Hi all, rebuilding my D90 on a new Marsland Chassis I thought it would be a straightforward swap for the Dixon Bate tow bar that came off the original chassis, how wrong I appear to be. Is it safe to bolt the tow bar to the lower captive nuts in the rear crossmember and the angle below?

Thanks Mick, A friend of mine is trying to convince me to paint it too! Lots of zip locks and boxes of parts. The car is described by my wife as Triggers Broom, giving the volume of deliveries

Engine now in situ, never easy on your own. Scratched the front of the chassis and the Buzzweld chassis in one paint came off too easily, thus doesn’t bode well for the chassis in use, time will tell. Been connecting the electrics and it is now that the copious photos come in to their own as my...

Mystery, you may just have provided the answer. Could be the diff lock switch.

Thanks guys, to answer AL203, the loom exits the chassis through a large hole into the engine bay at the bulkhead. Having looked again at the old loom, this wire has been “repaired” and has a female spade connection which makes me think it must have been in use. Scooby22, the car never had a...

I’m restoring my Def 90 200tdi and I have replaced the chassis wiring loom with a new one from AutoSparks. Nothing wrong with the loom, my query is what is this wire for? It is separate / branches from the loom as it exits the chassis in the engine bay. I have the old loom but has been so...

Managed to get the gearbox into place and fit the fuel tank. Axle breather pipes to be fitted next whist I still have easy access, oil into the axles and run fuel line before prep for dropping in the engine. Biggest step is to get the quote for painting all the panels:-( Then strip off the tub...

I just added some additional electrical tape to protect it from any rough edges inside the chassis. I will check each wire to earth to see if there is any interference or shorting before closing everything up. It does help that you can see through the various holes in the chassis to see the...

Finally took the step to drill the mounting holes in the tub. They say measure twice cut once well, I measured about fifty times and drilled once, all good so far. The Marsland chassis comes with an adjustable bar with the mounting tabs, once that is set it should be all ok, getting there brings...

The steering box and linkages now fitted into position. Not without issue as the new steering arm for the steering box was fitted yet the nut would not turn more than 1/2 to 1 turn. Not wanting to force it, I ended up buying pitch gauges to verify the nut and steering box shaft were indeed...

Test fit of the rear tub. Still to check final alignment and drill the new panels for fixing sills and to rear cross member. I’ll take it off and continue the build, it won’t go to paint until near the end once all other items are prepped.

Thanks Steve, not dissimilar on the Defender, it looks like i just need to find a suitable point to mount the bracket onto the chassis and ensure the flex hose is free top move with the axle articulation.

Thanks Steve, I’ve got these diagrams, it’s more of the physical routing / location i need. I suppose it is limited by the length of the flexible pipe

Finally some real progress, albeit difficult and awkward given I am working on my own with some of the larger lifts etc. Bulkhead on, suspension fitted but not yet torqued up as I need more weight on the chassis, I don’t have a ratchet strap to close up the gap between chassis and axle, will...

Sourced.

Defender 90, 200tdi

Hi, Looking for gearbox / transfer box chassis brackets for an LT77 gearbox on my 200Tdi. I need both brackets, anyone breaking a vehicle? Bill

Really pleased I’ve got to rolling chassis over the weekend, need to remember to torque bolts etc once more weight is added. Feels great to be actually building now.

Painting the chassis commences and the pressure is on to get it completed before the weather changes, as I’m doing this in a lean to work area with horticultural wind break for sides!!!

It has finally arrived after 12 weeks when told 4 weeks!! Hopefully have it painted this weekend.