Looking good, how much was the plumbing if you don't mind me asking? I can find loads for the disco engine but not the defender.

Wow! Bit of a head f**k that (pun intended) bet you are glad you found those marks. Glad you've got it sorted.

You could always use a set of door locks and striker plates

What does the engine number start with? Intake makes it look like a disco but could be a mix and match.

The replacement chassis part slides over the old by the looks of it so you should be able to get an amount of adjustment when fitting prior to welding. Make yourself a jig with some box or angle steel and use points on your original chassis (the part that's being replaced) to bolt it to, eg...

Bolt on bits do an alternative rocker switch with up on for wiper, middle off and down momentary for wash. But they seem to be out of stock on eBay and put the price up just to keep the listing live.

Personally I prefer the steels. On another point are those alloys rated for the weight of the 110?

Also has the advantage that if you do move later you can take it with much more easily (depending upon how you build it) and timber is often warmer without fitting insulation etc.

I can't remember what the access to them is like, have you got a picture? If there is space you could drill them out or it has been know for easy outs to be used to remove roll pins BUT if you snap one in there you are in for a real headache!

If you can't grip them to pull them out can you not use a fine punch to collapse them in on themselves to allow removal?

5mm flat bar is quite easy to bend (through one plane cold the other is much easier with added heat) but rigid when bolted up into a triangle between tow point and chassis. Make a cardboard template first then with heat, a hammer and a vice or similar immovable holding device(street furniture...

Also a decent blow torch would get it hot enough to bend by hand.

Which way would it need bending? ie across the wide section or 90 degrees to it.

Can you not just make some new bars that reach between chassis and tow plate?

Remember though if it's the full width bonnet protector rather than the one that sits down in the depression it will lift the wheel an inch or so, and not sure how kind chequer plate will be to the tyre's side wall.

With ex MOD bikes you get it insured on the vin number, then take it for an MOT, fill in the DVLA V form and send it to the DVLA with the money for road tax (sometimes with a photo or rubbing of the vin number) and MOD release paperwork. You then either get your registration docs sent through to...

Looks like a handy tool don't suppose you've got a link? Edit, found it http://www.frost.co.uk/automotive-special-offers-bargains/brake-die-vice-mount-set-for-bending-sheet-metal-125mm-5-inch.html

It's surprising what you can find in new stuff sometimes, I stripped a brand new grease gun once to find it full of machining swarf from it's manufacture o_O

Have you got a link to those at all?