My Defender 110 300TDi Rebuild

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Ya doing a great job though! chassis does look like its knacked but worth a careful going over as may just be out riggers and bits that need doing, so dont lose heart!
Even if a replacement is needed you will end up with a fab vehicle :)
 
So here it is all stripped to rolling chassis and then to when we cut it up!!! Not much use now but for cans!
















All that's left was a pile of scrap!
 
So here is the second hand chassis I got my hands on. Ok it's not galv but I didn't have the money at the time so it was the best I could do. Need a new rear cross member and very small welding works other than that it was a solid chassis co paid to what I had.



Here is the new cross member we built from scratch. No patten part for me. Like I said before very very thankful for my brother being the welder! Lol





Don't hit me I am very thick! Lol



Here it is fitted and complete with my new fabricated towing bar etc. also built from scratch. Made this very strong as I didn't want it falling off again. But also made it completely removable so when not in use I can take it off and pack away also better ground clearance off road. Sorry picture is upside down.


 
Up the right way. Welding in this picture not finished at this time.



Tow bar removed.




Ok bit of a jump but from finishing the welding I had chassis painted and then I Schultz it over and over again. Got myself new springs and shocks. Swing arms a frame etc etc. it was a 2 inch lift kit.












All new gaskets for axle rebuild swive joints poly bush kit etc etc. I couldn't save anything from the old parts. The list went on and on.
 
Got lots more pictures to upload so will do more soon. I have been doing this for over a year now so build is a lot further on this. I'm to the point of putting side panels back on etc so lots to come. Hope I'm doing it right. Lol
 
Thanks for all the great comments. Glad you all like it. This is my first defender so was worried I might not be doing things the right way etc. wouldn't be able to do it without my brother. Neither of us are mechanics in any way he is a welder and I'm a electrician so everything is self taught. We have also restored a mk1 golf before and a classic mini. But by far this defender is the most fun and easiest to work on.
 
Ok so more pictures.

Engine and gear box etc back in. Not much done to this.......... Well that's a lie.
All main gaskets and oil changed on engine and gear box and transfer box
Prop joint on transfer box changed it was abit slack
Exsaust gasket changed on turbo etc
Timing belt changed twice!!!!! Yes twice!!!!!!
After installing the first one all timed up and gaps adjusted between rockers near belt bearing etc etc it lasted 45mins. I had a major bearing fail. The new one. It locked up for some weird reason. Belt got very hot slipped off and jammed it all up. This in turn bent most of the push rods. So after rebuilding all that again and putting on another new belt kit all was well. Apart form my wallet.!
You live and learn I'm no mechanic so hay ho.







 
Here is my rebuilt seat box which was a right mess.
Also in picture new fuel tank and fuel lines etc.




Also thanks to my brother a fully stainless exsaust system from turbo back going to side exit. gains me a little hight in water and looks cool.lol

 
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