 | Home > My Defender > 200Tdi 110 |
 
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890  
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Agreed. Reasonably straightforward to refresh a Defender and have it looking presentable and all hang together well for a bit. But a different matter doing it in a way that lasts.
The previous owner of this had obviously spent lots of time and money on it with the replacement chassis, bulkhead, electrics and door post repairs. But as you dig in you find frustratingly shocking work and end up spending more time putting right previous stuff than doing the new stuff you set out to do. The C posts had been riveted together and were barely attached to the sill. The B post repairs were poor - bare metal left exposed and the reinforcements for the lower hinges were not attached to the skin to they pretty much collapsed. Frustratingly extensive use of these monstrosities: 
And covering everything in sound deadening is great until you want to work on it after as removing it is a pig. Still, it will be good in the end  |
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16th Aug 2024 9:48am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Heated windscreen has arrived as well now. Well packaged
Not quite sure if I will make up my own loom or buy ready made yet. But at least I can fill the hole when the time comes now. Click image to enlarge Click image to enlarge |
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16th Aug 2024 3:02pm |
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| Procta Member Since: 03 Dec 2016 Location: Sunderland Posts: 5138
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id buy the loom for it, saves you faffing on, you can get one with the switch that goes under the binnacle
I really should get photos of the workmanship that was done on my dads for 27k, you will be shocked. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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20th Aug 2024 4:53am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Access to fit the rear seat support brackets is almost impossible so I lifted the floor.
Click image to enlarge Click image to enlarge Click image to enlarge And obviously this led to more stuff to do. The floor supports have all been replaced in the past but have started to rust - so they need cleaning and repainting. And the coating on the fuel tank is coming off so that needs to be dropped, cleaned and painted as well. Did some dry-fitting of the seats to make sure the brackets were going to be in the right place. The brackets have since been fettled to fit better. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge As you can probably see, they do not look right. Turns out that double cab seats and station wagon seats are different ( https://www.defender2.net/forum/topic93086.html ). They are more upright (can be fixed) and also have different front hinges. So those seats were sold and I have procured a set from a SW. Ironically bought from a chap who wanted to fit them in a pickup and didn't know they were different. Fit up for the side frames / B and C posts: Click image to enlarge Click image to enlarge And then ready to fit: Click image to enlarge and finally it seems like stuff is actually going back on the car 
Click image to enlarge No pics but I also fitted a new OE ignition lock so I will have a single key for the whole car |
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6th Sep 2024 9:44am |
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| LJMARSDEN Member Since: 08 Jun 2021 Location: Nottingham Posts: 325 
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All this looks like a good project, nice job 4.0 V8 Defender 90
My Instagram |
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6th Sep 2024 10:53am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Preparing the car to be mobile enough to take it for welding on the bulkhead. Lights going back in, but updated all the connectors to superseal before I fitted them. Good use of the kitchen table, boss was in bed.
Click image to enlarge New seals for the bottom of the side panels. These are YRM ones. About £80 each. Ouch!! They fit well and look like they should do a good job. Click image to enlarge Click image to enlarge And added some insulation on top of the sound deadening on the roof. This is more to keep heat out and condensation down rather than for noise. 8mm foil backed closed cell foam. Click image to enlarge Then fitted them both. The roof is on to give it a bit more structural rigidity as I had to drive it to the garage for the welding. That was an exhilarating ride 
Click image to enlarge The bulkhead welding is now done so I am dressing and prepping ahead of paint. The rear chassis brackets are also now welded in so the rear floor can go back in when time permits. Everything else is painted so once the bulkhead is painted and dry I can start to reassemble. The bonnet is being replaced and inside the rear tub will also be painted. |
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20th Sep 2024 10:36am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Bulkhead is now painted - new bulkhead to windscreen seal
Click image to enlarge New vent flap seals Click image to enlarge New wiper boxes and cables to try and address the erratic behavior. And windscreen frame in and roof bolted down. Click image to enlarge Unfortunately there is a lot of play in the shaft of one of the new wiper boxes. Seems to work fine but if the tolerance is low then water will easily get in (despite the new seals) and only get worse. So I have to keep the dash apart for a little longer while a replacement arrives. New windscreen blocks and gaskets Click image to enlarge There is not enough height in the garage to be able to fit the bonnet but the newly painted hinges have now been fitted with new SS screws so it is ready to fit. Click image to enlarge I managed to drop one of the hinge bushes on my gravel drive so it has been lost forever. The replacements are really tight, it will be interesting to see if they can even move when the bonnet is fitted. The doors have all now been built up again. I fitted new seals and channels to the second row ones - what a pig of a job, nothing seemed to fit very well. Done now though. Fresh handles and locks on the fronts. These have EW and CL but that wiring will need to wait. Click image to enlarge The boss was out so I had the use of the 'paint warmer' to soften the waxoyl so I could coat the hard to reach parts in the doors as they were assembled. Don't tell her
Click image to enlarge And finally for now, I have managed to get the (3rd) set of puma rear seats to fit and latch correctly. Click image to enlarge Click image to enlarge Jobs to do as I work up to an MOT: Wiper box replacement and dash reassembly Windscreen in (heated but won't be wired up to start with) Remove the dynamat stuff from the rear arches so I can plug the many holes and then give a good coat of Dinitrol underneath Waxoyl the door pillar cavities and bulkhead before fitting the hinges. Fit the rear 1/4 windows Then the car can come out of the garage and I can: Fit the rear door and gas strut Fit the side doors (Optimill hinges and security plates to go on) Fit and fettle the bonnet. Fit the bonnet and wing-top chequer plate (not everyone's taste but I like the practicality and walk on it a lot) Put the wheels with tyres back on (thanks to gcc130 for the loan of the bare steel rims )
Should be able to MOT it then. Followed by: Plumb in the snorkel Fit the winch bumper and steering guard Internal wiring for aux stuff (heater lights etc) Headlining in Rear storage shelves and table Rear trims (after painting them) Paint the spare Wolf rims to match the body colour then swap the tyres over. And then, when my will builds back up again Wire in central locking wire elec windows fit and wire the aux heater Heated screen wiring |
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16th Oct 2024 11:44am |
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| Oldyellar Member Since: 04 Sep 2015 Location: Central Posts: 384  
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Great work mate keep it up
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16th Oct 2024 11:56am |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Thank you.
Some days it is all very simple and others the list of jobs seems huge. Especially when the bliddy thing was actually working just fine before I started working on it 
I am not sure it is ever actually worth the effort but it can be a nice distraction and sourcing the parts is also fun. I am being tempted by a 300tfi 110 local to me as well now. My wife is saying she want something other than her MX5 to drive to work in on the rubbish, wet and pot-holed roads. What better than a defender to see her through the winter? |
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16th Oct 2024 12:20pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10731 
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As said " great work "
I won't tell 
Can't get much better than your wife using a defender as a daily 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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16th Oct 2024 7:05pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Rear quarterlights now in, straightforward job. The rear door however
That was quite a pain. I am retrofitting a puma door and it was a little tight. I enlarged the holes for the hinges in the body to allow enough movement and managed to get it in the hole nicely. I then had to shave loads off both the front and back of the striker plate so it did not hit the door latch. Eventually done. Sealed the gaps between the panels (under the door seal) with butyl putty and tape then fitted the new door seal. Fits a treat now. I only had a few hours to play this afternoon and as the weather was good I took the opportunity to paint the rear trim panels - black to match the rest of the trim and interior. In order to do that the car had to come out, blinking into the sunshine. Still looking a little sorry for itself but coming together. Bare rims are the only way I can get it in and out of the garage. Click image to enlarge I painted the trim panels with black Raptor. Using higher pressure and the vario gun you can get quite a fine texture which works quite well (in my opinion anyway). Click image to enlarge You an see the texture better on this part. Click image to enlarge After some rain in the morning I think tomorrow afternoon is going to be OK so I think I'll paint the rims (bare and hanging around in the garage) next. Same fine texture Raptor but tinted Keswick Green. The doors and bonnet on I recon. |
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19th Oct 2024 6:04pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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Lashing it down all morning but brightened up in the afternoon so decided to press on.
Tintable raptor, vario gun and keswick green tint. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge I bought 2 bottles but each coat used less than 1/2 bottle. Could have been worth mixing outside the bottle and done half at a time but sods law would have stated that I would have run out of paint near the end. The pot life of Raptor is only 60 mins and you need to leave 60 mins between coats so you can't really get two coats out of one mix if you do it in the bottle. I had planned on using two bottle but I do hate waste 
Pleased with the end result though, just the look and finish I was after. I am looking forward to seeing them with tyres mounted, but I'll wait a week before doing that to give it a chance to fully cure. |
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20th Oct 2024 5:29pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6295 
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personally I wouldn't use it on the wheels (thats just a personal thing) - the finish however is very impressive.
I have to say however some of what you've done really does look the business - top job |
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21st Oct 2024 12:18pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 890
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I can see your point. It was either that or the coach enamel that the rest of the car is painted in. The coach enamel takes forever to harden, especially at this time of year, with Raptor it is touch dry quickly and hard enough to mount wheels on within a week.
But as you say, personal choice. I like the slightly textured finish, many other people dislike it. The good thing is, they are only wheels so if they look rubbish I can swap them over for the other set of Wolfs I have |
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21st Oct 2024 12:41pm |
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