 | 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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Had a very satisfying day yesterday, if only for the reason that it's starting to look like a defender again (well a bit anyway!)
So first I finished off the soundproofing on the engine side of the bulkhead (no picture of the finished job unfortunately but you'll get the idea) and then I dropped it into place and started to reattach pedal boxes, accelerator cable and clutch pipes, I bled the clutch (eezibleed made life so much easier!) and refitted the steering column. Everything has been sealed with black silicone or pu based adhesive as it goes into place to ensure that there are no leaks and that things stay in place with fewer rattles!  Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge I think the pictures should be fairly self explanatory and may be good references for some too. I also refitted the original driver side wing and a replacement passenger side wing before removing the outer skins, as can be seen below one of the wings had been filled with copious amounts of filler rather than having the majority of the dent removed first so more work to do there! Click image to enlarge And now for the camper conversion, I have started to put a plan together, one key piece being the use of a caravan sink/hob unit to provide cooking and cleaning arrangements Click image to enlarge So that's how things were left yesterday Click image to enlarge Thanks for looking 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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19th Sep 2012 8:08am |
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| LandRoverAnorak Member Since: 17 Jul 2011 Location: Surrey Posts: 11324
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Excellent stuff. Keep the updates coming
 Darren
110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak "You came in that thing? You're braver than I thought!" - Princess Leia |
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19th Sep 2012 8:28am |
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| CFB Member Since: 13 Sep 2007 Location: Bradford, West Yorkshire Posts: 803
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Great thread
Andy |
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19th Sep 2012 9:15am |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Another couple of days of work...updates...
I redid all of the brake lines front to back yesterday, really satisfying work, shame the front calipers are shot! Click image to enlarge Click image to enlarge And onto today... The capping on one side of the tub was completely rusted through at the front weld point, luckily someone on the LR4x4 forum has some rotten cappings that he wanted rid of so they became my repair pieces. So a couple of hours, a welder, grinder, cutting disks and flap disks; we go from rotten capping to: Click image to enlarge Then my attention turned to the bulkhead, to function as intended the 110 needs to have clear access front to back so out with the drill and Mr Angry Grinder sees this big hole cut: Click image to enlarge Click image to enlarge This will be reinforced by a home-made bulkhead removal bar similar to the Protection and Performance tubular one. That's all for now...lift will be finally wired up on saturday so that'll be a massive help! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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25th Sep 2012 7:07pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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So, no updates for ages...sorry!
These are copied from another forum so sorry of they seem a little confused 
So onto another update...and an exciting one..SHE RUNS!! Spent yesterday doing a service on the 110 before checking all engine mounts, bleeding the clutch and filling up with diesel and oil. After tracing all of the ignition wiring and eventually finding a battery with some charge in I set about turning the key...after some struggling she turned over quickly and went, big cloud of smoke and then silky smooth running...then nothing!? Seemed to be fuel starvation but why?? After some time I thought that maybe the lift pump had died...although it worked before the strip down...then it hit me. I had connected the diesel supply and return into the wrong ports on the tank But all sorted and I even went for a little drive That's all for now! NEXT Little more progress... I knew that the seat box was going to require repair or replacement, while away from the 110 I was browsing eBay and amongst numerous very expensive seatboxes (£150+++) I found one which i bid on and received for £55 delivered
It wasn't perfect but with a little work, paint, and flashing tape to act as a aluminium/steel insulator I ended up with a complete item: Click image to enlarge I then started up the 110 (still makes me smile!) and pulled it out so that I could spin it around on the lift to make the next step easier Click image to enlarge Click image to enlarge So after a general tinker and check of all fluid levels to ensure that everything is well I put her back on the lift and whipped off the tub, hopefully for the last time! And then attacked it with a good thick coating of Tetrosyl Tetra Schutz . It is a fab product, wasy to spray on, quite messy but then dries to form a flexible coating (also hides a multitude of sins on the bottom of the tub )
So this is how I left the 110 at the close of play today: Click image to enlarge That's all for now folks! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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1st Mar 2013 8:28pm |
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| WarPig Member Since: 04 Dec 2009 Location: Sheffield Posts: 1748  
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Fascinating reading
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1st Mar 2013 9:24pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Next installment!
Not much work done but a few jobs completed none the less!! So it was out with the schutz gun and time to get the underside of the tub all covered up: Click image to enlarge And then it was onto the chassis, as the whole chassis is layered in paint I am less worried about it rusting BUT fro cleaning it up to paint I know where the rust tends to form so I've coated the entire area on top of the chassis beneath the tub, paying special attention to the rear and middle crossmembers as as we all know these are like rust magnets: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge All nicely covered!! Then I moved onto the seatbox, I need to finish plating in the gearbox tunnel mounts but have run out of rivets so while the schutz was flowing I covered the 2 steel under seat boxes to try and keep them whole for longer: Click image to enlarge Click image to enlarge I then popped down the road to a company that recycles and produces rubber products (http://www.vulcanrubber.co.uk/ no affiliation etc) and picked up a 1m x 650mm sheet of 10mm conveyor belt to allow me to replace the rubber tub mounts and leave me with enough material to create extensions to the front inner wings to help preserve the bulkhead outriggers (no photos of these yet as I haven't made them!!) Click image to enlarge I also started on the final tub repair, the nearside rotten seatbelt mount - so a nice plate has been cut up but yet again NEED MORE RIVETS - must order! Click image to enlarge So next is more welding gas and rivets, need to sort out the minor misalignment of my bulkhead repair...dammit! Click image to enlarge Thanks for looking! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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12th Mar 2013 4:18pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Again, apologies, no updates in ages!!
Lots has changed with the 110, fuel hoses have been fixed into place with P-clips before the whole tub was lowered into place and fitted for what I hope will be the final time. All bolts have been copper-slipped along with rubber isolation washers and rubber sheet separating all alu/steel contact points. Hopefully this will slow down the corrosion and also eliminate some rattles at the same time! Many panels have been fitted, removed, fitted, removed, fitted etc to ensure that their fit is good and to check whether any further modifications are required before painting and final assembly. The bulkhead-screen frame is still not quite right but am running out of ways to solve this , I have one more idea though which might cure the symptoms rather than the underlying cause! Click image to enlarge Click image to enlarge I've started looking at the camper conversion now as some panels need modifying prior to paint etc. The major one is the roof, lots of spot welds drilled out followed by removing a lot of factory sealant (it is a wonder that the roofs leak really when you see the amount of mastic in there!) and we get to this stage: Click image to enlarge Stage 2 is to mount the rear section on a set of telescopic tubes which will give the head room needed for camping and also create the space for the double bed. I then did a little KAD (Kingspan Aided Design) to allow me to start to visualise the interior space: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge On the right is a folding sofa/bed that will have storage under the seat, whether or not this comes to fruition I do not know. On the left is the hob, grill and sink unit that will have a fridge next to it (behind the passenger seat) I also fitted (very temporarily) one of my LR Spring Adventure purchases, a set of series headlamp bezels: Click image to enlarge That's all for now! Thanks for looking, Harry 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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21st May 2013 5:18pm |
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| I.AM_a driver Member Since: 11 Jun 2009 Location: Edinburgh, Scotland Posts: 404  
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Looking good Harry. What happened to your Td5 90? Mark S
CONVOY for HEROES www.facebook.com/convoy4heroes www.lothian4x4response.org ------ Td5 90 Thread in 'My Defender' Forum |
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21st May 2013 5:38pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Rather not talk about it... Click image to enlarge 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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21st May 2013 7:02pm |
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| GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555 
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^^Ouch. That must've hurt
 An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948" |
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21st May 2013 7:34pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Yep I was a little stiff the next day, otherwise I came out unscathed. Got to love land rovers! 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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21st May 2013 7:53pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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So time for another update,
This work was all done in early June while I changed from one job to another. Since then I've been run off my feet but should be back to getting time on the LR very soon! Just a selection of photos really to show what I've been up to. Had a general tidy up under the bonnet, new air filter-turbo hose and the likes and then started her up and ran her for a good while to check for leaks and that the thermostat was working etc, all seems good although the sump has a tiny leak as does the rear crank seal. Stripped the Offside rear brakes and rebuilt with new shoes and cylinder as the old nipple sheared off when I tried to bleed it. Also took the back plate apart and knocked the mudshield flat before reassembly as it was all bent and bucked. Also fitted a discovery handbrake lever just to make life a little easier Final job was to drop all of the dashboard back in before making up a new center console and adding 2 classic mini air vents as directional air, chuffed with these as they work an absolute treat! And added 2 side window demisters all plumbed into the original heater ducting. Few pics for your enjoyment! Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge [/img] 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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2nd Feb 2014 7:09pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 213
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Hello all,
I know it's been a long time since the last update on this, sorry! I've been getting on with it and have managed 1-2 days a week on the 110 recently so things are starting to move on! Since the last update the weather changed and things got colder, not ideal when body work was the next job on the list. So a staple gun, some plastic sheeting and some old pallet racking saw an old stable turned into a fairly well insulated workshop: Click image to enlarge Difficult to get a photo of the whole room, sorry! You can see that I also sheeted off a corner to create a dust free zone for painting to make things a bit easier. Doors and windows have all had bars put across them too. I've seen the gas bottle woodburners that people create and had a bottle that I'd planned to convert but as this project is now into it's second year I picked a completed one up off ebay: Click image to enlarge It certainly helps when I walk in first thing to find the windows looking like this: Click image to enlarge SO workshop sorted, onto the defender! I started with the wings, one of which was a used replacement for the original. I'm new to bodywork but am happy with the results even after one coat of paint. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge I couldn't resist loosely putting these together to get a feel for the end product! I've been using a brush and roller for the paint and this seems to be working well for me so far. Few more pics of progress... Click image to enlarge Click image to enlarge The parts that are hanging were dry when hung up, I just wanted to get them out of the way. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Lots left to do but i'm enjoying being in the warm with the radio on! The only other job that I've completed is the fitting of the first of my side lockers. I've had these made up by a mate as I wanted some that would fit above the rocksliders unlike the military style ones. I know that I can't fit a jerry can into these but they are still a great size and should be very useful for kit when camping etc. Pics should be self explanatory. Click image to enlarge Click image to enlarge Just need to do the other side then fit the doors! Thats all for now. Cheers 1990 Defender 110 200TDI Camper - now converted to Td5 power |
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2nd Feb 2014 7:15pm |
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| GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555
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Looking well, nice colour! An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948" |
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2nd Feb 2014 7:37pm |
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