Defender 90 300tdi strip down and rebuild

Allyipod · Sep 10, 2011

Been quite productive day got the following done Fitted rear brake callipers, (old ones were shot and badley rusted) near side came off ok but off side i had to use the grinder with cutting disk as the bolts were u/s. Fitted the new brake pipes from the calipers to the union on top of the back axel although the flexy hose that goes to the chassis has the wrong thread. (will need to look into this) Fitted diesel tank and pipe work from engine bay but need some clips to tie it them to the chassis. Fitted the exhaust although the hangers dont line up very well and the second one from the engine had to be mounted upside down.:doh:
Think britpart need to re think there employment strat. Did a bit more painting of parts. Tommorow is not looking good weather wise so will batten down the hatches and see what happens.

Allyipod · Feb 19, 2012

Was hopeing today to get back to the lany but still to mutch ice about. It is now light till about 530pm so next week should make some headway...

discomania · Feb 20, 2012

You done anything since September?

Allyipod · Feb 20, 2012

discomania said:
You done anything since September?

Yes been doing small jobs like fixing and retaping the wiring loom fitting brake pipes etc. But mostly working so not had much time for it.

Allyipod · Mar 5, 2012

Well got a couple of hours on it last week and a few hours on Saterday

The bulkhead is back on and i have been bought two new batterys for it the numax ones along with a new roll cage,two seat retrim kit from exmore and a cubby box to match in black with the land rover logo (anyone got them do they look good). Been looking at colours for paint for a couple of monthes now and think i will go for the epson green metalic still not 100% sure lol. Photos below

Stupot4x4 · Mar 5, 2012

Looking good, the big washers on the top mount of the rear shocks looks like its on the wrong way round, the domed side should be against the shock, that goes for both inner and outer washers.

Allyipod · Mar 5, 2012

Stupot4x4 said:
Looking good, the big washers on the top mount of the rear shocks looks like its on the wrong way round, the domed side should be against the shock, that goes for both inner and outer washers.

Well spotted Stu i put that photo in there to see if anyone would spot the deliberate mistake.lol. Not

Stupot4x4 · Mar 5, 2012

allyipod said:
well spotted stu i put that photo in there to see if anyone would spot the deliberate mistake.lol. Not :d

Allyipod · Mar 6, 2012

Well i looked at batterys online and never made up my mind, I had filled in the details but never put in my cc details about ten seconds later the phone rang could not belive it a phone call from the company i was lookin at. Still i ordered the batts only to come home today and find them on my back step less than 24 h unbelivible first class to Tayna first class company and the bird on there home page hase got some pair of legs.

buy the way i have f%ck all do do with the company.

Allyipod · Mar 15, 2012

No pic's today as batt on phone was dead but i have a problem. Bolted the tub in and fitted the bulkhead and i have 34.25 inches on both doors bottom and top. The problem is the bulkhead meets the chassis on the ofside ok but on the nearside i have a gap of about 1/4 of an inch. Do i make up a spacer or is there somthing wrong?

jamesmartin · Mar 15, 2012

bulkhead is adjustable by putting washers in between it and outrigger some times 1/2 inch worth

Allyipod · Mar 15, 2012

jamesmartin said:
bulkhead is adjustable by putting washers in between it and outrigger some times 1/2 inch worth

Thanks James that puts my mind at rest. Was speaking with a guy last week who is into landys in a big way he cracked a joke. What are the only two things you can see from space. I could only think of the great wall of china and he added the gap in landy/s panels

jamesmartin · Mar 15, 2012

true, bulkhead is only part which has much scope for adjustment

Allyipod · Mar 15, 2012

Nothing is set in stone will get on the lathe this week end and make a spacer. Thanks again

DavidJR · Mar 16, 2012

Ensuring that you are putting it together on a flat surface is also vitally important, finding you have spaced it when the difference is due to chassis tweak on uneven ground would be quite annoying. Even then the varying differences of preload on old or even new springs can make a difference.

Without the body there will be several inches of flex in the chassis, going to the extreme the only way to work around this is to support the chassis itself on a flat surface or support the legs out riggers and then get a level on it, but even then you are counting on the fact that a welder on price work has done a good job, and which point of reference do you go off.

Landy's have leaks, drafts and gaps and the chances are that whatever job u do it will be as good if not better than factory.

RAGNAR BENSON · Mar 16, 2012

This thread has been a great read! I'm seriously impressed by what you've done there. I'd love to be able to do that sort of work but simply don't have the knowhow. Also, the only tools I own are a Leatherman Wave and an old hammer. Where do you learn this stuff?

I can't believe the level of corrosion of that old chassis. I know Defenders are known for prodigious bouts of tinworm, but god almighty! I guess numerous harsh Scottish winters and plenty of salt over the years will not have helped.

I have an 05 TD5 and the chassis appears to be in very good nick. I had it coated, but your pictures have really got me wondering about what ghastliness lurks within.

What is the DVLA threshold for declaring that a car is no longer the same car that has been registered? From what I can see, only the engine and gearbox remain from the old rig - and they're not original so the car is surely technically no more!

Top thread!

Allyipod · Mar 18, 2012

RAGNAR BENSON said:
What is the DVLA threshold for declaring that a car is no longer the same car that has been registered? From what I can see, only the engine and gearbox remain from the old rig - and they're not original so the car is surely technically no more!

Top thread!

Yes it is still the same car, you are aloud to change the chassis as long as it is new and to the original spec. Same with the engine it is still a 300TDi also the axels and box are original. With a car this age a lot of parts will have been changed at some point in the past.

Not a lot to add this weekend as i was at a mates 45th on Friday so Sat I was hungover. started rebuilding the seats with a kit for Exmore looking good but will need to post pic's later as phone is dead.

Allyipod · Mar 29, 2012

Just a wee update with some pic's sorry forgot to take some of the seat bottoms.
Some pikey has been up round the back of the house and taken a seat frame that was waiting on me rubbing it down to spray it. So today i have sat the roof on with a couple of bolts so it dont fly off also fitted a new lift pump as mine was knackered.
<a href="eleventh pictures by AllyConlon - Photobucket" target="_blank"><img src="http://i958.photobucket.com/albums/ae69/AllyConlon/eleventh/IMG_0763.jpg" border="0" alt="Photobucket"></a>
<a href="eleventh pictures by AllyConlon - Photobucket" target="_blank"><img src="http://i958.photobucket.com/albums/ae69/AllyConlon/eleventh/IMG_0764.jpg" border="0" alt="Photobucket"></a>
This brings me to my next question has anyone got a pic of how the brake pipe from the flexy on the offside to the brake bias valve runs. It has got to run under the innerwing and it is that long since taking it apart i cannot remember pic below.
<a href="eleventh pictures by AllyConlon - Photobucket" target="_blank"><img src="http://i958.photobucket.com/albums/ae69/AllyConlon/eleventh/IMG_0765.jpg" border="0" alt="Photobucket"></a>
Also i had to take the tank back out as it was filling with water. Got it dryed out and a new seal for the fuel guage sender as i think this is where the water was getting in. Should get some more done this weekend.

Allyipod · Apr 11, 2012

Ok found out where the water was getting into the fuel tank. It was the sender itself it had a hairline crack in it around the top. New one fitted and tank is back in WooHoo! the roof is now all bolted down along with the screen and the seatbox.
Iv'e got a problem with the rails that run along the bottoms of the doors. The drivers side where it goes vertical at the tub the bolt is hitting the fuel tank so off whith them tommorow and a wee mod to suit.

Spent a bit of time on the wiring and plumbing side of things tying down loose stuff and have most of it under control now.

Allyipod · Apr 17, 2012

Ok so been working away over the last couple of weekends and got the front doors on and a lot of other things done as well even managed to start the engine on sunday woo hoo. Forgot to loop the oil cooler pipes though and got oil all over the place

Anyway found some pics of when i got it.

Hope the pic's work as i cant seem to find the right link to pic.
The last pic looks like iv'e got a fag in my mouth lol.

Spoke with the guy next door and he is of on hols from the 8th of May so said i can use his garage to spray it in when he is away.

Some pics from Sunday.

Defender 90 300tdi strip down and rebuild

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