Aaron's 90 rebuild round 4

Great work, Aaron. But, this is bringing back bad memories from when I did mine.

Looking good Aaron. That self adhesive strip you've got for the floor strengtheners looks good. Much better than the bits of old inner tube idea that I had thought of doing. Can you tell me where you got it from please?

Al2O3 said:

Great work, Aaron. But, this is bringing back bad memories from when I did mine.

Click to expand...

Cheers mate but why bad from when you did yours?

LincolnSteve said:

Looking good Aaron. That self adhesive strip you've got for the floor strengtheners looks good. Much better than the bits of old inner tube idea that I had thought of doing. Can you tell me where you got it from please?

Click to expand...

Thanks Steve, Yes it is good stuff and relatively cheap, I use it a lot, anywhere where steel or alloy may come into contact.
I got it from here.
http://www.ebay.co.uk/itm/262838352...49&var=561836776410&ssPageName=STRK:MEBIDX:IT

aaronmorris said:

Cheers mate but why bad from when you did yours?

Click to expand...

I replaced both quarter panels on mine and one of them wasn't made to the correct dimensions, so the geometry was out and I had to take it apart again and cut it. Plus, I replaced the floor, under floor cross members and the rear body member. It was a bit tricky getting it all to line up, get the gap between the quarter panels correct and parallel and so on. In fact, now that I think on, I took one quarter panel off twice and was lucky to be able to move the drill holes enough to still get the pop rivets to grip. I just remember that bit of the rebuild being a lot of hassle for me.

Did a little bit yesterday, today was ruined by rain
Carried on with the tub, now I'm sure the drivers side has been repaired in the past and the side skin had been riveted on, whereas original is spot welded. I didn't like this so I decided to stick it on instead and I will fill over the rivet holes.
The rear quarter as AL203 said wasn't quite as simple as it should be. Maybe it is poor quality parts, maybe it is the fact the tub moves when you take them apart.
Anyway I got the new one stuck and riveted in place with a bit of jiggling about.
And as you can see where the door seal sits the new one isn't quite as wide as the old, so will have to trim that back a little with the grinder.
The door opening wasn't square top to bottom when just sitting the panel in place. (ran out 10mm or so top to bottom)
So I ratchet strapped the tub together to get it right then drilled and riveted in place. Hopefully it doesn't move too much.
Also made a start on general prep work and test fitted the cappings and holes drilled.
Da sander also randomly gave up the ghost Went and bought another within an hour





Think I will get all the panels prepped whilst the weather is still shit'e as and when I can be arsed, although looking and thinking about it I really, really do not know why I am doing the project.. it is going to be a money pit, their isn't a straight panel on the vehicle and likely will be more hassle than it is worth.
Should probably of stuck to what I bought it for and that was a donor, but I was sucked in because I can't bloody help myself It is always best to find a good donor to start with.
But the reality is their isn't any going back now, you chaps know what it is like with these projects, too much time, effort and money into it now.
Sick of working out of a leaky, pokey little garage/shed, sick of moving things from pillar to post or tripping over it trying to find stuff, fancy a change, need a change.. something has to change!
Currently trying to gather funds for shed build, but that wont be a quick process.

By my reconing I still need..
Wings. Dinted on the front and sides oh and the tops , so idealy a good set of second hand ones. Or buy new skins and fronts and try and flatten the tops out. Budget approx. £300-400

Doors. Dinted to buggery. Minimum new skins and a set of door hinges, handles and locks. But who knows what will be uncovered once stripped. They look solid but will likely need something. Thought about buying a set of new lift up door handle type from SP landrovers but not sure on that. Budget say anything from £250 to £400.

Bonnet. I need another. Dinted to buggery, probably beyond saving. Probably pick a mint one up for sub £100.

Tub is now ok. Minor bodywork to do.

Already bought an R380 type seat box, tunnel and diaphragm.

Not sure if it will be a truck cab or hard top yet. Quite fancying a truck cab after I sold it, doh
If it is a hard top I have a roof. I have sides. Would need a rear door (skin)

Other than that their is general stuff. I need a windscreen and seal. interior trim, seat re-trim, floor matting, roof lining etc. Exterior, wheels/tyres, lights and surrounds/grill, bumper, need a set a spats (old ones broken)
Various seals (door etc..) wiper boxes, general fixings and fasteners, paint, proper 300tdi defender air box and pipework and all the other little bits and pieces that you don't think about, they're the ones that add up.
Not all strictly necessary I know, but if I am doing something I want to do it properly, my own downfall I guess.

Anyway, sorry for the rant, it just started coming out More next week hopefully, if the weather is on my side.
And I don't mean more ranting Hopefully some proper progress

aaronmorris said:

Did a little bit yesterday, today was ruined by rain
Carried on with the tub, now I'm sure the drivers side has been repaired in the past and the side skin had been riveted on, whereas original is spot welded. I didn't like this so I decided to stick it on instead and I will fill over the rivet holes.
The rear quarter as AL203 said wasn't quite as simple as it should be. Maybe it is poor quality parts, maybe it is the fact the tub moves when you take them apart.
Anyway I got the new one stuck and riveted in place with a bit of jiggling about.
And as you can see where the door seal sits the new one isn't quite as wide as the old, so will have to trim that back a little with the grinder.
The door opening wasn't square top to bottom when just sitting the panel in place. (ran out 10mm or so top to bottom)
So I ratchet strapped the tub together to get it right then drilled and riveted in place. Hopefully it doesn't move too much.
Also made a start on general prep work and test fitted the cappings and holes drilled.
Da sander also randomly gave up the ghost Went and bought another within an hour

View attachment 118761

View attachment 118764

Think I will get all the panels prepped whilst the weather is still shit'e as and when I can be arsed, although looking and thinking about it I really, really do not know why I am doing the project.. it is going to be a money pit, their isn't a straight panel on the vehicle and likely will be more hassle than it is worth.
Should probably of stuck to what I bought it for and that was a donor, but I was sucked in because I can't bloody help myself It is always best to find a good donor to start with.
But the reality is their isn't any going back now, you chaps know what it is like with these projects, too much time, effort and money into it now.
Sick of working out of a leaky, pokey little garage/shed, sick of moving things from pillar to post or tripping over it trying to find stuff, fancy a change, need a change.. something has to change!
Currently trying to gather funds for shed build, but that wont be a quick process.

By my reconing I still need..
Wings. Dinted on the front and sides oh and the tops , so idealy a good set of second hand ones. Or buy new skins and fronts and try and flatten the tops out. Budget approx. £300-400

Doors. Dinted to buggery. Minimum new skins and a set of door hinges, handles and locks. But who knows what will be uncovered once stripped. They look solid but will likely need something. Thought about buying a set of new lift up door handle type from SP landrovers but not sure on that. Budget say anything from £250 to £400.

Bonnet. I need another. Dinted to buggery, probably beyond saving. Probably pick a mint one up for sub £100.

Tub is now ok. Minor bodywork to do.

Already bought an R380 type seat box, tunnel and diaphragm.

Not sure if it will be a truck cab or hard top yet. Quite fancying a truck cab after I sold it, doh
If it is a hard top I have a roof. I have sides. Would need a rear door (skin)

Other than that their is general stuff. I need a windscreen and seal. interior trim, seat re-trim, floor matting, roof lining etc. Exterior, wheels/tyres, lights and surrounds/grill, bumper, need a set a spats (old ones broken)
Various seals (door etc..) wiper boxes, general fixings and fasteners, paint, proper 300tdi defender air box and pipework and all the other little bits and pieces that you don't think about, they're the ones that add up.
Not all strictly necessary I know, but if I am doing something I want to do it properly, my own downfall I guess.

Anyway, sorry for the rant, it just started coming out More next week hopefully, if the weather is on my side.
And I don't mean more ranting Hopefully some proper progress

Click to expand...

Welcome to my world lol. Btw, what photo sharing app are you using? i used photobucket but its stopped uploading pics to my laptop making it impossible ( for me ) to share images.

aaronmorris said:

Did a little bit yesterday, today was ruined by rain
Carried on with the tub, now I'm sure the drivers side has been repaired in the past and the side skin had been riveted on, whereas original is spot welded. I didn't like this so I decided to stick it on instead and I will fill over the rivet holes.
The rear quarter as AL203 said wasn't quite as simple as it should be. Maybe it is poor quality parts, maybe it is the fact the tub moves when you take them apart.
Anyway I got the new one stuck and riveted in place with a bit of jiggling about.
And as you can see where the door seal sits the new one isn't quite as wide as the old, so will have to trim that back a little with the grinder.
The door opening wasn't square top to bottom when just sitting the panel in place. (ran out 10mm or so top to bottom)
So I ratchet strapped the tub together to get it right then drilled and riveted in place. Hopefully it doesn't move too much.
Also made a start on general prep work and test fitted the cappings and holes drilled.
Da sander also randomly gave up the ghost Went and bought another within an hour

View attachment 118761

View attachment 118764

Think I will get all the panels prepped whilst the weather is still shit'e as and when I can be arsed, although looking and thinking about it I really, really do not know why I am doing the project.. it is going to be a money pit, their isn't a straight panel on the vehicle and likely will be more hassle than it is worth.
Should probably of stuck to what I bought it for and that was a donor, but I was sucked in because I can't bloody help myself It is always best to find a good donor to start with.
But the reality is their isn't any going back now, you chaps know what it is like with these projects, too much time, effort and money into it now.
Sick of working out of a leaky, pokey little garage/shed, sick of moving things from pillar to post or tripping over it trying to find stuff, fancy a change, need a change.. something has to change!
Currently trying to gather funds for shed build, but that wont be a quick process.

By my reconing I still need..
Wings. Dinted on the front and sides oh and the tops , so idealy a good set of second hand ones. Or buy new skins and fronts and try and flatten the tops out. Budget approx. £300-400

Doors. Dinted to buggery. Minimum new skins and a set of door hinges, handles and locks. But who knows what will be uncovered once stripped. They look solid but will likely need something. Thought about buying a set of new lift up door handle type from SP landrovers but not sure on that. Budget say anything from £250 to £400.

Bonnet. I need another. Dinted to buggery, probably beyond saving. Probably pick a mint one up for sub £100.

Tub is now ok. Minor bodywork to do.

Already bought an R380 type seat box, tunnel and diaphragm.

Not sure if it will be a truck cab or hard top yet. Quite fancying a truck cab after I sold it, doh
If it is a hard top I have a roof. I have sides. Would need a rear door (skin)

Other than that their is general stuff. I need a windscreen and seal. interior trim, seat re-trim, floor matting, roof lining etc. Exterior, wheels/tyres, lights and surrounds/grill, bumper, need a set a spats (old ones broken)
Various seals (door etc..) wiper boxes, general fixings and fasteners, paint, proper 300tdi defender air box and pipework and all the other little bits and pieces that you don't think about, they're the ones that add up.
Not all strictly necessary I know, but if I am doing something I want to do it properly, my own downfall I guess.

Anyway, sorry for the rant, it just started coming out More next week hopefully, if the weather is on my side.
And I don't mean more ranting Hopefully some proper progress

Click to expand...

Probably a number of things getting on your wick and the rain was the straw that broke the camels back today. It'll be sunny soon and cheer you up.

Your tub problems sound very similar to mine. I thought about leaving mine with the wider gap at the top, thinking when I put the roof on it would pull it all inline. I was concerned about the force required pulling on the sides to tub joint, which is just a rubber seal with three bolt points. The seal will be squashed flat at the door joint, but will probably pull open along the sides. Worth thinking about, mate.
Also, remember that seam down the side of the new rear quarter panel will get covered by the door seal.

Sorry to hear you are having a bad time mate. Home restorations are a massive undertaking. You have to master a huge range of skills, not always with all the tools you need and usually with not enough space. All this while keeping within a budget and dealing with suppliers and other outsiders who sometimes seem to be working against you. And then when it's all done most of the people who see it will never understand what it took to complete. Anyone restoring an old car ought to get a bloody medal. Just remember that your work is admired by everyone on this forum and inspires many of us. Why not have a break for a short while. Don't even think about Land Rovers for a week, let the frustrations pass and it might help get your mojo back. Take care.

Hi Aaron
Re the dinted panels if they are dinted on the flat areas I have had some success in the past getting the dints out by laying them on a flat sheet of plywood and rollering them with a hard 1" wide wallpaper roller. The small roller allows you to get enough pressure onto the panel. It sounds daft but it works.
If you are looking for plans for a garage I have just built a 6m*6m blockwork one and can email them to you.
I also put underfloor heating pipes in the slab when I cast it (pipe is cheap) and put solar thermal (water) panels on the roof. I heat the house water with them but am heating the garage floor from the return part of the system as the water is still quite warm after it has been to the house. The plan is not to get the garage really warm but to keep it warmer than the outside and keep it dry.

sidewinder said:

Hi Aaron
Re the dinted panels if they are dinted on the flat areas I have had some success in the past getting the dints out by laying them on a flat sheet of plywood and rollering them with a hard 1" wide wallpaper roller. The small roller allows you to get enough pressure onto the panel. It sounds daft but it works.
If you are looking for plans for a garage I have just built a 6m*6m blockwork one and can email them to you.
I also put underfloor heating pipes in the slab when I cast it (pipe is cheap) and put solar thermal (water) panels on the roof. I heat the house water with them but am heating the garage floor from the return part of the system as the water is still quite warm after it has been to the house. The plan is not to get the garage really warm but to keep it warmer than the outside and keep it dry.

Click to expand...

If you've got any pictures of the garage going up, would you consider doing a thread on it? I'm sure I can't be the only one who likes to see pictures of sheds being built.

Brown said:

If you've got any pictures of the garage going up, would you consider doing a thread on it? I'm sure I can't be the only one who likes to see pictures of sheds being built.

Click to expand...

Not ashamed to say I'm with you there, mate.

I would like to see that too. especially the underground heating - very interested in knowing more about this please.

I'll start a wee write up in the anything goes section when I get home tonight.

Garage build pictures and a short write up here.
https://www.landyzone.co.uk/land-rover/stephens-garage.312588/#post-3946278

mick the builder said:

Welcome to my world lol. Btw, what photo sharing app are you using? i used photobucket but its stopped uploading pics to my laptop making it impossible ( for me ) to share images.

Click to expand...

Haha, yes, I have just been letting things get on top of me of late. Pictures I stopped using photobucket as I found it just kept crashing on me, I now just upload direct from my phone, took a while to work out how to do it, but easy now I know. I'm no good with this fandangled phone technology to be fair.

Al2O3 said:

Probably a number of things getting on your wick and the rain was the straw that broke the camels back today. It'll be sunny soon and cheer you up.

Your tub problems sound very similar to mine. I thought about leaving mine with the wider gap at the top, thinking when I put the roof on it would pull it all inline. I was concerned about the force required pulling on the sides to tub joint, which is just a rubber seal with three bolt points. The seal will be squashed flat at the door joint, but will probably pull open along the sides. Worth thinking about, mate.
Also, remember that seam down the side of the new rear quarter panel will get covered by the door seal.

Click to expand...

Yeah I know I wanted it reasonably square as you are right it will cause nothing but problems at a later date, so better to sort it now than when it is all painted.
That is why I ratchet strapped it together then fixed it, it is 2mm out now from top to bottom, so I can live with that, probably as close as LR ever got them

LincolnSteve said:

Sorry to hear you are having a bad time mate. Home restorations are a massive undertaking. You have to master a huge range of skills, not always with all the tools you need and usually with not enough space. All this while keeping within a budget and dealing with suppliers and other outsiders who sometimes seem to be working against you. And then when it's all done most of the people who see it will never understand what it took to complete. Anyone restoring an old car ought to get a bloody medal. Just remember that your work is admired by everyone on this forum and inspires many of us. Why not have a break for a short while. Don't even think about Land Rovers for a week, let the frustrations pass and it might help get your mojo back. Take care.

Click to expand...

Thankyou for your kind words Steve, you are right most people just don't understand, I get myself down if I am honest and my own worst enemy, but hopefully I snap out of it soon, not been like this for some time.

sidewinder said:

Hi Aaron
Re the dinted panels if they are dinted on the flat areas I have had some success in the past getting the dints out by laying them on a flat sheet of plywood and rollering them with a hard 1" wide wallpaper roller. The small roller allows you to get enough pressure onto the panel. It sounds daft but it works.
If you are looking for plans for a garage I have just built a 6m*6m blockwork one and can email them to you.
I also put underfloor heating pipes in the slab when I cast it (pipe is cheap) and put solar thermal (water) panels on the roof. I heat the house water with them but am heating the garage floor from the return part of the system as the water is still quite warm after it has been to the house. The plan is not to get the garage really warm but to keep it warmer than the outside and keep it dry.

Click to expand...

Ah that makes sense and a bloody good idea with the panels, I will have to give that a go.
And thanks for the info on the garage and the offer of plans all good ideas and underfloor heating would be great., I may well take you up on the offer of that and send you a pm later thanks

sidewinder said:

Garage build pictures and a short write up here.
https://www.landyzone.co.uk/land-rover/stephens-garage.312588/#post-3946278

Click to expand...

Great thread, only had a quick scan through but will have a proper read later.

Spent this weeks money and ordered a new set of wing skins and a set of headlight panel ones.
I was looking and debating getting the abs plastic ones, but having never used or seen any in person I decided against them and went with the standard Aluminium ones. More expensive, but I know exactly what I am getting then, and painting the abs was another deliberation as I would think it differs from standard, probably so! If only a plastic primer, but still, it is easier to stick with what you know ay..
Working today mind, so hopefully get something done tomorrow.

Didn't quite get around to starting on the wings at the weekend, but the panels for them arrived.
Wing skins it was a pleasant surprise to see they came in primer already, I expected them to come in bare allu to be fair.



And genuine lr nose cones as the call them, I don't think they're too bad considering at around £50 each, had I known that I'd have probably used them previously.



Tub is almost their prep wise on the outside, just takes so long
And made a start on the load area, currently thinking about using a raptor type product for it, has anyone used them? and if so how did you find them, durability, ease of application etc..

£50 each is still a canny amount and these things soon mount up, don't they! Been roughly adding up prices for my engine rebuild, £100 each for injectors, £50 each for pistons, £100 for re-bore, gaskets, bearings seals, engine stand soon mounts up

The skins look ok, eyebrow holes in anorl

Made a start on the wings today. The headlight nose cone thing was more time consuming to replace than I thought as it is all spot welded together.
But it doesn't help I haven't done one before, second one came apart much quicker.

What I started with

Unbolted and disassembled.



Nose cone disassembled, took a little longer than I thought as I said above, but it's nothing difficult, just spot welds and the odd rivets, second one came apart much quicker once I knew how.



0




All the individual parts where sanded whilst in pieces to make life easier, including the new bit and riveted back together.



Wing top rubbed down, I decided to try and remove as much of the vile red paint as I could, for a couple of reasons really, because I don't know what it is, finish is rough as hell, and I don't think the vehicles original paint was keyed prior to applying it and it hasn't adhered properly and kind of chips off, and under that is the original paint that is still shiny.
Not exactly flat either but not the worst I have seen, I may or may not do some repair work later on, but I think I will try the roller idea suggested the other week first.



Started re-assembly.




And done, still needs some more prep work, but it is back together and should only need minor bits.





I am reasonably pleased with how the panels have lined up, the wing skin is a little high on the front corner where the wing top and nose cone meet, but other than that all is good.
Got the other side stripped and started cleaning/prepping but didn't get time for re-assembly, so that's tomorrows job.

Al2O3 said:

£50 each is still a canny amount and these things soon mount up, don't they! Been roughly adding up prices for my engine rebuild, £100 each for injectors, £50 each for pistons, £100 for re-bore, gaskets, bearings seals, engine stand soon mounts up

The skins look ok, eyebrow holes in anorl

Click to expand...

It does soon add up
I don't think some realise and appreciate how much it costs to do a rebuild, and do it right, until you do one yourself.
And yes, good quality engine bits soon add up too