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abomb1969

Member Since: 23 Jul 2011
Location: Welwyn, Hertfordshire
Posts: 79

1998 Defender 110 Td5 CSW Santorini Black

Bulkhead repair help, and a list of work, TD5 1998

My 110CSW has only done 74k but is not well at all. Photos in the gallery.

Having secured a recent MOT I now have a long list of jobs which have to be completed in the next 11 months, or the Defender will be sold in 6 months if I have not sorted as it will fail on a number of items for sure.

The passenger bulkhead is rusty in one spot by the wing mirror. Is the solution here to grind the rust out and plate over it or is the diagnosis further rust inside?

The rear crossmember is very thin and will need replacing its not really patchable. There was a significant amount of rust in the rear main chassis beams just behind the rear wheels which had to be patched, due to rot setting in from the inside out. There is currently a 5cm rectangular hole in the rearmost chassis rail. I was going to source a blacksheep crossmember and get some extensions made up, and maybe get the chap to fit it for me. The rest of the chassis seems sound, with maybe one outrigger needing replacement in the next few years. I would prefer to put a galvanised chassis on it, but I suspect I wil end up £2k down as it is not going to increase the value of the Landy that much.

ABS and TC lights are on. I have done some diagnostics and think its just the shuttle wiring. I am sure I can fix it but may take a bit of time.

I have quite a few areas of electrolytic corrosion and bubbling on the paintwork, and the capping is rusty.

Aircon not working.

Rear door frame broken and outerskin cracked.

I also need to kill and clean the rust on the chassis and Denitrol.

I am seriously considering cutting my losses and selling it with the faults, or maybe break it into parts?

10th Sep 2013 5:30pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2639

Bloody hell, if everyone cut their losses and sold their Defender every time it needed some work there'd be none left on the road! You need to fix it

The re-chassis is the best option, though there should be plenty of life left in your current one if you replace the back end. Losing 2k is only really an issue if you plan to sell it, and you wouldn't be doing that if you were re-placing its chassis.

Bulkhead can be fixed, it will be full of rust internally.

Rusty capping is just an aesthetic thing unless it's really bad. Again can be fixed fairly easily.

Nothing insurmountable

10th Sep 2013 7:45pm

Mud Dog

Member Since: 11 Jul 2013
Location: Kent
Posts: 31

Hi I've got a rusty front bulkhead too but nothing on the chassis. Was going to take it to Gigglepin as I understand they repair/replace them. Has anyone used them and want to share they're experience or used another shop they'd recommend?

Thanks,
Matt We're not stuck...just enjoying the scenery!

29th Dec 2013 4:36pm

jimbob7

Member Since: 06 Jul 2013
Location: uk
Posts: 2055

Eek, thats a fair bit of work,my sympathies.Oh,welcome to the "faulty ABS" club

Theses guys are recommended for ABS pump repairs.
http://www.ecutesting.com/ Pov.spec,ftw. 2006, 110,TD5.

29th Dec 2013 9:01pm

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