Refurbishing my 1997 defender 300 TDI

marksman · Mar 10, 2018

As the title, I'm about to start my refurb. and would like recommendations regarding what best to carry out based of other members experiences so far on my list are

1, Galvanised chassis
2, Bulkhead repair / galvanising
3, New brakes all round
4, New STD suspension all round
5, Buzz weld cavity wax and chassis in one
6, Full fluids change
7, Timing belt change
8, Full re spray
9, New clutch &master cyl, check rear crank seal

Budget is not limitless

Anything else I should consider

Kwakerman · Mar 10, 2018

Chuck a clutch in while the engine/gearbox is out unless it is very new. Will be a lot easier doing it now than when its installed

marksman · Mar 10, 2018

Thanks I now I have this on my list, new clutch, cyl. & flywheel, check rear crank seal at same time

marksman · Mar 10, 2018

Wheel bearings renewed at the same time

landy-lee · Mar 10, 2018

lots of photos please!!!!

Flossie · Mar 10, 2018

New brake pipes.

zeaphod · Mar 10, 2018

I'd add fitting led sidelights and indicators, maybe a boomslang headlight harness. If you fit a galvanised chassis you won't have to worry about injecting wax , in my opinion. Don't forget to budget for new fasteners all round.

Kev12 · Mar 10, 2018

Bushes & bolts, A-frame ball joint, exhaust rubbers, steering ball joints. All cheap parts and much easier to change while you have it in bits. Possibly swivel rebuilds unless they have been done recently.

neilly · Mar 10, 2018

Wiring in for extras, Lights , fuse box with extra outlets, , etc etc. so you are not adding to it later.

Making the wiring harness "big" enough to avoid the normal LR issues and have excess earth cables.

Cheers

Al2O3 · Mar 11, 2018

marksman said:
As the title, I'm about to start my refurb. and would like recommendations regarding what best to carry out based of other members experiences so far on my list are

1, Galvanised chassis
2, Bulkhead repair / galvanising
3, New brakes all round
4, New STD suspension all round
5, Buzz weld cavity wax and chassis in one
6, Full fluids change
7, Timing belt change
8, Full re spray
9, New clutch &master cyl, check rear crank seal

Budget is not limitless

Anything else I should consider

You'll probably need to do a fair few body panel repairs. Particularly the front of the tub and where it bolts to chassis. YRM do a very solid, galvanised repair section. If you are going that far then get galvanised cappings for the tub. You can also get galvanised rear floor struts. Check out their site for ideas YRM They could well be close to you, depending on where you are in Durham.

EDIT
As you strip it down you will see what you need to add to your list

mick the builder · Mar 11, 2018

Have a couple of grand in a slush fund.

zeaphod · Mar 11, 2018

mick the builder said:
Have a couple of grand in a slush fund.

And then be prepared to spend more as you go along and find "issues"

Jan the man · Mar 11, 2018

Not sure if you bought a galv chassis, but you can try Shielder. I got one for £1400 delivered and it includes a gearbox Xmbr. From there on, it's safe to go mad and buy everything new. Yep, the pit gets deeper!

Mo younesi · Mar 11, 2018

Hay Mark, good luck mate. Sounds like that you are going to be very busy for somtimes. Given the extent of refurbishment you are planning, I would say brand new wiring loom could save you a lot electric type hassels in future.
Cheers.

Foxyred · Mar 11, 2018

Loads of little bits and bobs soon mount up in price, While you list the big items the bolts/washers pipes and clips cost little money they all add up and you will find issues you wont know about until you strip and rebuild.
Good luck its a long road ahead

Sting Ray · Mar 13, 2018

See here for inspiration/potential pitfalls. It's a bloody expensive affair!

https://www.landyzone.co.uk/land-rover/sting-rays-89-90-complete-restoration.317719/

marksman · Mar 13, 2018

Thanks,
I'm adding suggestions (clean ones) as I get them, I'll keep the thread updated as I proceed

Jimsky Korsokov · Mar 13, 2018

I'd include a slick-shift in there - put one in mine and it makes the whole driving experience better. The cheapest mod for the most reward! Great video from the guys at Tirsbaek TV

marksman · Mar 13, 2018

Had one fitted to my Impretza, does it make that much difference on a Defender ?

Jimsky Korsokov · Mar 13, 2018

Mine was a bit like stirring a bowl of porridge - the slick-shift made it tight and driveable by the whole family - almost like a proper car (how do you go from an Impretza to a Defender?)

Refurbishing my 1997 defender 300 TDI

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