James Mac's Defender 90 Rebuild

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mick the builder said:
Looking good mate.
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cheers

GATSO said:
WOW O WOW SHE IS LOOINK FOOKIN ACE ,,,its great when they start comimin together,great work !!!!!!!!!!!
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hopefully it'll be almost as good as yours

defenderdog said:
Hi mate. Great build. Must get on with mine😩. Did you make up your brake pipe work. If so was it hard.
Keep up the great work. 👍
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Yeah i made my brake pipes myself, just buy a flaring tool off ebay and crack on, iv got a franklin one that cost me about £20 and it does the job perfectly.

MayorQuimby said:
What did you do regarding your earths in the end?
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nothing as of yet, i just sprayed the whole chassis so I'll have to take some paint off at some point to fit them :(
 
So, Iv put a fair few hours into the Landy today. First job was to put the axles under the chassis and get it rolling, easier said than done. It took me ages to get it all together. It looks great having axles complete with everything on but then they didn't want to fit but after a few hours of messaging about i sorted it :)



Had to put some improvised weight on the front to get the radius arms to fit in the chassis properly :-D
Good job there's some sand bags kicking about in here

 
After I got it rolling I decided to for the rear A frame. That didn't go to plan either but after an hour or two I persuaded it to fit :)

The I fitted the gearbox crossmember so has to jack the chassis open slightly to get it to fit but I believe that's the case with most galv chassis.



And then my Snap-on Impact gun decided that it wanted to stop working. To be fair I have had it for around 6years and only paid £100 for it in the first place but still, that's something I could of done without. Anybody know how to fix them?



Then I fitted the bump stops and that is about it for today, the plan for tomorrow is to Dintrol the inside of the chassis, and then put the engine on. So hopefully that will all go smoothly.
Here's a few more pics after I finished today



 
And I also realized Iv put a kink in the NSF brake pipe when fitting the track rod so I'll have to make a new one at some point :)
 
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First job this weekend was to dinitrol inside the chassis, so I did that and got it everywhere in the process :)



Next I attached the new pan hard rod, and sort of out the steering damper in place, I'm
Waiting on my steering box coming back from being reconditioned so once I get that I'll be able to attach it all up.



My next job was to put the engine on, so I attached the new mounts and lifted it into place, had to strap the back down for now as it leans forward a lot because the gearbox isn't attached yet, and I didn't want all the extra stress on the mounts. But it's in for now :)




And then I spent most of today cleaning thing up ready to go back on, vacuum pump, PAS pump, altinator, starter, bell housing and I'm sure I did some other stuff too.
I need to order myself some gaskets now and a clutch kit so when my gearbox gets back I can attatch it up straight away :)
Overall it's been a successful few days :)
 
aaronmorris said:
Nice work mate. Looking very good :) I want another project, getting withdrawal symptoms :lol::eek:
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I bet you are, you always seem to have a project on the go!

Iv almost done as much as I can now before I need to start to striping my 90 down. And I can't start that as I'm moving with work and not going to have a workshop for a while. So I'm going to have to mothball it until I find somewhere to continue with the rebuild.

Or I could bring it around to you and you could finish it for me :-D it'll only take you a weekend :) lol
 
Looks great mate. Is that an adrenalin a-frame? How did you find fitting? Mine was a nightmare! Also what kinda torque you put on the castle nuts?
 
mikeh501 said:
Looks great mate. Is that an adrenalin a-frame? How did you find fitting? Mine was a nightmare! Also what kinda torque you put on the castle nuts?
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Yeah it's an adrenaline frame, was a pig to fit but I got there in the end, it's not adjusted up properly yet as I wanted to wait until there was some weight on the chassis but it is in the hole. I'll probably just do it as tight as I can and then put the split pins through both sides, that way the torque shouldn't matter as much as the split pins would hold it tight.
 
Looking good mate!!!

If the batteries on the impact gun are still good then it would be worth taking to your local snap on dealer for a refurb. I sent my drill when the gearbox blew up and they refurbed everything other than the casing for £75 :)

I don't like picking out flaws in peoples work but are you sure those diff guards are the right way round? I'm sure the curved cutout should be on the filler plug side of the front pan?
 
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James_mac said:
Yeah it's an adrenaline frame, was a pig to fit but I got there in the end, it's not adjusted up properly yet as I wanted to wait until there was some weight on the chassis but it is in the hole. I'll probably just do it as tight as I can and then put the split pins through both sides, that way the torque shouldn't matter as much as the split pins would hold it tight.
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glad to see i wasnt the only one, and we both put it the right way up lol! I reckon my build is about 4 weeks behind you at current rate of knots. I have the rear end done, but the front end is built up but without swivel balls so its resting on the floor :)

I went with gwyn lewis kit too, but all galv rather than blue. I had the radius and trailing arms from adrenalin though.
 
AlbertDefender90 said:
Looking good mate!!!

If the batteries on the impact gun are still good then it would be worth taking to your local snap on dealer for a refurb. I sent my drill when the gearbox blew up and they refurbed everything other than the casing for £75 :)

I don't like picking out flaws in peoples work but are you sure those diff guards are the right way round? I'm sure the curved cutout should be on the filler plug side of the front pan?
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I think that's what I'm going to do with my gun, either that or just buy a new one.

The diff guards only go one way, not sure why it's curved on that side but that's just the shape of them.

mikeh501 said:
glad to see i wasnt the only one, and we both put it the right way up lol! I reckon my build is about 4 weeks behind you at current rate of knots. I have the rear end done, but the front end is built up but without swivel balls so its resting on the floor :)

I went with gwyn lewis kit too, but all galv rather than blue. I had the radius and trailing arms from adrenalin though.
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Nice one mate, it's great when you get something that resembles a landrover again.

Gwyn's suspensions kits are the best you can get, i got the adrenaline radius arms too but my trailing arms are from Gwyn.
 
Spent a couple of hours on the landy today, got the clutch fitted then attached the gearbox and transfer box and put the mounts on for them.
Hopefully I'll get a few more hours in tomorrow :)

Only took a few pics today.





 
I fitted new flanges to the transfer box, which then enabled me to put the new propshafts on, i tightened the front one up but left the rear loose as I'll have to take it off when I fit the disk brake conversion for the handbrake.
 
After that I decided it's time to pain the galvanised bulkhead, so I gave it 2 coats of high build primer, let it dry overnight. Then I flattened it in the morning, wiped it down the sprayed the top coat. I'm surprised how well it turned out, it's not perfect, there's a few pin holes on it but it's good enough for me. I wasn't sure if I liked the colour but it's not too bad, the colour in the pics isn't quite accurate.





Once I get it out into the light I'll take some more pics of the colour
 
wow ure ahead of me by a long way now keep up the great work ,,,may have to pull ma finger out and get some done on mine ,,,,,,,,,,will be winter before i know it lol ..,
 
GATSO said:
wow ure ahead of me by a long way now keep up the great work ,,,may have to pull ma finger out and get some done on mine ,,,,,,,,,,will be winter before i know it lol ..,
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Cheers mate :-D
Iv pretty much done as much as I can do now. I'll attach the bulkhead at some point this week and then the rebuild will be put on hold until I can take my 90 off the road so you'll have plenty of time to overtake me :)
 
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