 | Home > My Defender > Camper 110 Project Thread |
 
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213   
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From 1month ago:
So having been out of the the green oval fold since early january I gave in and bought myself a project, a G reg 200TDi Ex Ambulance:  Click image to enlarge Click image to enlarge It was too good a deal to miss and only 6miles down the road from me! It was purchased as a project by the previous owner following an LPG related V8 fault which drove the previous previous owner to sell it, the V8 was removed and a 75k mile 200TDi dropped it, since then it has sat unused since 2007. The good bits: All transmission/Engine are in great order with minimal rust on axles and a sound rear salisbury. Tub is straight, as are all doors and OS wing. Most of the chassis is in great nick too! NS Footwell has been replaced as has nearside bulkhead outrigger The Bad Bits: Bulkhead top corners are rotten, OS Footwell is rotten as is outrigger (someone got bored i think!!), NS Wing was filled with about 5litres of filler (seriously!) Click image to enlarge Click image to enlarge Click image to enlarge So since buying it 3days ago I have removed the roof and the tub and given it a good ahem 'test' (code for booted it around a field!) Click image to enlarge Click image to enlarge Click image to enlarge All seems well and since stripping the tub I have found the chassis to be in fantastic condition which is a massive relief, next is wings off and then to replace the bulkhead outrigger (spare came with the car) then bulkhead off and replace driverside footwell (again replacement came with the car!) NOW: Bought a new toy Click image to enlarge A 2 post lift! Was very cheap, has been sat outside a mates workshop for a couple of years and he no longer had a use for it, so it's been fully stripped and rebuild with lots of grease on the threads and a spangly new chain to connect the two, then £50 worth of rag bolts to fix it to the floor and we're almost there, the inverter that came with the motor for it was U/S so that's gone back and should have a working one delivered and fitted this week! So to get the chassis up in the air like that took a lot of hard work with a ratchet and a scaffolding bar extension, but now it's up life is so much easier! Back to the landy... The diesel tank decided that it no longer fancied being a sealed container so now have a nice new tank to fit, once it has received liberal coatings of red oxide and then chassis black paint with a shultz top! I'm also fitting a new style fuel filler as these a. don't rust and b. seem to have a better seal on the filler cap. They do however have a different sized vent pipe so need to adapt that! Click image to enlarge Here are the holes in the old one once i'd given it a beating to show up the weak points (of which there were many!!) Click image to enlarge I've also started on the few rust patches, first the bulkhead outrigger and chassis beneath were removed: Click image to enlarge Just need to get some plates cut and welded then this goes somewhere around here: Click image to enlarge Found another patch of rust here: Click image to enlarge so another plate required, but otherwise the chassis is looking good, nearly time to whip out the wire cup and take the rust off before more red oxide and chassis paint and shultz! Apart from that I've taken off the front axle and stripped the rear in situ (can't get the trailing arm bolts undone, as the next photo will show...we had a casualty...) Click image to enlarge So that'll be going back to machine mart!! And I found that I have a leak, any ideas where this will be coming from? Click image to enlarge So that's where I stand currently, will update as things progress!! Hazza 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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25th Apr 2012 9:11pm |
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| chadjizz Member Since: 25 Apr 2012 Location: sussex Posts: 559  
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that is such a nice looking work shop, with the old brick walls, well lit, makes a change from the usual concrete block walls and steel framed barns.
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28th Apr 2012 3:51pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Thankyou, I was lucky that this was an unused building at home that was just right to be converted into a workshop, prior to this it was just an empty barn! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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28th Apr 2012 10:08pm |
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| bpman Member Since: 21 May 2008 Location: Oslo Posts: 8069 
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garage envy
 ... counting the days to getting my garage |
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29th Apr 2012 8:41am |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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It's far better than working outside like I used to! It's not quite right yet, but it's getting there! 1990 Defender 110 200TDI Camper - now converted to Td5 power
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29th Apr 2012 6:09pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Managed to get some bits done before work yesterday,
Plated the hole in the chassis underneath the bulkhead outrigger and then welded the outrigger into place: Click image to enlarge Click image to enlarge Bearing in mind I haven't done any welding in 4 years I was happy with the results (any criticism/advice welcome): Click image to enlarge Have also removed both axles now, ready for a thorough cleaning, new swivel seals and a paint! Click image to enlarge Managed to make a start on the bulkhead too: Click image to enlarge Most of this would not have been possible without the purchase of a 2lt BOC Argoshield bottle, these are fantastic value (£35ish) i think and are a million times better than the disposable bottles that i was trying to use! Click image to enlarge I've also picked up a 'new' wing to replace the N/S one that was made from filler! This came from 4x41, a company that I had never heard of before this but Ray the owner is incredibly helpful and a great guy to deal with! Click image to enlarge More updates soon! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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6th May 2012 8:17am |
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| The Musketeer Member Since: 07 Feb 2012 Location: United Kingdom Posts: 193 
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Very cool, looks like a cracking project! Good things come to the wild and free
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7th May 2012 7:00pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Right, an update! I have been working on the landy but I've moved out of the family home and have no internet at the moment! SO here is how things are progressing...
After treating the whole chassis and both axles with neutrarust, they were all painted with red oxide (no pics...sorry) and then painted with 2 coats of tractol chassis black: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Once that was done and reassembled with new bushes EVERYWHERE I moved on to the very rotten bulkhead today, some YRM repair panels that came with the 110 and then a load of bits of steel and half a bottle of welding gas led to this: Click image to enlarge Click image to enlarge Click image to enlarge Now all I need is to find someone who has a knackered bulkhead and would be willing to donate the end of a bulkhead air vent so I can fill in this gap... Click image to enlarge Can anyone help?? That's all for now 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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12th Jun 2012 2:58pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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So no updates for a while, i've been working on the 110 but with it being away from where i live i always forget to take photos!
So where was I? Bulkhead basically finished, some soundproofing applied already with more to come. I never found a repair for the vent surround so armed with an angle grinder and a welder i made a series of 3mm plates which layered one on top of the other to form the correct basic profile and then filled the steps with weld before grinding back to give... Click image to enlarge Lots of cleaning up with a dremel required but it's basically there. Click image to enlarge So I've moved onto the doors, old frames were shot and the skins had bubbled, so i started by peeling back the skins with the intention of reusing them, the bottoms disintegrated though so £140 later and some new door skins arrived. Meanwhile I stripped both skins, attacked the frames with the wire cup on the grinder and then replaced the rotten metal with YRM repair panels. A lot of measuring, cutting, welding, grinding and red oxide later I have... Click image to enlarge Click image to enlarge Click image to enlarge One down and one to reskin! The skin side of the door frame was primered and then layered with gaffa tape to act as an insulating material between steel and aluminium before using a poly urethane based adhesive to bond frame and skin together and provide another layer of protection against galvanic corrosion and water ingress. So what's next after finishing the driver's door? Well my attention moved to the seat box at some point, both tool and battery boxes were shot so these were removed and then dissasembled to give a tool box jigsaw: Click image to enlarge A new one will be made from aluminium to prevent it turning to swiss cheese like it's predecessor. The battery box is a similar story. And then the tub, standard reaction between steel tub mounts/seatbelt mounts and aluminium tub leading to... Click image to enlarge Click image to enlarge So it's going to be out with the cutting disks and aluminium sheet for some heavy duty patch work. And that is how things stand now! Cheers Hazza 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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6th Sep 2012 7:50am |
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| boxer Member Since: 12 Jun 2011 Location: north yorkshire Posts: 48 
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Hi excellent project keep it coming i would love to do something like that but i have no space,a bit of welding advice slow the wire speed down and it looks like you are using the mig torch like a manual metal arc torch ie dragging, what you need to do is push the molten metal pool rather than dragging but well done.
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6th Sep 2012 6:45pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Thanks for the comments and advice, they are always welcome as this has been a massive learning curve for me! I've been very lucky with the space, wouldn't have considered a project like this without it! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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7th Sep 2012 12:07pm |
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| Sockpuppet Member Since: 17 Sep 2011 Location: Leicester Posts: 479
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For the argoshield ask for the volkzone offer and a size Y. Its basically £70 for a 20ltr @ 230 bar bottle of gas so ~ 5000 litres of gas.
Those small 2ltr bottles hold 494 litres - so 10 times as much gas for twice the price. |
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10th Sep 2012 8:38am |
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| T1G UP Member Since: 08 Dec 2009 Location: Bath Posts: 3101 
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I take it your stick and mig welding? a few tips, cleanliness is next to holiness so get all the crud out. With the stick remember to weave over the last run in a figure of 8 pattern to get full coverage. Also the correct, DRY!, rods are important. Good on you, i tried it recently and gave in! |
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10th Sep 2012 8:49am |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Just MIG welding, and I have learnt about cleanliness now 
Another day's work and another update, no photos though this time! Now have both doors skinned ready for soundproofing and rebuilding! Got started on the tub, eventually got the cappings off, they'd been filled with massive amounts of sealant so Mr blow torch was brought into action and left inside the capping for 20minutes before they'd budge, small amount of repairs needed to one of these. Also removed the old fuel filler panel, drilled out all of the spot welds before templating and making up a new one from a sheet of aluminium, this is now fixed back into place. I've also cleaned all of the loose paint and other rust/muck from the inside and bottom of the tub using a wire wheel on the angle grinder. That's all for now, will take photos next week! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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13th Sep 2012 9:12am |
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