S884s Defender 90 Full Galvanised Rebuild
- Thread starter S884
- Start date
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Reason for sale is because they're not +2 front turrets, they're just standard height but when I purchased them I was led to believe they were +2
So didn't manage to put an update up on Saturday as didn't get chance to do anything with the landrover, however the callipers are well on their way to being another finished part ready to go back on the vehicle,
Just to show how far these have come here is the calliper before we did any work on it!
And now the refurbished piece in all its glory, have to say its quite a dramatic difference, and hopefully will make a massive change to the brakes not having seized pistons and shiny polished stainless steel ones instead!
Been in contact with Richards chassis' today also, meaning that in 4 weeks our galvanised chassis will be ready to collect and hopefully that weekend will see a rolling chassis being assembled!
Just to show how far these have come here is the calliper before we did any work on it!
And now the refurbished piece in all its glory, have to say its quite a dramatic difference, and hopefully will make a massive change to the brakes not having seized pistons and shiny polished stainless steel ones instead!
Been in contact with Richards chassis' today also, meaning that in 4 weeks our galvanised chassis will be ready to collect and hopefully that weekend will see a rolling chassis being assembled!
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So pulled the engine out of the chassis and set to one side, the chassis was then moved out with the forklift truck, this wasn't as easy as it should of been with access being minimal due to a tipper with no engine being in the way, hence the dodgy angle of the chassis coming out
once the chassis was in the air it was pretty clear to see why a galvanised chassis was 100% necessary, this is just one of many holes that weren't patched up by the previous owner
Decided to start stripping down the axle further as this is the last thing that needs prepping before every thing can be taken to be galvanising, ending up finding a pin hole in the top of the diff pan meaning we'll have to cut this off and either replace with a KAM diff pan ready for a diff lock or a heavy duty one from 'Gwyn Lewis 4X4'
Next was to remove the half shafts, these came out pretty easily with no major problems, however the half shaft seals were pretty shot, the near side one being the worst, luckily they haven't done too much damage but will need a rebuild kit.
learnt a new trick today as well to clean threads up when you really cant be bothered to search for hours to find the correct size tap, to do this you simply grind a cut into the end of the bolt, then wind it through the threads, the cut allows any crap to escape instead of getting trapped between threads, most people may know this trick, but can be useful to those who don't!
So should be shot blasting plenty of parts tomorrow including the axles so they can go for galvanising so i'll try and update again tomorrow night
once the chassis was in the air it was pretty clear to see why a galvanised chassis was 100% necessary, this is just one of many holes that weren't patched up by the previous owner
Decided to start stripping down the axle further as this is the last thing that needs prepping before every thing can be taken to be galvanising, ending up finding a pin hole in the top of the diff pan meaning we'll have to cut this off and either replace with a KAM diff pan ready for a diff lock or a heavy duty one from 'Gwyn Lewis 4X4'
Next was to remove the half shafts, these came out pretty easily with no major problems, however the half shaft seals were pretty shot, the near side one being the worst, luckily they haven't done too much damage but will need a rebuild kit.
learnt a new trick today as well to clean threads up when you really cant be bothered to search for hours to find the correct size tap, to do this you simply grind a cut into the end of the bolt, then wind it through the threads, the cut allows any crap to escape instead of getting trapped between threads, most people may know this trick, but can be useful to those who don't!
So should be shot blasting plenty of parts tomorrow including the axles so they can go for galvanising so i'll try and update again tomorrow night
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200
Active Member
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- 939
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- huddersfield
I can't believe the corrosion on the axles, my chassis was fooked but the axles and brakes were in pretty good shape to the point of every bolt undid and came out without persuasion. Keep up the good work though.
defenderdog
Active Member
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- 328
- Location
- Bedfordshire
Great build mate. I'm doing mine at the moment going on a galv and I feel your pain with all the rust. I think mine was used to launch fishing boats looking at the state of all mine. 😖😖😖😖
Yes they can be a nightmare! Mine has lived on a farm from new, meaning it's been covered in crap all the time and never been cleaned!
So as promised got some more blasting done on the axle today, didn't manage to complete it mind as there was some pretty tough corrosion sitting there, makeshift blast hut is surprisingly useful too!
So as mentioned yesterday there was a pinhole in the diff pan, I blocked this up with a small self tapping screw to stop blast media entering the diff, and well look what I found, even more 'pin holes'! the diff will therefore have traces of blast media so it'll have to be fully stripped down and cleaned in the parts bath, ahh well.
The diff plan will obviously need replacing, think we will be buying the diff pan kit for the KAM diff locks to be welded on, hoping to get cracking on now and getting plenty of stuff done seen as I have just passed my driving test
So as mentioned yesterday there was a pinhole in the diff pan, I blocked this up with a small self tapping screw to stop blast media entering the diff, and well look what I found, even more 'pin holes'!
the diff will therefore have traces of blast media so it'll have to be fully stripped down and cleaned in the parts bath, ahh well. The diff plan will obviously need replacing, think we will be buying the diff pan kit for the KAM diff locks to be welded on, hoping to get cracking on now and getting plenty of stuff done seen as I have just passed my driving test
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- 7,877
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I can't believe the rust on those components (it must have lived at the seaside, surely), but at least you have the right tools to deal with it. I especially like the improvised blasting cubicle.
700Quid
Active Member
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- The Iceni Badlands
Great work on the build mate!! Just a couple of questions for you. In the distant future, when my house is finished, I will be doing another project. If you don't mind me asking, how much is the galv costing? Where do you get your blasting media from and what size compressor do you use? Keep up the good work. Always inspiring
Just a couple of questions for you. In the distant future, when my house is finished, I will be doing another project. If you don't mind me asking, how much is the galv costing? Where do you get your blasting media from and what size compressor do you use? Keep up the good work. Always inspiring Great work on the build mate!!
Thanks! The galvanising is being done by two different places, one being a local spin galvanisers in Yorkshire because we know people who do runs there, and one place is in Chesterfield, can't remember the name of the top of my head but it is £150+VAT per ton of items you take, as for the blast media we get that from a place in Matlock called Stacey processing, when there they only sempt to sell ton loads at £70+VAT if you pick it up yourself, think to have it deliverd was more near the £150 mark, I've been selling the odd bag to people who need it but don't want to buy one ton of the stuff, the compressor is a 3 phase screw compressor that delivers 65cfm at 10bar pressure and holds 200litres I think, hope this information is useful to you, happy to help
700Quid
Active Member
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- The Iceni Badlands
Thanks! The galvanising is being done by two different places, one being a local spin galvanisers in Yorkshire because we know people who do runs there, and one place is in Chesterfield, can't remember the name of the top of my head but it is £150+VAT per ton of items you take, as for the blast media we get that from a place in Matlock called Stacey processing, when there they only sempt to sell ton loads at £70+VAT if you pick it up yourself, think to have it deliverd was more near the £150 mark, I've been selling the odd bag to people who need it but don't want to buy one ton of the stuff, the compressor is a 3 phase screw compressor that delivers 65cfm at 10bar pressure and holds 200litres I think, hope this information is useful to you, happy to help
Wow... ok, so a mans compressor then
Thanks for the info guess I'll be buying a bigger compressor!! I'll have to see if there is anyone nearer me who does the blasting medium. Its so expensive to buy in small amounts I've just used kiln dried sand so far, but my compressor is very weedy. Good luck with the rest of the build mate its cracking Wow... ok, so a mans compressor then
Well if you ever need anything of a substantial size blasting I can always try and help out the the best I can, everything I've blasted so far has gone alright
700Quid
Active Member
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Appreciate the offer mate
you may be a bit far away from me. I bought the same pot as you i just need a better medium and bigger compressor. 
AlbertDefender90
Active Member
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- 955
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- Ellesmere, Shropshire
I imagine that's what my old axles would have looked like if I blasted them but I decided to get good second hand ones instead. This build is looking good mate!!
Managed to get hold of a cheap pair of CSW side panels today, hmm maybe there will be a CSW conversion in the making..
one of the first parts we finished but never added a picture of is the fuel tank, was pretty happy with how it came out and very happy no holes were found in the refurbishment process
Also managed to get a hold of a load of stainless steel sheet, hopefully this will be useful when making all the brackets that disappeared or rotted away, just have to make sure to make gaskets to put between the stainless and aluminium!
one of the first parts we finished but never added a picture of is the fuel tank, was pretty happy with how it came out and very happy no holes were found in the refurbishment process
Also managed to get a hold of a load of stainless steel sheet, hopefully this will be useful when making all the brackets that disappeared or rotted away, just have to make sure to make gaskets to put between the stainless and aluminium!
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Not Dropped them off yet no, axles are taking longer than expected so may even be up to a couple of weeks before I have everything ready to take, will let you know before I go
So had a trip out to Paddocks today to try and collect as much bits and pieces that we need, luckily for us everything was in stock, also met a nice guy there who served us who was willing to help us out with anything we forgot or need to send back as he lives local, saving us an hour or so trip if need be
got some:
+40mm springs (F+R)
+4" pro comp shocks
+4" Brake Lines
Extended Bump Stops
Tie Rod Ends
Standard Diff Pan
Front Axles Spring Mounts
Spring Seats
All 4 Wheel Bearings
Castor Corrected Swivels
Heavy Duty Steering Arm
Diff Gaskets
Front Calliper Stainless Steel Pistons
Stub Axle Rebuild Kit
So that means we should now have plenty of parts to get the chassis rolling once it is collected
got some:
+40mm springs (F+R)
+4" pro comp shocks
+4" Brake Lines
Extended Bump Stops
Tie Rod Ends
Standard Diff Pan
Front Axles Spring Mounts
Spring Seats
All 4 Wheel Bearings
Castor Corrected Swivels
Heavy Duty Steering Arm
Diff Gaskets
Front Calliper Stainless Steel Pistons
Stub Axle Rebuild Kit
So that means we should now have plenty of parts to get the chassis rolling once it is collected
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- North of the Wall
New shiny parts are always a good thing to see. Reminds me, I've not got my bump stops yet!
