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IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

1986 Defender 90 200 Tdi SW Keswick Green

IKke's military 90

This is my 90 from 1986, it has a discovery 200tdi fitted. I have bought it in the UK and drove her home. Sleeping in it overnight waiting for the ferry back home wasn't a great success though.

Picture of the arrival back home:

Click image to enlarge

It had spilled quite some oil and once I was home and able to sort everything out. It appeared that the turbo oil return hose was very loose, tightening it back up solved 75% of the oil leakage. Then the steering house started leaking, trying to tightening the screw it was leaking past made it leak much worse. After draining it and replacing an o-ring that leak was sorted too. After the leak was fixed it was time to fix the enormous amount of play in the steering system. This was quite a simple job. Just adjusting the steering box, and fastening one of the universal joints back on the steering shaft.

I also replaced the oil cap on top of the engine because oil was seeping past it. I also replaced the diesel return pipes on the injectors because they were literally split open.

After this was all done it was time to clean up the underside. After using the pressure washer on the chassis there was a bit of a disappointment. Most of the waxoil fell off. Revealling quite a bit of rust. While most of it is just surface rust the outriggers are rusted through. The left one is almost fully rotten away while the one on the right side only has 2 small holes in it.

So today I started working on removing the left outrigger.

Click image to enlarge

Click image to enlarge

Viewing the left outrigger from the front:

Click image to enlarge

And from the rear:

Click image to enlarge

Will have some more tomorrow when I hope I can finish up removing the outrigger. Scaling the real deal.

6th Jul 2012 10:26pm

GREENI

Member Since: 22 Aug 2010
Location: staffs
Posts: 10379

Good project you got there

6th Jul 2012 11:01pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

More project than I was hoping for

But atleast I'll know it through and through when I'm done. And it will be 99% rust free

Scaling the real deal.

6th Jul 2012 11:11pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

Todays progress. Was finally able to cut out a big section of the outrigger. Cutting loose the plate on the bottom of the outrigger was a bit of a pain. Had to removed the floor to cut it loose.

The swiss cheese that came out.

Click image to enlarge

And what is left to be removed.

Click image to enlarge

Anybody has any tips how to remove the rest of the outrigger. Cause the radius arm and the foot well are in the way a bit. I think I can work my way around the radius arm. But cutting the outrigger on top of the chassis is gonna be more difficult.

Any advice appreciated

Scaling the real deal.

7th Jul 2012 10:14pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2638

It's a

. A thin cutting disc in a grinder might do it if you can get the access. Or a cut-off wheel in a die grinder or a Dremel type tool might be better access-wise.

I did the same job this morning...but I cheated and used a plasma cutter!

Click image to enlarge

7th Jul 2012 10:46pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

That convinced me even more to buy one. But for the time being I'll have to solve it with an cutting disk in a grinder.

I'm guessing you cut it with the gearbox tunnel also removed? Did you also remove the plate that connects between the chassis rail and the foot well? Scaling the real deal.

7th Jul 2012 11:06pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2638

Yeah, the whole floor is out of the vehicle at the moment as I'm mid-way through an engine swap. One reason why I've chosen to do the outrigger, access is a whole lot easier when you can get to the engine-bay side of the chassis rail!

Not sure what you mean by "the plate that connects between the chassis rail and the foot well"? Do you mean the vertical support bracket that bolts to the chassis in front of the bulkhead, and then also to the front edge of the footwell?

7th Jul 2012 11:09pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6091

Plasma cutters rule!!

8th Jul 2012 6:09am

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

Yes that plate Retroanaconda Scaling the real deal.

9th Jul 2012 12:53pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2638

No I didn't. Primarily because with the outrigger bolt removed that plate is what supports the bulkhead in the mean time. Secondarily because I didn't need to with the plasma. If you were to use a normal grinder, it might be worth removing it. However you'd then need to stick a bottle jack or similar under the a-pillar to hold the bulkhead up!

Welded my new outrigger on yesterday evening (in between rain storms!)

@diesel_jim: Yes they certainly do! Unfortunately this is a borrowed one and not mine, but it's going on the wish list that's for sure!

9th Jul 2012 6:28pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

Well I have removed the plate and indeed had to place a jack under the A-pillar. But I already had to do that before I removed it, because I couldn't close the door without one.

I'm now 99% done removing the old outrigger. Only have some material left on top of the chassis but I'll probably have to remove the clutch pipework to get that last bit off. So tomorrow I'm going to remove the last bit and clean it up for welding. And Wednesday is welding day

Scaling the real deal.

9th Jul 2012 9:07pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

Little photo update:

Sawed of the top section by hand:

Click image to enlarge

Just some material left on the place I couldn't get with the grinder.

Click image to enlarge

The plan is to remove the rest with a file and perhaps some more hand sawing tomorrow morning and get it welded in the afternoon. Lets hope all goes to plan. Scaling the real deal.

10th Jul 2012 7:03pm

chiefstoker

Member Since: 11 Oct 2010
Location: Weston-super-Mud
Posts: 897

Great write up and pix, thanks

2005 TD5 90 Hard Top

Beer 'n Sex 'n Chips 'n Gravy

10th Jul 2012 7:26pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2638

Good job. It appears that like me you're lucky and there is no rot in the main chassis rail hidden beneath the outrigger.

10th Jul 2012 7:41pm

IKke

Member Since: 16 Aug 2008
Location: Brabant
Posts: 117

@chiefstoker: You're welcome. Do you also need to replace an outrigger?

@Retroanaconda: I was quite happy to discover no rot because I've read in quite a few places that people discovered holes in their chassis after they cut the outrigger off. Scaling the real deal.

10th Jul 2012 9:07pm

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