repaired I went for a little drive .....




















Seriously let down by front bumper , No sills and the lovely original wheels and 205 tyres .

All will be rectified soon - Spacers ordered , Wheels blasted and painted , tyres sorted etc ...

Very nearly done .

some seriously good work as usual 65deluxe going to be great when its finished.

Defender-Sam said:

some seriously good work as usual 65deluxe going to be great when its finished.

Click to expand...

Im really excited as its nearly there , wheel spacers are here and so are sills so its just the tyres to be fitted tomorrow and we are all done cosmetically .

The only sad thing is that I may have to sell as a Vehicle I have been after for 20 years has just come up for sale .

I do have another 90 lined up though ;-)
I might do that one with a bit more attitude ....

Glad you have enjoyed the build so far

Spacers arrived , wheels painted , tree sliders arrived
all fitted

nice.

Top work, well done.

very smart great work mate

Great job, thanks for taking the time to share

Amazing what a bit of paint did for those old steel rims...

Looks great mate!we are fighting the urge of buying a early 60's beetle now lol!

Cracking job and only 2 and half months to do it!!!!
Just looked back at photo's on first page of this thread and it's unrecognisable as same Landy apart from reg No.