Defender Tdci bulkhead on a 300 tdi

Galvernisednuts · Nov 4, 2014

Hello everyone, just joined the forum and can't wait to get started

I'm running a defender 300 tdi with a very successful Tdci bulkhead and dash and still have a manual gearbox
I've met lots of people who tried and gave up or fitted an auto to clear the dash but I offer hope
Anyone interested?
Ta

daddy2coull · Nov 4, 2014

Galvernisednuts · Nov 4, 2014

I'll sort sum once the rains given it a rest
Let's get one thing straight though it wasn't simple but I was lucky to have access to the bits to work it out
New Tdci wiring uses a bit of canbus stuff to work with the ecu but junk that most of the warning lamp wires are the same ie diff lock sidelights etc
I used an r380 from a disco with it's more rearward gear selector and modded a disco 3 centre console to fit, I've now got a cubby fridge
The gauges are currently 300 tdi but I'm putting td5 ones in soon
As said I had access to a lot of stuff but luckily I needed to change my notchy gearbox so was worthwhile

Galvernisednuts · Nov 4, 2014

I'm currently making black polycarbonate gauge holders for the dash if anyone's interested

You need an instrument pack to butcher but it's not a hard conversion to do

Galvernisednuts · Nov 5, 2014

Here's the instrument pack as dismantled to remove the can network gauges

Remove this white plastic piece and cut out its centre

Retain the outer frame, discard the middle bit

Here's the outer lens and modded back
The black polycarbonate plate is shown prior to cutting the gauge holes and warning lamp panel

The template test shows my planned instrument layout

Here's my current tdi gauges lit with led bulbs and a td5 warning lamp unit
I'm fitting td5 gauges soon which will match the illumination of the rest of the Tdci stuff

Galvernisednuts · Nov 5, 2014

More pics as requested
Here's the centre console too

I made a sank alloy centre plate to allow the cubby fridge to fit the seat box and just modded seatbox leading edge and Tdci tunnel
Before ya ask the disco 3 hi lo lever does nowt not does the hdc button but I plan to either fit blanks or turn them into other switches

Once I get the rear vent ducts tapped into dash I'll have rear vents for the kids too

To be fair I like the old tdi and td5 dash but the heater is truly brilliant with the Tdci bulkhead and it's rarely used at full heat

I was lucky and won a 2010 bulkhead for £400 which considering my old bulkhead was knackered was a bargain
At least if you know where you stand you can decide whether it's worthwhile a job to do

GATSO · Nov 5, 2014

Wow brilliant fit out 😊 may do this to my build it looks ace weldone and thanx for sharing 😊🍰

Galvernisednuts · Nov 5, 2014

Thanks am really pleased with it and have a wealth of info I'm willing to share

td5tool · Nov 5, 2014

Looks very nice I'm impressed

Galvernisednuts · Nov 5, 2014

A standard r380 gearstick comes up where the dash is on the Tdci and that's the stall point, folks seem to end up fitting the auto as the disco selector doesn't just bolt onto the defender gearbox
The shaft inside has a grub screw that's 90 degrees different for starters
The wiring by and large is hard wired not needing ecu input although the glow plug relay needed a rework to Tdi type on mine
I got td5 connectors for the warning lamp display off eBay and just cut the Tdci instrument pack plug off
Had to run in a couple of wires for the temp gauge which was ecu controlled
Other than that use the redundant wires for other jobs
Make sure u get the harness and under driver seat fuse box with relays

Galvernisednuts · Nov 6, 2014

As I keep scratching my head I'll add more info......
The heater valve for the Tdci is used but plumb in correct flow rate see pic

Notice I added a bleed valve here too as it's quite a high point on a Tdi and it works a treat when bleeding the cooling system

I also moved the air filter onto the bulkhead where the ecu was after getting fed up of replacing those rubber bobbing mounts

You also get the benefit depending on spec to have leccy windows and central locking
I've replaced the alarm ecu 10as with the new black type and programmed it on a Tdci before fitting, with a bit of rework and an rf receiver it now uses the latest type 434 hz fobs which are fantastic for range and you no longer need to put the fob to your head

Galvernisednuts · Nov 8, 2014

And finally ........

Td5 gauges in progress

As you can see it's a snug install and you've got to get everything just right to fit

The warning panel needs special attention otherwise there won't be room for it

See below for the extra trim needed on the white bit

Just need to order a rev counter and a set of alloy rings for the gauges

Hope you like it I've had plenty of time to upload all this , am stuck at home with MRSA :-/

GATSO · Nov 8, 2014

Get well dude 😷😷nice dash work 😎

Galvernisednuts · Nov 8, 2014

Thanks Gatso
As the saying goes .......
I'll be back

aaronmorris · Nov 8, 2014

Top work dude, Looks good.

Galvernisednuts · Nov 19, 2014

Moving forwards my td5 clocks are ready to mount
Looking forward to the weekend

Feeling somewhat lighter in the wallet but the row spec rev counter is the best bit

I opted for a DT deutsch 12 way waterproof connector from eBay, can't recommend this connector enough, easy to build and good quality

I've added the rev signal wire and spliced into the harness to provide ign feed for the rev counter too
Seen as my tdci bulkhead has an alarm led wire I'll run it to the speedo to illuminate the led

I'll send a final pic once were all fitted up

aaronmorris · Nov 20, 2014

Nice work bud, I like the thought of this, but way above my head try it

Galvernisednuts · Nov 20, 2014

Now that I've made a few I'm gonna start making up the gauge panels, ideally I'll get another lot of gauges so I can test build em to ensure everything fits then offer em for sale
Glad to report I'm back at work again Hooray er Boooo ha ha

Galvernisednuts · Nov 23, 2014

Here we are all in and working

Superb illumination and they match the Tdci dash that little bit better

I'm loving the row spec rev counter

Next job will be a Tdci mud pod and more gauges from the vdo vision range

bencorkill · Nov 24, 2014

Great job looks welldone

Defender Tdci bulkhead on a 300 tdi

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