Ian's 90 300tdi rebuild

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must be satisfying getting rid of those cold welds.
I have to say that your fabrication and welding skills are superb, a proper job your doing there, well done!
 
I cheated a bit :D I'm a fab/welder by trade . So on to this installment the tub , this needed some major work and some home made panels .
First up the outer plates on the driver's and passenger sides door pillars were removed , they were shot at the bottom .
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Then the bottom panel the seat box bolts to and the lower panel that attaches the tub to the chassis were removed .
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then some new panels were made out of alli
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Also some new plates for the door pillars made and fixed in position .
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The lower panels were fixed in place later , next a new floor was fitted and new cappings and rear quarter panels pics on that tomorrow .
cheers Ian
 

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I had a quick look resto_d1 some good work there ,will have a better read when I get more time . so first up I found some pics of when I made the door pillar plates for anyone that's interested , got loads more pics than this but trying to not upload all as there's to many when I'm trying to catch up , so on to the door plates .
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Used a bit of 12mm bar with a slot in it to bend the returns , should have used a different grade of ally but told the place I brought it from what it was for and they said that grade it was a bit to hard .
So the tub ended up like this ,
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I then fitted a new 3mm floor to keep it all square , next it was on to the rear quarter panels and cappings .
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Then the floor was fixed in position and new top hat strengtheners from YRM and the new lower panels I'd made were fitted , the strengthening cross channels were cleaned up painted and refitted .
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I do apologise that some of the photos are out of sequence but its been hard to find all the best ones . I do have a more detailed set of photos showing were all the spot welds are on the rear quarter panels and how to remove them if anyone is interested i'll put them up .
cheers Ian
 
Well time for the next installment , first up tub bulkhead removal I'd looked round the net saw the manufactured ones I didn't want to remove it totally thought I can make one for a few quid lets have a go . So firstly removed the top rail .
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Then decided I was going to use some 40x20 I had brought for the roof rack I was making , fitted nice and looked okay .
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Then cut it out where I wanted it .
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Then slit the cross and side tubes so they fitted over the lip that was left .
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Then a test fit .
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Didn't like the corners so cut the corner piece so it fitted flush in there and decided fixing wise , the frame would be welded in situ , sides would be welded to the tub cappings and the bottom rail was drilled through rivnuts fitted the screwed down with counter sunk head screws . So you ended up with this . I did put some closed cell foam in between the bottom rail and the tub .
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Next up was to move the fuel filler as if you remember from earlier I'd fitted a TD5 tank , the filler neck frame was brought from YRM.
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So first up was mark out the hole , measurements were taken from a TD5 90 which was the father-in -laws .
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You'll notice there's 2 lines the cut was made on the inner one with a plasma cutter ( which I brought from ebay for £200 , well worth the investment) the outer line was the appeture so the first line was bent back to make the return .
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Like so ,the back was cut out also then the frame test fitted , the holes were for plug welds , it was also bonded in to seal it well .
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Welded an sanded flat . Next a small frame was made to secure the filler to the tub inside and riveted in place .
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The old hole was then filled , a plate was cut to make a snug fit then welded in with small stiches and was smothed over with filler later to make it look flush .
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The inner frame was removed but not fully as it helps strengthen the panel . Next was the access panel for the fuel tank sender , means you can change the sender without dropping the tank , makes life a lot easier . So the floor was cut at the correct distances , which I found on the internet , and edged with alli strip . You have to remove part of the floor strengthener but it looked fine and I'd upped the floor thickness to 3mm anyway.
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the side strips were then riveted in place .
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And the cut out piece was used as the cover plate .
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The plate was drilled straight through and rivnuts fitted to the straps underneath so it could be fitted down and ended up like this .
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Next up is the seat box rebuild .
cheers Ian
 

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So last bit of rebuilding for now was the seat box , all the parts were brought from the LRO show last year off YRM . As the fuel tank has now been moved from under the drivers seat to the rear then more storage could be added under the driver . And a shiny pile of bits from YRM. there was 2 new end panels , a battery box and a tool box for under the drivers seat .
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The battery compartment wasn't totally gone but was a bit cruddy so got removed ready to be replaced by a shiny new ALi one .
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This is one of the more straight forward jobs it's held together with rivets and plug welds and you only need to rivet it back together . The YRM parts are pre-drilled and come like a jigsaw so it's easy when you find out what goes where , you just need to be gentle and make sure you get all the rivets and welds out before you start to pry it apart . So plug welds drilled out down the end panel ,
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and rivets out of the top and you're left with this
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New side fixed into place with closed head rivets .
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The other side was replaced in the same way then the boxes assembled with rivets .
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Then the underside was cleaned off .
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And the 2 boxes were fixed into place with rivets .
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And the end result .
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So with only the doors left to repair and with the nice weather we were having last year I decided to spray all the parts that were ready , with the thought being that I could assemble the truck over the winter and the mechanicals could be done then as well . So next up is the spraying of all the parts and Rioja Red Pearl was the chosen colour .
cheers Ian
 
So it was time to get on with the spraying as this mean't that I'd have plenty to do over the winter , the paint was Rioja Red Pearl from Jawel paints and was good stuff . It was a 4 stage paint epoxy primer was used , then a red base coat , then the red pearl coat and lastly laquer , this was used because that's how the colour came from them and it was easy enough to spray on .
So here you go all parts were rubbed down , I did each set of parts to a finish when I did them but I've grouped the photo's together to make life easier , so sand down stage .
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The seat box , bulkhead and side panels were done as well but I can't find any pics of them , the gutter sealant was replaced as it was cracked and not looking good before painting . The inside of the wings , the engine bay side of the bulkhead and the underside of the tub were all painted with buzzweld CIO after being primered , so on to the primer .
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Then the base coat .
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And finally after the pearl coat and laquer , they had 3 coats of each with a flating off after each coat had dried .
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So that was the painting done so far still got the doors , sills and a few other bits left to do , but the main thing was I could start re-assembly . So up next is actually putting stuff back on axles , suspension , body parts , and all the other oily bits .
cheers Ian
 

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Thank you all , so next axles and suspension . Axles were blasted then under coated with Tractol then Buzzweld chassis extreme .
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All the other suspension parts were done the same , as well as hubs and swivel housings .Shiny new parts , got some Monroe adventurer shocks of ebay at a good price so went with them .
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Assembled the axle then fitted it to the chassis .
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New wheel bearings and discs .
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All sorted the brake lines .
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Not quite as straight as factory . Next up front end and another box of shiny bits .
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And assembling the front .
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And voila axles , suspension done .
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Didn't do the front brake lines as I need a new brake compensator valve , next up is assembling the body back on and I've still not caught up yet .
cheers Ian
 

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Thank you all , it has took about 18 months to get as far as I have and there’s been a lot of head scratching and stress along the way . As I said the thread was well behind I actually fitted the engine this week after I rebuilt it and there’s a custom dash and a wiper modification to come so plenty more to come .
Cheers all Ian
 
Hi all , next installment is the re assembly , so first up fuel lines fitted ,
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next up tub re-fitted ,
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access hole for fuel sender was in the right place , that was a relief .
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then a new chassis loom was made and fitted .
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Next was the bulkhead .
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next the steering was installed
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Next up the transfer box was rebuilt .
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Then the auto gearbox was given a service and a spruce up .
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fitted together and dropped into the chassis .
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Steering column was fitted .
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Then the roof and side panels , sill rails and seatbox were fitted all with new seals .
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Rear windows in,
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then the side windows were over hauled and refitted along with the alpine windows which were a rite PITA , I brought some allmakes seals and the windows wouldn't go in any way shape or form , I then brought some genuine seals and they went in , it wasn't an easy job but I definatly wouldn't buy anything other then genuine seals to do this job again .
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and the sunroof .
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Next up fuel filler ,
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brake pedals ,
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And some nice new Perei LED lights at the rear .
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So next up is the engine which should bring the thread up to date near enough , then it's the dash and center console , which I'm making myself as I'm to tight to pay £400 quid for a plastic one I've already managed to get a disco 1 auto gear lever surround in very good condition , which took 12 months as most were in a rite state that I've saw .
 

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Thank you your making a proper job of yours too from what I’ve saw , yes I’m looking forward to driving it with an auto in , have heard a lot about how nice they are .
 
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