Hi All, relatively new to posting on here but I'm always looking round! Had my 90 for a while now but it needs a bit of work doing rot get it how I want it so I thought I'd rebuild it. Bought as a 2.5td but fairly recently converted to 300tdi, it needs a new bulkhead, a bit of welding on the LH bulkhead outrigger, new suspension all round and the body work is a bit rough after bumping it whilst laning, I also hand painted it Matt black but it needs to be done properly!
Any suggestions or advice is appreciated! I did the engine swap myself and I like to think I'm quite logical but experience is something you can't learn!

Here is a pic, albeit not a very good one, of how it started before the rebuild! It was originally a station wagon but I replaced the ridged roof with a smooth one and van sides so there were less rattles!

After spending a little time removing seized bolts (ended up with the grinder on a few) I removed the fuel tank and the rear tub using my new engine crane! Quite useful actually!

Obviously had the seats out, roof off doors off etc, then my dad got back from work so gave me a hand removing the windscreen from a very rusty bulkhead (pictures to follow) and I also had a bit of extra time so I took out the seat box and finally the gearbox!

You can see my half hearted attempt at painting it with the outline of the snorkel! This is where it has got to so far! Everything forward of the bulkhead needs removing! The chassis is actually very solid except the outrigger, it's a little caked in mud/dirt from the past 25 years but I've wire brush a bit of it and remarkably it's in good condition!

Here is a bit of the rust on the bulkhead, I'm going to make a photobucket account to post the pictures so I can post more than one at a time

The worst rot on the bulkhead... There is a bit along the bottom of the drivers footwell too. Is it worth repairing or just bin it and replace it? I thought I would give it a chance and try to repair it but I'm not really sure! Any advice?

you can get repair panels from YRM, might be worth repairing if you have the time

Thanks doc, I'll have a look! Been looking at your rebuild thread... Gunna be a bit of a beast when it's done!

I like silly engines

Haven't had much chance to do a lot until yesterday, I've now stripped it down to a rolling chassis.
The wiring was a bit of a mess so I will redo most of that.
I've got myself a 1.2 transfer box from Mr Noisy which I'll fit to the gearbox shortly.
I'm still not sure whether to repair or replace the bulkhead. I'll strip it down and have a look at the extent of the rust!
Speaking of rust today I've jet washed the chassis, got all of the mud which has accumulated over the past few years off of the chassis and tapped over it with my welding hammer, not much extra rust than I was expecting! The LH outrigger has holes on the front and the back which I've cut out and I will weld a plate on the front and the back.. Other than that all that I found was a small section on top of the front crossmember and also in the corners on the back of the cross member.
I've patched most of it, just need to get some paint on it all to stop it going rusty again!
Remarkably the chassis and axles still have some original paint on! Not bad for 25 year old rusty metal!
I'll do more work on it over the weekend and in a couple of weeks I have a week off work so I can crack on a bit!