the parent metal needs to be hot hot hot too, people forget that.

awesome info from @jamesmartin. I've got this exact problem and my engine was rebuilt by a professional outfit. I'm guessing I've a loose pickup or a loose squirter as the oil pump is new. Will update once I confirm what oil pressure I actually have, but at the moment oil light is flickering...

jeez. no frogs I hope. But sand.... that's harsh

rainwater does me ok.

Dimmable led's need an led dimmable switch and the led's need to be dimmable too but my information comes from domestic lighting which what I said is true.

You can use the old races, just grind em down a bit. I used a drift, gently gently and I was fine. Going at it like a cave man wouldn't be a good thing !

https://www.ebay.co.uk/sch/i.html?_odkw=UV+Dye+%26+Torch+Kit&LH_PrefLoc=1&_osacat=0&_from=R40&_trksid=m570.l1313&_nkw=UV+Dye+oil&_sacat=0 The above gives you some of the dye I was looking at. The dye needs to be oil specific by the looks of things.

UV Dye with UV torch, I need to do the same as I suspect the head gasket is leaking but the oil is everywhere at the moment

screwdriver and hammer, hoping the screwdriver to bite in ?

those retaining rings I used a small tack hammer, a very small one ans tap tap tapped it in as they caught on their way home. I did slightly dent them but I thought it made them stay in the recess more firmly.

receiver hitch is the best option as you can take the hitch off to give you ground clearance if you plan to go offroad. However if you don't plan to need the use for offroading then the dixon bate is probably the best option.

what kind of vacuum should one expect from the vacuum pump, just out of curiosity. I do have a vacuum gauge and i'd like to measure mine.

new bearing shells and new piston rings with a freshly honed cylinders. I'm no pro engine builder, but if it were me id get the hone done at an engine shop with a proper honing set up to get the angles correct and even. Couple that with with measuring the cylinder wear to see how egg shaped...

New galv chassis is what I would do. Your chassis looks beyond worse than mine, and i debated to fix mine, and whilst I tried to give it a go, what i found is that the rust went much further than it appeared, all on the inside of the box sections. By the time I would have fixed it, I would more...

the sender arm got bent on re installation ?

When i was doing this on my 200tdi i had a similar problem. However my issue was that i'd installed all the studs in all the holes on the engine which is wrong ! There is one stud hole that's meant to be left without a stud and that stud was stopping the gearbox from pushing home. The reality is...

On my Defender 90 1993 the pipe size is imperial like all brake most brake pipes but the fitting were metric and the flares I did were DIN as they best resembles what was there already. Had no issues since that so it must be ok.

shame, nothing wrong with a bit of flap

measure and find out ? Also use plastcgauge to confirm clearances.

A fellow North Walean, a small world innit. I rebuilt my 200tdi just becasue I wanted to ensure it was ok for the long road ahead, and in all honesty it didn't need anything more than the cylinders re cross-hatched. There was some wear obviously but nothing excessive. It was working fine...