200tdiRob
Active Member
I'd say go for it. The YRM repair sections are great. Pretty much anything on the doors can be repaired if you have the time and the patience. I only bought a new door as I was in a time crunch to get stuff to the painter. Probably better to repair than buy as everything defender seems to cost a bomb now!
IamRobbie
Well-Known Member
Everything defender has shot up to stupid price. Although it's dropped back down slightly. I simply refuse to purchase anything off anyone who wants a stupid price no matter how desperate I am for parts
200tdiRob
Active Member
It's the small stuff that really seems to be ridiculous. I was looking at the small copper washers that go on the fuel filter banjo bolts and they we're £2.50 each!
crazy. I'm trying to buy good condition genuine stuff now for things like the seatbelts and various brackets I need to try and help keep the spend down.
200tdiRob
Active Member
Managed to get a bit done the last couple of weeks. Got the bulkhead back from the painter so set about filling it and the chassis with Dinitrol to try and keep the rust at bay for a while. Before I took it too the painter I gave the middle sections a coat of corroless rust stabalizing primer. Went for Bonatti grey for the colour in the end and pretty happy with how it looks.
Bulkhead hung up ready to be primed
Primed before it went to the paint shop
Painted
Bulkhead on and chassis filled with Dinitrol
Also managed to get the front anti-roll bar fitted. When I ordered the chassis I forgot to spec the front mounts for the front bar so I had to buy them from YRM. The mounts are normally welded onto the chassis but I didn't like the idea of having to grind off the galv on the chassis to weld them on. I opted to weld some tabs onto the brackets then use rivnuts in the chassis to bolt them on.
Stainless rivnuts fitted to the chassis:
Mounts all bolted up with stainless bolts:
Went to fit the rear anti-roll bar but found out that the wrong bushes and u brackets come with the kit paddocks sell. Be warned if you buy the roll bar kit from paddocks that say "Fits all defenders" it doesn't. If you have a td5 spec'd chassis you will need different rear bushes and brackets. Tried emailing paddocks to query this and see if I could get supplied the right bushes but never got a response so I've had to put them on the next order.
Bulkhead hung up ready to be primed
Primed before it went to the paint shop
Painted
Bulkhead on and chassis filled with Dinitrol
Also managed to get the front anti-roll bar fitted. When I ordered the chassis I forgot to spec the front mounts for the front bar so I had to buy them from YRM. The mounts are normally welded onto the chassis but I didn't like the idea of having to grind off the galv on the chassis to weld them on. I opted to weld some tabs onto the brackets then use rivnuts in the chassis to bolt them on.
Stainless rivnuts fitted to the chassis:
Mounts all bolted up with stainless bolts:
Went to fit the rear anti-roll bar but found out that the wrong bushes and u brackets come with the kit paddocks sell.
Be warned if you buy the roll bar kit from paddocks that say "Fits all defenders" it doesn't. If you have a td5 spec'd chassis you will need different rear bushes and brackets. Tried emailing paddocks to query this and see if I could get supplied the right bushes but never got a response so I've had to put them on the next order.
200tdiRob
Active Member
Got a call from the painter saying the tub was almost ready to be picked up so needed to get the fuel lines to the rear td5 tank run and also a few other jobs finished before fitting it.
Used some fuel line hose I got off eBay and clipped it to the chassis rail up to the engine.
As the tank is now at the back the original tank sender loom was too short. Luckily my chassis loom had the connector at the back which made wiring in the sender in the tank easy. Wasn't sure what the connector was when I stripped the loom out of the old chassis and thought it was maybe a socket for a tow bar as nothing was plugged into it. After some googling I stumbled across a pic of a 110 fuel tank connector which looked exactly the same. Ordered the connector (part number AMR1494) but had to cut off the sender end of the loom as it was only 2 pin plug and swap it for a 4 pin plug that fits the Row spec sender. Also lengthened the loom at the same time so it reached.
Pic of the new loom before altering it.
Pic of the loom altered and fitted
Next job was to make the brake line from the brake valve up front back to the rear axle. As I'm running a td5 rear axle I had ordered a 200tdi braided brake line kit I had to make a bracket to move the tee piece forward so the flexi line reached.
Got a few jobs done on the bulkhead too. My heat reflecting closed cell foam was delivered so stuck it around the bell housing area the same as on the original bulkhead.
Also got the inside of the bulkhead covered in Dynamat to try and help with noise reduction. Made a load of paper templates to make sure I had minimum wastage. Used 4 sheets in the end.
Once the Dynamat was done I fitted the wiper motor assembly and the lower dash.
Last job this week was to alter the wiring on the wiper stalk/indicator stalk assembly. When I bought the new td5 bulkhead it came with all the wiper stalks and indicator stalks. As these were in alot better condition than the original ones I had I wanted to use them rather than buying new. The only difference the td5 ones have to the 200tdi ones is the plugs. The td5 ones have better plugs but it was easier to swap the plugs on the stalks rather than cut up the main loom to splice the newer type connectors in. The wiring on the stalks is easy enough to swap being bullet type connectors. I only had to cut and solder two wires on each stalk to swap them over. The two wires are the ones that run inside the stalk for the horn on the one stalk and the window washer on the other.
All swapped and ready to go
Used some fuel line hose I got off eBay and clipped it to the chassis rail up to the engine.
As the tank is now at the back the original tank sender loom was too short. Luckily my chassis loom had the connector at the back which made wiring in the sender in the tank easy. Wasn't sure what the connector was when I stripped the loom out of the old chassis and thought it was maybe a socket for a tow bar as nothing was plugged into it. After some googling I stumbled across a pic of a 110 fuel tank connector which looked exactly the same. Ordered the connector (part number AMR1494) but had to cut off the sender end of the loom as it was only 2 pin plug and swap it for a 4 pin plug that fits the Row spec sender. Also lengthened the loom at the same time so it reached.
Pic of the new loom before altering it.
Pic of the loom altered and fitted
Next job was to make the brake line from the brake valve up front back to the rear axle. As I'm running a td5 rear axle I had ordered a 200tdi braided brake line kit I had to make a bracket to move the tee piece forward so the flexi line reached.
Got a few jobs done on the bulkhead too. My heat reflecting closed cell foam was delivered so stuck it around the bell housing area the same as on the original bulkhead.
Also got the inside of the bulkhead covered in Dynamat to try and help with noise reduction. Made a load of paper templates to make sure I had minimum wastage. Used 4 sheets in the end.
Once the Dynamat was done I fitted the wiper motor assembly and the lower dash.
Last job this week was to alter the wiring on the wiper stalk/indicator stalk assembly. When I bought the new td5 bulkhead it came with all the wiper stalks and indicator stalks. As these were in alot better condition than the original ones I had I wanted to use them rather than buying new. The only difference the td5 ones have to the 200tdi ones is the plugs. The td5 ones have better plugs but it was easier to swap the plugs on the stalks rather than cut up the main loom to splice the newer type connectors in. The wiring on the stalks is easy enough to swap being bullet type connectors. I only had to cut and solder two wires on each stalk to swap them over. The two wires are the ones that run inside the stalk for the horn on the one stalk and the window washer on the other.
All swapped and ready to go
200tdiRob
Active Member
Got this little lot back from galv so can now start reassembling the heater box and steering colomn. Also finally got the bulkhe ad supports fitted to stop it wobbling around
Also got all this lot to start the process of wiring in the td5 dash binnacle and centre console.
Also got all this lot to start the process of wiring in the td5 dash binnacle and centre console.
200tdiRob
Active Member
All looking very shiny.
Awesome work, mate. Looking superb.
Cheers for the kind words bud
mick the builder
Well-Known Member
Nice work, keep the photos coming
200tdiRob
Active Member
Ha maybe! I get up earlier than her so I'll have first dibs
Great tip about the wiper wheel boxes. Hadn't even thought of that! That's why I love posting on this forum. Loads of great friendly advise.
200tdiRob
Active Member
I was a bit like that at first. If you can get hold of a wiring diagram which shows wire colours it makes it alot easier. Just a case of being methodical doing a bit at a time and double checking things with a multimeter.
Saying that I've yet to hook up a battery yet to properly test it. May go bang yet!!!
Ash2304
Active Member
I was a bit like that at first. If you can get hold of a wiring diagram which shows wire colours it makes it alot easier. Just a case of being methodical doing a bit at a time and double checking things with a multimeter.
Saying that I've yet to hook up a battery yet to properly test it. May go bang yet!!!
Ive got a Haynes but that's as close I've got unfortunately. Doesn't help that none of the lights or the fuel gauge worked before I stripped it down
so I don't even have a good base to start with! Shall look forward to more updates
200tdiRob
Active Member
A very expensive box turned up this week which put a big smile on my face. My fully reconditioned turbo back from turbo techniques.
It came with a graph too showing the before and after.
Also got this from Gwyn Lewis to fit the double battery setup I'm going to run and all the kit so I should be able to wade without fear of filling the axles or engine with water
Been doing some more painting now the weather has warmed up a bit too. Got the handbrake drum, clutch pedal assembly, steering column and heater box painted in corroless to try and keep the rust at bay once it's all fitted back on.
Spotted this on eBay and had to have it. It's an original defender 200tdi owners handbook. It's mint! All the service stamps are blank ready to start fresh when mines finished and back on the road.
It came with a graph too showing the before and after.
Also got this from Gwyn Lewis to fit the double battery setup I'm going to run and all the kit so I should be able to wade without fear of filling the axles or engine with water
Been doing some more painting now the weather has warmed up a bit too. Got the handbrake drum, clutch pedal assembly, steering column and heater box painted in corroless to try and keep the rust at bay once it's all fitted back on.
Spotted this on eBay and had to have it. It's an original defender 200tdi owners handbook. It's mint! All the service stamps are blank ready to start fresh when mines finished and back on the road.
