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Home > My Defender > My 90- Galvanised Rebuild

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GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555

My 90- Galvanised Rebuild I bought my 1997 300tdi Defender 90 Hard Top back in October 2011. With 131,000 miles on the clock, it was in good condition, apart from the rust, and there was lots of that! Click image to enlarge Click image to enlarge It was a project for me and my dad, although we seriously underestimated how bad it was! We bought it thinking that the chassis would need some repairs, but nothing that some welding wouldn’t fix! How we were wrong! I steam cleaned it, and the water pressure alone blew great big holes in the chassis. We then decided to completely rebuild it on a galvanised chassis. Click image to enlarge First to come off was the doors, then the interior, the roof and then rear sides. Click image to enlarge Then the rest of the panels came off, until we were left with a rather sorry looking chassis. Click image to enlarge The engine was rebuilt and made to look beautiful! Click image to enlarge Click image to enlarge A galvanised chassis was bought from the excellent Richards Chassis of Doncaster. Click image to enlarge This was then complimented by an Ashtree Land Rover International Galvanised bulkhead. The axles and running gear were fitted, and then the engine and gearbox slotted in. Click image to enlarge It was then the turn of the bodywork, which went on very slowly. It all fitted together very well, but then it all had to be rubbed down ready for painting. Another slow process. Click image to enlarge When it came back from the paint shop, it looked so naked! No lights, no wipers and no windows! Click image to enlarge Over the next few weeks, all the little things got bolted on, but it’s the little things that make a big difference! Click image to enlarge Then it was time for the most dramatic modification so far. The panoramic privacy glass supplied and fitted by LandGlass of Birmingham. It really is a wonderful product and I think it looks fantastic! Click image to enlarge Then, most recently, we’ve fitted a First Four Shadow tubular winch bumper and winch. Along with the Brunel silver light surrounds and grille. Click image to enlarge The restoration project is finished, but the modification project will never be finished! Quite a transformation I think you’ll agree! Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  An engine to TDi for! "Land Rover- Proudly turning drivers into mechanics since 1948" Last edited by GUM97 on 10th Jan 2013 9:05pm. Edited 2 times in total

24th Sep 2012 4:43pm

Go Beyond Member Since: 30 Jan 2012 Location: Headcorn, Kent Posts: 6677	That looks fantastic ! Are you leaving the plastic arches off ?
24th Sep 2012 4:53pm

MPN Member Since: 23 Sep 2012 Location: Tuusula Posts: 18	Awesome! I wish I had the patience...
24th Sep 2012 4:56pm

GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555	Go Beyond wrote: That looks fantastic ! Are you leaving the plastic arches off ? They're going back on soon, I left them off to get more access for waxoyl  An engine to TDi for! "Land Rover- Proudly turning drivers into mechanics since 1948"
24th Sep 2012 5:05pm

Landlord Member Since: 27 Oct 2009 Location: Hampshire Posts: 582	Nice job, loving the engine detail  2007 TD5 90 Hard Top
24th Sep 2012 5:05pm

Thud Member Since: 21 Jul 2012 Location: London Posts: 667	That looks brilliant! Good work.
24th Sep 2012 6:17pm

alfajock Member Since: 12 Jan 2011 Location: Bedfordshire Posts: 227	Looks like a lovely job, well done  Fully Restored 89 110 CSW V8 CLS 350 CDI for the sensible stuff
24th Sep 2012 6:20pm

Pam W Member Since: 25 Oct 2011 Location: North Yorkshire Posts: 1169

Great Job!! Looks fab - I imagine you'll be as proud of yours as I am of mine! Galv restos / rebuilds / ongoing additions and mods are the way to go... Mine 1998 300 tdi went from this in 2003 ...... Click image to enlarge .... To this state by 2010... ... in stages from 2010 to this by September 2012!  Our blog - http://landytravels.com/ Yorkshire Off Road Club - http://www.yorkshireoffroadclub.net

24th Sep 2012 6:49pm

Landlord Member Since: 27 Oct 2009 Location: Hampshire Posts: 582	Nice colour Pam  2007 TD5 90 Hard Top
24th Sep 2012 7:00pm

chadjizz Member Since: 25 Apr 2012 Location: sussex Posts: 559	that glass looks amazing. if and when i have to get my misses a 90 i think that will need to be a mod for it so she doesn't have the excuse of "i couldn't see" when she backs into stuff....!
24th Sep 2012 7:16pm

BigRuss Member Since: 15 May 2010 Location: Norfolk Posts: 2785	Well done, it's amazing how much muck builds up over the years  Russell 2011MY 110 XS USW Black
24th Sep 2012 7:24pm

GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555	Thanks for all the nice comments Pam- it's that feeling of achievement when you finish it BigRuss- it's amazing how much mud you get out of your chassis! There were weeds growing from the mud in my rear crossmember Don't think the previous owner washed it too often! An engine to TDi for! "Land Rover- Proudly turning drivers into mechanics since 1948"
24th Sep 2012 7:47pm

strang Member Since: 16 May 2012 Location: Happy Valley Posts: 1379	Nice work and looks great! Euro-Leafing to infinity and beyond.....
24th Sep 2012 7:52pm

Pam W Member Since: 25 Oct 2011 Location: North Yorkshire Posts: 1169	GUM97 wrote: Pam- it's that feeling of achievement when you finish it They are never really finished though ! Have just been chatting with the other half about my next bits - ARBs and extra fuel tanks !  Our blog - http://landytravels.com/ Yorkshire Off Road Club - http://www.yorkshireoffroadclub.net
24th Sep 2012 8:08pm

Landlord Member Since: 27 Oct 2009 Location: Hampshire Posts: 582	Pam - you changed the position of your fuel filler to the newer TD5 location ? If you have you can use the new Safari Equip auxiliary fuel tank. 2007 TD5 90 Hard Top
24th Sep 2012 8:16pm

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