Rebuilding my 90
- Thread starter GATSO
- Start date
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mick the builder
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- Sligo,Wild West of Ireland.
Looking good. Glad to see this one moving again. Are you using any of the old parts or are you building a brand new one??
well ventured into the not so cold now garage to do some on the lanny (has you do)so leisure battery for my garage lights flat ,,,,,,,,so hook up the freshly charged lanny battery ,,,,,pop inverter chucks its hand in so onward and upward out comes the led torch !!!!! managed to fit new gen wiper wheel boxes wiper motor and cable ,sound proofing back on tdci dash support bar and fitted wiring harness , I'm fitting tdci bulkhead with all its gulament ,,so I've managed to route 300tdi harness to get the fuse box to line up with the position of the old tdci unit and can mate the two fuse holder mounts so as to retain access panel under column as per puma set up will now have to extend wiper motor wires to reach but i have full tdci loom to cut what i need for that and also to re locate hazard switch and heater control wires to mate to tdci heater motor will also need to extend or make a link loom for nearside lights as they are now12 inch to short but thats the easy bit lol ,( pictures on next post )fitted some of the dash and carpet brackets i had plated last year so its nice to start bolting some shinny bits on !!
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They're all shiny bits 
alexc2701
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Hi gatso, I'm on a similar project 90; I've got a 300 tdi rebuilt on a galv chassis with a disco r380 box. Was wondering what you plan on doing with the clocks (I'm thinking td5 clocks in a custom housing) sadly my wiring is an absolute cobweb. And what are you doing with the gaitors for gear/hi/lo leavers? As not fit the standard. It looks great mate wish mine was as shiny! And my garage was as big lol
my 90 has 200 with Disco R380 and l cut the top off the tunnel where gaiters fit and riveted it on further back. Gaiter just turns back to front and fits lovely, had to fill hole in tunnel with some ally. I welded a longer stick to the Disco lever cause l like a long one : )
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alexc2701
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This is what I was thinking, since I'm using the puma dash I got an old 200 gear tunnel fibreglass one off a friend and an old style gaitor. I was thinking riveting that to my custom housing I made and using the gaitor back go front. But the angle seems bad on the gear stick? I have an old defender lever i was going to adjust to a more sideways bend towards driving seat (also prefer the long bendy ones) but the gaitor doesn't seem to sit too amazing. Hard to tell as I don't have a lever to put on yet. Was gana chop the Disco lever and tap the defender one into it so as to still use the clamp. Do you have any pics of yours in the cab? Or still in progress? I'm wondering what to do for soundproofing and carpet/rubbering up as I've got puma dash td5 seatbox and the further back gear levers. It all seemed to make sense in the beginning haha.
alexc2701
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Me too. Did yours sit about here?
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alexc2701
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Yeah I've used some 2mm steel plate, might put a strengthening rib of angled steel in too. Not sure if needs it still sits stiff
Gana use a defender handbreak though so I can still put a chubby box in. Tight with cable and how bend is but works. Pit the plates in and gana do floor panels and handbreak tomorrow. Hope it doesn't need adjusting just done all prop bolts. Not sure whether to do front prop changed back one and with 2" lift kit the front is already pretty extended when sat still
alexc2701
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Good idea, I wanted to used the td5 out my disco but I realised be alot of work haha. Plus I can do everything on a tdi or learn how. bit more simple lol
if guys you can see in the pics I've made a new gear selector housing so gear stick comes through puma tunnel and I'm altering a disco hi lo lever cable operated and modified to do dif lok ,so tdci tunnel and sticks will be altered to fit so when you look inside it looks like a six speed box
alexc2701
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Ah so you've adapted the box to meet the puma tunnel? I thought it looked diffirent just assumed a later version r380 or something! So will yours sit side by side like the tdci? I altered mine to have the diff lock but still using the standard stick layout. Don't know enough to do anything like what you've done I'll be honest haha. First rebuildif guys you can see in the pics I've made a new gear selector housing so gear stick comes through puma tunnel and I'm altering a disco hi lo lever cable operated and modified to do dif lok ,so tdci tunnel and sticks will be altered to fit so when you look inside it looks like a six speed box
alexc2701
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Like it. Think ima do something similar. Did you put a bend forward inside the rubber to stop it bending too far back?
Think ima do this on mine maybe not quote as long. Should fit bit less room with the puma dash though sits farther back
