Defender Tdci bulkhead on a 300 tdi

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ive done leccy fan and put thermostat in top near water pump also made a float switch for the expansion tank gonna wire both into the leccy fan so if water level drops too much fan will run till i top it up i bought some propper led symbol lights for dash too off ebay make it look better,am still in two minds what to do with clocks ive got td5 ones and 200 tdi with speedo cable got one with 76k original miles on it ,trying to make reliable as i can,you can make alternator bracket that sits above diesel pump if you want a second alternator ive got a vectra one i am gonna use as its got loads of amps to run all my crap,its funny looking at pic of yours it looks like the front og mine when i sanded it down had to put blocking primer on as god knows what it was painted with as it reacted with the 2k primer i tried on it.
 
air filter is mounted on the bulkhead on the tdci ecu bracket i simply tac welded it onto the bracket and moved a pipe on the intake side the engine breather one,ref lights i use clear indicators and put led bulbs in them you bust have the standard bulb holders as pins are offset for indicators ,headlights are led the fly eye type multiple leds got my pals putting them in there pajeros done two sets of them installed that is and led light bars
 
Got pic of filter bracket? Think that's what ima do now, better than the overpriced brackets and origional position no rubber mounts to replace either!
I'd say td5 clocks like I did! Isn't that hard if your wiring isn't as mixed as mine was way clearer and brighter too. Look better with the tdci interior too. Cables mess up too
Yeah defo LEDS look way better too. Can't wait to get mine finished when gets warmer days too short now no time when light. Disco just let me down again too can't wait for nice simple tdi again!
 
i will sort you a pic out sorry aint been on here for a while been building one of those 500 quid brit part roof racks for my double cab for a 100 quid lol price of the new steel tube and square tube will post pics of that too couldn't justify paying stupid money for one when i can make myself ,had to buy new mask though as all the welding with my crap mask gave me welding flash for 5 days of eye paid not nice.gonna weld tabs onto rack for four round spotlights on front and 4 square led work lamps on back two ive bought red lens covers so gonna have them as brake lights and rigged thru flasher unit as emergency lights too so standard brake lights will be flashing but in different pattern thru led unit and plenty of blocking diodes,you never know when you may need some emergency warning lights.
gonna mount 20 inch led light bar on top too as reversing light so i dont hit owt too used to my beepy things in other 4x4 crashed my car into a gate as i was waiting for beepy thing then realised i wasnt in that car big mistake and a big hole in my bumper.
got heated front screen to sort out too not sure what unit i need to use as a timer to turn it off on its own any ideas anyone.
 
gmne07966 said:
i will sort you a pic out sorry aint been on here for a while been building one of those 500 quid brit part roof racks for my double cab for a 100 quid lol price of the new steel tube and square tube will post pics of that too couldn't justify paying stupid money for one when i can make myself ,had to buy new mask though as all the welding with my crap mask gave me welding flash for 5 days of eye paid not nice.gonna weld tabs onto rack for four round spotlights on front and 4 square led work lamps on back two ive bought red lens covers so gonna have them as brake lights and rigged thru flasher unit as emergency lights too so standard brake lights will be flashing but in different pattern thru led unit and plenty of blocking diodes,you never know when you may need some emergency warning lights.
gonna mount 20 inch led light bar on top too as reversing light so i dont hit owt too used to my beepy things in other 4x4 crashed my car into a gate as i was waiting for beepy thing then realised i wasnt in that car big mistake and a big hole in my bumper.
got heated front screen to sort out too not sure what unit i need to use as a timer to turn it off on its own any ideas anyone.
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easy to get too busy to go on here! :D
yeah theyre loads for what they are! i was looking at the old transit ones, bet you could use the gutter rail fixings off them practically the same and just make a frame out of some square steel or something. dunno how much you can make it up though imagine if fell off! :D:D
you want one of those daylight mask things, we had em at work they look seethrough till arc then it blacks out so you can actually see to aim unlike the old ones! made it way easier when i was making mounts. not touched fender for abit to be fair been too busy and its too cold and too dark!
thats good idea save putting a light bar in ontop
rev light is a good idea, why not put one of those reversing cameras on if worried? easier and better than beepers. just mount in rear door or above it theyre awesome
i wasnt sure whether to bother with heated front screen since i wont be using it as a daily. but i have the screen out so might do it for sake of it. isnt much more expensive either
i think you can buy a proper timed relay for it on fleabay with a lil loom. be easy to install.
if not a glowplug relay would work i guess be about same time?
 
Yup on glow plug relay, my racks nearly done will stick a picture on here let you see it been doing loads of welding I was thinking my welding was crap till I seen a propper rack and it was rubbish compared to mine lol
 
haha welding is always crap on things like that! you dont need amazing welds anyway, 1 inch of weld should hold 1 ton
you using an arc or gas? i keep meaning to get a gas set but havent had anything big enough to bother yet the lil arc welder i have is awesome too. looks like a toaster but makes awesome welds perfect seams, way better than the old ones
 
Got mig welding with co2 did you know you can turn an arc welder into a tig by reversing polarity and using a manual tig torch with a manual gas valve on it for forty quid off flea bay .was thinking about giving it a go and if you get yaself a co2 bottle you can take it to a fire extinguisher place were they test and fill them they will test bottle good for ten years and fill it for fifteen quid lasts for ages they also can fill and test argon bottles too so worth doing tried to get them to put co2 and argon in mine but they wouldn't for some reason not bothered still does the job for me
 
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just realised i forgot to send you pictures of the way air filter was mounted onto the tdci bulkhead will sort that out getting too dark outside to do it now but will do it soon,ive had that mig for about twenty years and its still going strong it was that rusty i rubbed the front down and sprayed it with pound shop gloss black to tidy it up lol,gonna order a 100w solar panel too for the top of the roof rack so i can keep my batts charged when its standing about doing nowt cost about 90 quid for panel and control unit which dont seem too bad gonna stick and inverter on it too its costing me a bloody fortune this one and i still need to buy some big wheels and tyres was gonna leave it standard hight but am now thinking lift dont know what to do i know one thing its never gonna see the mud ever lol ive got another double cab for that pmsl.
 
that roof rack looks wicked! what kind of pipe bender did you use? guessing need a bigger on than a conduit bender?
joins are really good, looks better than most the ones you buy :p
solar is a good idea, wouldnt 2 batts be enough though? or stand for a long time?
i want to do a double cab 110 when i finish this 90. dunno if ill be happy parking anywhere cept my house incase it gets nabbed though!
wish id got another v8 instead of swapping to 300 now too. might do on next eh
haha i got my first arc welder out a skip! only had an earth fault on it was easy fix :D
new ones way better feels empty compared to old one though! witchcraft
i was just thinking of welding some tabs on and using the lil studs in the bulkhead where the ecu goes in new ones. wont have to keep swapping those stupid rubber washers then too
need to order new pipe for air intake like 50 quid rip off for some reason mine had part of a petrol pipe and half a 300 one when got lol
lil things dont think of but soon add to costs air filter cylinder was expensive too, on second thoughts could have just used a disco air box but brought it now :rolleyes:
hopefully make some money back selling the spare tdci dash
i got some boost alloys on mine at mo not sure whether to get em painted black or get some sawtooths or plain steels black. the tyres arent that great anyway. haha mines same. be too much in it to thrash it so defo gana get a rougher one for playing in
 
pipe benders off ebay goes upto inch manual bolt down to a bench jobby had to use a scaffy pole for leverage ref thickness of pipe cant remember and tossed invoice i think lol its quite thick though,bought a hydraulic one didnt work has to have the wheel to follow the pipe around so it dont kink,ive seen the same rack advertised for 700 quid bollocks to that ive just been doing it in spare time cost 107 quid for pipe will take a pic of it all done looks canny good
 
if i was you i would keep the tdci dash and fit old clocks into new cluster saves all the hassle as tdci bulkhead is different to normal one ie td5 or 300 as i found out and use the tdci heater matrix mine is lush and warm inside when engines running also removed viscos fan put leccy one on gets toasty
 
gmne07966 said:
if i was you i would keep the tdci dash and fit old clocks into new cluster saves all the hassle as tdci bulkhead is different to normal one ie td5 or 300 as i found out and use the tdci heater matrix mine is lush and warm inside when engines running also removed viscos fan put leccy one on gets toasty
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i know i am the heater is mint, just the bulkhead and dash i got together the dash was rough so i got a newer plastic dash peice so got a dash going spare now. got the bulkhead cheap so was still worth buying seperate
 
you cannit use tdci heater with old style dash you will need to use tdci one then you have the issue of the gearstick unless you use disco box this is what ive done to get round that but thinking of going auto box
 
i know i have done, i just ended up with two tdci dashes cos one wasnt in good nick, not an old one, i used disco box to avoid heater
cant stand autos!
 
haha my dad loves them, i just end up slamming the handbreak pedal thinking its a clutch! :rolleyes::D
friend at works had 4 q5s now on company cars. im getting a ranger off them soon which looking forward too, wish they had discos instead! or even an old fender haha. ranger prob be warmer though :D
 
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