Project 90 300TDI shi**er

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What makes you think the calipers were sticking?
The disk looked like it had a good wear pattern (at least on the outer surface) and the caliper looks like it has been performing fine too... the pistons are all out equally, the pads have even wear both compared to each other and also from piston to piston.
They clearly haven't had much love and have decayed through the outer wipers popping off but i can't see any indication of sticking?
 
I know the outer seals on one caliper were out completely and touching the pads! So that's an indication that they are dangerously in poor condition.

Made some good progress recently, here are the discs. pads and calipers fitted. New caliper bolts used also, and a bit of copper grease on the pack of the pads and top and bottom areas that make contact with the caliper. Just waiting for the new hub bearings and fittings to come tomorrow.

brakes.JPG


Also decided to order new radius arm nuts, as the ones fitted had no nylon locks on them, but the old ones didn't
 
Great thread, just thought i'd point out that your genuine defender alloys are genuine discovery "castor" alloys. Same as the ones on my discovery. Also, I have the same compressor. Great bit of kit.

Mark
 
Brilliant thread, just read all 7 pages. I'll be keeping my eye on this one so I know what to do when I finally get my Landy
 
Hi All,

Time for an update. Well the Landy managed to get an MOT just before Christmas, thanks to Gumtree 4x4. I did as much of the work as I could beforehand, but alas the weather got the better of me.

The last job I did was replace the rear exhaust section.

Can you see the hole yet ?

exhaust_old.jpg


exhaust_new.jpg


The first port of call was a trip upto the top of Mill Hill in Shoreham, just up the road from me. This used to be my training ground when I competed in Duathlons.

downs1.jpg


downs2.jpg


Son and GF are having fun!

fun.jpg


Then a bit more adventurous greenlaning, through deep mud the landy was superb at Wilshires lane. This is the view from Duncton Hill Viewing point.

place1.jpg

place3.jpg


Then come a real test. We needed to make it up to Guildford over the weekend and the conditions were poor in some places. The landy again did very well, however the X5 wasn't so lucky.

guildford1.jpg


guildford2.jpg


The plan is now to tidy up a few bits. The headgasket is blowing but it's not overheating or losing water. I shall whip the head off and see if the head needs treatment. But for £180 Ive seen a place that will test, skim and rebuild the head with new valves.

I'm also going to add a few items to assist with recovery and protection, ready for some more organised off-roading fun and training.

Thanks to everyone's feedback and help so far!
 
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great thread making for a great read. thank very much. isn't it satisfying to reap the reward of hard work. enjoy it :)
 
So I fitted the Steering guard. Thanks for the advice regarding the crud. Just plenty of oil and hammering each side to get it loose.

steering_guard.jpg


Next up is the rear door swap and cleaning up the rear bulkhead.

More rusty nuts to deal with when removing the old towbar and assembley.

1.jpg


I have only managed to remove one of the 8 torx screws. Looks like the rest will have to be drilled out or hack sawed :mad:

2.jpg
 
Thoroughly enjoyed reading the whole full thread, laughed out loud at the crap on the petrol tank....

Well done Sean, looking forward to the next 8 pages.
 
Very interesting, we seem to be doing parrallel builds with all the same problems, wish id done a build thread now. Keep the posts coming.
 
Hi all,

I havent updated i na long while, as the Landy has been used regularly for duties. IT may look like a piece if **** but it's been very reliable indeed. So onto some jobs....

Here's the state of the rear cross member...

1.jpg


2.jpg


1.JPG


5.JPG


So I spent a good while researching the best approach, and decided on POR15 using the metal ready and marine cheaner process

Here's my very first effort of spraying. When I opened the can of POR-15 it appeared very runny, so I decided to give it a go through the air compressor sprayer. I'm rather happy with the results

6.JPG


Spraying was the only option to get this lot covered qiuckly.

3.JPG


I have a set of stainless steel fasteners on the way, that should top the xmember off nicely!
 
Cant quite see from the photos but have you done anything about the rust on the passenger side of the crossmember
 
may sound like a stupid question but i also have a 300tdi in my defender that someone has put in previous. looking at your pictures yours is sat much further forward than mine and your air in take can go behind, so why is mine so far back you couldnt even fit your hand behind? so my air intake is crammed out with a sharp bend that i wouldnt say is great
 
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