 | Home > My Defender > Overland 110 Build from the Ground Up! |
 
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| grizz Member Since: 31 Aug 2014 Location: cheshire Posts: 208  
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wow .....
I've built a 90 and 110cs from the ground up but this is amazing .. |
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9th Oct 2014 4:57pm |
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| gilarion Member Since: 05 Dec 2013 Location: Wales Posts: 5110  
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Excellent, having done similar myself i know the hard work you have put into it. Looks a beauty
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9th Oct 2014 5:41pm |
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| scotty38 Member Since: 21 May 2011 Location: Lincolnshire Posts: 571  
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very, very nice!
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9th Oct 2014 6:17pm |
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| GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555  
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Impressive, looks really well done!
 An engine to TDi for!
"Land Rover- Proudly turning drivers into mechanics since 1948"  |
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9th Oct 2014 6:23pm |
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| BigM Member Since: 12 Nov 2011 Location: Nairobi Posts: 36  
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Impressive, well thought through, executed and presented. This is an inspired gift to us all who would love to do the same.
All best from Kenya where such a 110 would suit conditions here. BigM |
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9th Oct 2014 6:27pm |
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| Defender_Td5 Member Since: 20 Jul 2009 Location: Devon/Australia Posts: 69 
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Thank you for all the replies, I had better keep on going then...
Onto some bodywork - the B-Posts! These are well know major rust spots on 110 CSW and mine really didn't disappoint. While I was up in Aberdeen I managed to purchase another pair which were just about worth saving as mine that came with the 110 as purchased were completely shot. This is one of the B-Posts during repair, basically the entire lower part of the B-Post had to be completely rebuilt was new steel: Click image to enlarge Cover plate welded on and all flatted back: Click image to enlarge The sills were also pretty shot, so a new set was folded out of 3mm steel: Click image to enlarge Sill to Bulkhead fixing ends were fabricated as copies of the originals: Click image to enlarge Click image to enlarge The repaired B-Post was then positioned on the sill: Click image to enlarge The C-Posts were also in quite a state: Click image to enlarge A simple jig was make to hold the C-Post in place while the new sections were bent up and spot welded in place: Click image to enlarge New steel was folded up exactly to the original profile: Click image to enlarge And spot welded in place: Click image to enlarge To align the C-Post with the B-Post an old secondhand door was bolted up and measurements were taken from a friends 110. Click image to enlarge Click image to enlarge Comparison between the old and new: Click image to enlarge Click image to enlarge Once complete both the completed B-Posts were bead blasted and hot dip galvanized: Click image to enlarge Click image to enlarge Click image to enlarge Good for the next 50 years hopefully! They were then T-Washed, cleaned and painted Stornoway Grey and bolted onto the chassis: Click image to enlarge Regards Rob Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated |
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9th Oct 2014 9:47pm |
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| Defender_Td5 Member Since: 20 Jul 2009 Location: Devon/Australia Posts: 69
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NEXT!
A whole load of parts went off to be shot blasted and then either re-galvanized or be galvanized as Land Rover should have done at the factory (i.e door frames, brake disk dust protectors, fuel tank strap etc). Click image to enlarge Click image to enlarge Some parts back from galvanizing, I am planning on building the doors up with the new style electroplated door skins to try and address the dreaded Defender door rust issues: Click image to enlarge Click image to enlarge While the shot blasting and galvanizing was going on, lots of panels were stripped back to bare aluminum with the two part aircraft grade paint stripper I mentioned earlier on. It is really good stuff. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Also got busy and purchased more some parts! This is the spare room at home with around 50 to 70 packages of all shapes and sizes. Click image to enlarge Click image to enlarge Regards Rob Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated |
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9th Oct 2014 10:03pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347 
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Beautiful beautiful work.
Mine is having a bit of a rebuild soon (which I thought was extensive until I saw yours  )
Glad to see another TDI brought back to life! You are clearly doing it the way it should have been done from the factory. Fantastic work Keep the updates coming they are giving me ideas and ideas and bits to check  |
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9th Oct 2014 10:14pm |
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| smb Member Since: 15 Jan 2013 Location: Cheshire Posts: 1232 
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Rob,
Excellent job and great to see some quality work. You'd put a lot of these 'professional' rebuilds to shame with your work. What is the make of paint stripper you are using? Keep up the good work
Steve |
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10th Oct 2014 12:02am |
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| Defender_Td5 Member Since: 20 Jul 2009 Location: Devon/Australia Posts: 69
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Hi Steve,
Thank you for the praise. I put a lot of thought and planning into how exactly I wanted to put this one together and after the previous rebuilds I had done, I learned a lot about how to do it the right way! I wanted to build a vehicle that didn't just look good, but was built to last and be used for what it was intended for. The company that supplied the paint stripping solution was called "Strippers Paint Removers" they can be contacted on 01787 371524. Here is a link to their website: http://stripperspaintremovers.com/view_products.htm To completely strip a Defender 110 of all paint (I mean both sides of the panels) I used around 25L of stripper. It is not nice stuff though and will burn through household rubber gloves in no time! I ended up putting on two layers of really thick industrial cleaning gloves. Rob |
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10th Oct 2014 12:55am |
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| gilarion Member Since: 05 Dec 2013 Location: Wales Posts: 5110
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Yet again I have to congratulate you on your skilled work. I could do with you as a neighbour
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10th Oct 2014 1:37pm |
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| Peter Td4 Member Since: 23 Oct 2010 Location: Antwerp, Belgium Posts: 227  
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Hi Rob,
This is truly amazing work and based on your pictures probably the most extensive rebuilt I've even seen. Congrats and really looking forward to see the final result
Keep up the excellent work Peter,
Defender 110 StaWa - Td5 Defender 110 HCPU - Puma Defender 90 Soft Top - Td5 |
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10th Oct 2014 4:25pm |
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| redzob Member Since: 16 Jul 2014 Location: St. Peter Port Posts: 137  
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Hi Rob,
Simply amazing. I'm in total awe. Defender Puma 2.2 XS 90
Vespa GTS 300 Way too many racing bikes. |
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10th Oct 2014 6:00pm |
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| X4SKP Member Since: 29 Nov 2013 Location: Berkshire Posts: 2295 
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Hi Rob,
I can only echo others on here... absolutely top job, well done. On top of actually doing the work, taking the time to post it up too...
This one looks to be setting the bench mark for rebuilds... Definitely going to follow this until the end... keep it up hardly seems necessary  SKIP
https://www.defender2.net/forum/topic83242.html |
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10th Oct 2014 6:07pm |
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