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Caterham



Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6300

England 2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey
they most definitively don't look rubbish. they look great (just not my choice Mr. Green )

keep up the great work Thumbs Up
Post #1049327 21st Oct 2024 1:13pm
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bodstruck



Member Since: 09 May 2020
Location: Wiltshire
Posts: 922

United Kingdom 
Bonnet now fitted and fettled. And Chequer plate fixed.


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I have a full set of Gwyn Lewis mud shields, made a start on fitting. These ones go to the rear of the rear wheels and have the removable mud flaps. I have still to fit the mud flaps to the brackets.


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They fit nicely and seem like they should stop a lot of crud getting to the rear of the tub and crossmember. It is a shame that you have the bolt the upper bracket through the tub, you end up with 2 M6 bolt heads on the inside.

The other two sets I have prepped but will wait until the doors, infil panel and arches are on. I had these fitted to my Puma and they keep the crud traps really clean Thumbs Up

Anfter much deliberation I opted for Mantec spare wheel carrier. It did hurt a little paying for it but I have stopped counting now Smile


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It was not packaged particularly well, and no instructions. Not a great problem but i would have hoped for better.

Bottom bracket and back plate fitted fine, I just had to enlarge 2 holes in the crossmember. Top bracket was a little trickier than it should have been. It is supposed to fin in place of the tub capping rivets but on mine i had to fit it about 10mm lower. I am putting that down to the chassis which does have a lot of alignment issues.


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The carrier does not quite swing in the same arc as the door - the end (piston bolt) is about 2mm lower when fully opened in relation to the door. I am putting nylon washes either side of the piston bolt to allow it to slide for now but aim to pack out the lower bracket at some point to eliminate this.

And yesterday's job, while it was reasonably warm, was to fit the front and rear glass. Rear is straightforward. Teenager number 2 helped.


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Front is a heated screen and I was cr@pping myself that I may damage it. It was tricky to fit but we managed to get there in the end.


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Wiring will come another day. At least I can reassemble the dash now.

Next job is fitting the doors. I made a start on the NSF. Problematic. The Optimill hinges make it a little tricker too. First attempt it would barely fit and the top was only just clear of the B pillar. I had to take it off in the end and will need to fettle with the holes for the hinge captive nuts to allow for more movement. This side had the bulkhead repair and the holes were too small and in the wrong place, I wish I had just used a blank sheet and drilled new holes to suit. I fear I am going to run out of metal and the captive nut will have little to hold it in.

I had run out of mojo by that point yesterday, took the door off again, put the car back in the garage and retired for a brew. I'll think on it more and perhaps tackle again today. After doing bulkhead repairs, fitting new b and c pillars AND having new doors and hinges this area was probably one of my biggest worries, after doing all this work it woudl be a bummer if the door fit is poor.
Post #1050017 28th Oct 2024 9:43am
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bodstruck



Member Since: 09 May 2020
Location: Wiltshire
Posts: 922

United Kingdom 
Doors fitted. It took some fettling but I got there in the end. I'd say I am 95% happy with the alignment but there is nothing further I can do to get the shoulders completely in line. It is pretty good though.

Fitted the rear arch infil panels and then refitted the arches. I had deliberated over painting them body colour but decided that original black plastic was a better bet given the use of the vehicle. I picked a set up at the Newbury Spares day a while ago for about £30. A good splosh of bumper and trim polish and elbow grease and they have come up really well.

Next was fitting the remainder of the mud shields. I wanted to wait until the arches were on so I could get a good coat of underbody wax in there beforehand. I have Dinitrol and Waxoyl but decided to use Lanoguard this time. I opted for this for the ease of use and application. Time will tell how well it protects but applying was really straightforward, no compressor needed and it is thin enough in mild conditions to coat really well.

Fronts:


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Rear:


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And the removable rear mudlfaps that come with the other kit I fitted - I like this idea and they work well.


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And then out of the garage ready for the wheels to be refitted. I have been delaying this as once the wheels are on it cannot go back into the garage.


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Wheels ready to fit:


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And the car mobile again on its way for MOT


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Unfortunately it failed, but I knew it was going to Sad . I was doing last minute checks and the washers had packed up. turns out BOTH pumps had failed - nothing I could do about that in time. Also a track rod end needed replacing and there was a little play in a couple of wheel bearings.
A set of new HD track rod ends and silicone boots are on their way from Gwyn Lewis, new washer pump should be here today and I'll tighten up the bearings this weekend.

Fingers crossed it should then be roadworthy again next week Thumbs Up

Still a fair bit to do. Snorkel, winch, second battery install, interior electrics (lights, EW, CL, heated seats) carpet the rear sides, fit cargo cages, shelf and door table, fit the wright offroad matting. But it will still be usable while I do all of this which is great.

Ideally I would repaint the sliders and winch bumper. But they are both galvanised and they will only get scratched again so I may not.
Post #1051047 8th Nov 2024 8:53am
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Procta



Member Since: 03 Dec 2016
Location: Sunderland
Posts: 5183

United Kingdom 
that's a work of art and a proper rebuild, not like the F88kin shi8t that my dad paid 30k for and still putting money into, and finding issues with!

Mot failure wise, i wouldn't worry, see those as just ironing it out. My rover metro me and my dad rebuilt failed on a two sheet of paper Laughing but that was only things needed tightening up. The two testers were smiling, not for it failing it, but for what we had done. One tester said You want to be well over the moon for that like! the other said, Andy its alright isnt! just sort those spanner jobs and its ready. i worked through the sheet, the Mot testers checked it over and said its good to go Thumbs Up real dish is ironing it out once its had miles on it. The metro was back in for wheel a lineament, after me and my dad dropped the suspension, My dad said it was fine, i said a long with the mot tester and the lads on the forum it was a too high. After that the car really came a long very strong Very Happy

Looking at the quality of my dads rebuild, me and him could have done a bloody better job, we have done it in the past on our own, with out any forum help practically Thumbs Up Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

Success is 90% Inspiration and 4 minutes Preparation # you can make it!
Post #1051874 16th Nov 2024 1:48am
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bodstruck



Member Since: 09 May 2020
Location: Wiltshire
Posts: 922

United Kingdom 
I hope your Dad gets his motor sorted and can find a way of enjoying it. Sometimes tricky not to associate the car with the shoddy garage. Good luck Thumbs Up

I fixed all the issues last weekend. New track rod ends, silicone boots, new washer pump and tweaked the bearings up a bit. MOT passed on Monday.

While greasing the props I did realise the front diff pinion bearing is rough when turning. It is a 10 spline diff so I think time for an upgrade of some sort. Probably just to 24 spline internals and new cvs and shafts.

I seem to have a mass of electrics to sort which I am procrastinating over. Windows are a priority. Then I think central locking, heated screen and heated seats. In that order.
Post #1051881 16th Nov 2024 8:38am
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10782

England 
Great she passed the mot, i would put the heated windscreen to the top of the list as i wouldn't be without mine now after putting of for a while Very Happy 1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.
Post #1052337 20th Nov 2024 7:58pm
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bodstruck



Member Since: 09 May 2020
Location: Wiltshire
Posts: 922

United Kingdom 
I have all the switches, relays and wiring now so once it stops being so flipping freezing I can set about sorting the windows and screen. One issue with it being out of the garage now is that I am limited by daylight hours and weather, which are short and cr@p at the moment Sad

Not being able to wind down the windows, even a crack, is more of a pain than I thought it would be, I find that you often need a bit of fresh air circulating to keep the screen and windows clear.

Maybe this weekend will be better Smile
Post #1052397 21st Nov 2024 11:17am
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