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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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!


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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!


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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


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So that's how things were left yesterday


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Thanks for looking 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #169215 19th Sep 2012 8:08am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 11324

United Kingdom 
Excellent stuff. Keep the updates coming Thumbs Up 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
Post #169216 19th Sep 2012 8:28am
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CFB



Member Since: 13 Sep 2007
Location: Bradford, West Yorkshire
Posts: 803

United Kingdom 
Great thread Thumbs Up Andy
Post #169225 19th Sep 2012 9:15am
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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!


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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:


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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:


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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
Post #170842 25th Sep 2012 7:07pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
So, no updates for ages...sorry!

These are copied from another forum so sorry of they seem a little confused Very Happy




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 Very Happy Very Happy

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:


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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


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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 Very Happy )

So this is how I left the 110 at the close of play today:


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That's all for now folks! 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #215376 1st Mar 2013 8:28pm
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WarPig



Member Since: 04 Dec 2009
Location: Sheffield
Posts: 1748

England 1996 Defender 110 300 Tdi USW Bonatti Grey
Fascinating reading Thumbs Up
Post #215394 1st Mar 2013 9:24pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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:


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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:


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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:


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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!!)


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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!


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So next is more welding gas and rivets, need to sort out the minor misalignment of my bulkhead repair...dammit!


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Thanks for looking! 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #218359 12th Mar 2013 4:18pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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!


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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:


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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:


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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:


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That's all for now!

Thanks for looking, Harry 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #237540 21st May 2013 5:18pm
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I.AM_a driver



Member Since: 11 Jun 2009
Location: Edinburgh, Scotland
Posts: 404

Scotland 2002 Defender 90 Td5 CSW Oslo Blue
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
Post #237545 21st May 2013 5:38pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
I.AM_a driver wrote:
Looking good Harry. What happened to your Td5 90?


Rather not talk about it...
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 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #237563 21st May 2013 7:02pm
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GUM97



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

United Kingdom 1997 Defender 90 300 Tdi HT Stornoway Grey
^^Ouch. That must've hurt Shocked An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948"
Post #237573 21st May 2013 7:34pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
GUM97 wrote:
^^Ouch. That must've hurt Shocked


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
Post #237577 21st May 2013 7:53pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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!


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[/img] 1990 Defender 110 200TDI Camper - now converted to Td5 power
Post #304492 2nd Feb 2014 7:09pm
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Hazza



Member Since: 10 Jan 2011
Location: North Yorkshire / Leeds
Posts: 213

United Kingdom 1990 Defender 110 Td5 HT Bronze Green
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:


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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:


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It certainly helps when I walk in first thing to find the windows looking like this:


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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.


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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...


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The parts that are hanging were dry when hung up, I just wanted to get them out of the way.


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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.


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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
Post #304494 2nd Feb 2014 7:15pm
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GUM97



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

United Kingdom 1997 Defender 90 300 Tdi HT Stornoway Grey
Looking well, nice colour! An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948"
Post #304507 2nd Feb 2014 7:37pm
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