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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Defender 90 Rebuild (Galv, v8, auto!)
My first rebuild, so i welcome the help from everyone Mr. Green
(actually my first major mechanical rebuild of anything, so its going to be interesting! if i can do it, anybody can.)

So, the genesis.... ive had a 200tdi 1994 defender for a few years now and done all the usual "upgrades" which culminated last year in me ripping the roof off and converting it to a soft top. Ive always had a hankering for a v8 and saw a couple of lots come up at an auction. a cheeky bid later and the project had started - i didnt even know what id bought and to some degree still dont; but it provided the jump start this project needed.

Where it all started. lot 328. listed as "4.2V8 engine possibly reconditioned"


...and lot 296. listed as "defender 90 chassis"


So without seeing either item (i was on holiday when i bid for it on my phone lol) i paid the cash and got a man with a big trailer to help pick it up.

Click image to enlarge


and away we went Rolling with laughter
Post #430393 12th Jun 2015 10:11am
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YOLO110



Member Since: 14 Feb 2015
Location: Perth Oz and Stansted UK
Posts: 1645

Australia 
THIS...

IS going to be a great story!!! Thumbs Up YOLO... You Only Live Once...
Post #430397 12th Jun 2015 10:22am
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10383

United Kingdom 
I'll be happy to give any advice, I'm doing the exact build... v8 auto galv !

If you're ever stuck, PM me and I'll pick up the email notification.
Always on the phone for advice too.

Watching with interest!!
Here's mine..
http://www.defender2.net/forum/topic34827.html
Post #430404 12th Jun 2015 11:04am
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Engine looks smart. That a carbon air box?
Post #430409 12th Jun 2015 11:13am
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10383

United Kingdom 
Post #430411 12th Jun 2015 11:21am
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shaggydog



Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

United Kingdom 1991 Defender 110 200 Tdi USW Arles Blue
What are you doing with the old 200Tdi Whistle ?

Looks like a great build!

Where was the auction? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter Very Happy
Post #430418 12th Jun 2015 11:56am
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
GREENI wrote:
I'll be happy to give any advice, I'm doing the exact build... v8 auto galv !

If you're ever stuck, PM me and I'll pick up the email notification.
Always on the phone for advice too.

Watching with interest!!
Here's mine..
http://www.defender2.net/forum/topic34827.html


Thanks, ill absolutely check it out! Im sure ill wear out the help offer Rolling with laughter

GREENI wrote:
Not cheap either...
http://www.actproducts.co.uk/product/ti026...-throttle/


I had no idea, but it does look exactly like that. Its definitely real carbon fibre.

GREENI wrote:

What are you doing with the old 200Tdi Whistle ?

Looks like a great build!

Where was the auction?


Undecided as yet on what im doing with the engine etc Whistle
The auction was from a website called "bidspotter". They have all kinds of stuff on it. Get on their mailing list and you will get stuff on email. The entire caterham F1 team stuff was on there not long ago.

Thanks for the kind words all. Im actually a bit further on than ive posted above, so ill stick something on with regularity until your up to date; at which point it will slow to a crawl lol Rolling with laughter
Post #430421 12th Jun 2015 12:21pm
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Devon-Rover



Member Since: 22 Jan 2015
Location: South Devon
Posts: 917

United Kingdom 2014 Defender 110 Puma 2.2 USW Aintree Green
Whilst mine was a conversion from an existing V8 90. i am the author of >>> http://forum.landrovernet.com/showthread.p...-questions

I have done the full conversion so if you want feel free to pm me and i can run through the ins and outs of the conversion and give you some pointers and help with those head scratching moments.

All the Best..
Post #430428 12th Jun 2015 12:37pm
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Aaron



Member Since: 09 Dec 2010
Location: Surrey
Posts: 46

United Kingdom 1998 Defender 90 V8 Petrol 50th Auto Atlantis Blue
GREENI wrote:
Not cheap either...
http://www.actproducts.co.uk/product/ti026...-throttle/


Certainly looks like ACT, well known in the TVR circles for the upgrades. The twin/triple carbon plenum kit look fantastic.

Look forward to following the project Bow down ex-MY1998 Defender 50th GB343 5.0L JE Supersports
MY2000 TVR Griffith 500
MY2003 TVR Cerbera SP6
Post #430453 12th Jun 2015 2:13pm
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Right then. Once I got the engine and chassis home I needed to find out what it was! So I did some major googling and research and it turns out the "4.2v8 possibly reconditioned" was actually a bran new recon/remanufactured motor from RPI. The 4.2 became the 4.6 Stage3+! result! Mr. Green

Next job was to try and turn it over to ensure it hadnt seized up from 3 months outside under a tarp! Unfortunately it just wouldnt turn AT ALL using a 1m breaker bar on the pulley. Anyhow, heres some more pics. Everyone likes pics right Thumbs Up


Click image to enlarge


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Click image to enlarge
Post #430520 12th Jun 2015 8:30pm
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gilarion



Member Since: 05 Dec 2013
Location: Wales
Posts: 5111

Wales 2007 Defender 90 Other CSW Trident Green
Great auction find and good luck with the build. Just out of interest did the lot come with the gear box cross member as shown on mine.



Click image to enlarge
 For those who like Welsh Mountains and narrow boats have a look at my videos and photos at..

http://www.youtube.com/user/conwy1
Post #430629 13th Jun 2015 11:04am
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Well spotted, no it didn't. One of the things which has been worrying me lol. I spoke to mmarslands and they think it's a v8 nas chassis, and on those they don't supply one. Rare as rocking horse droppings........ Spoke to my local landy guy and he reckons it won't be a problem. We shall see!
Post #430724 13th Jun 2015 5:50pm
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Romadog



Member Since: 07 Jul 2011
Location: Powys
Posts: 1749

I used one from Disco 1
Post #430729 13th Jun 2015 6:18pm
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Thank you sir!
Post #430742 13th Jun 2015 7:36pm
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 1142

United Kingdom 
Okay, this weekends update. Axles!

One of the bug bears on my current 90 is the way my diff pan protectors are the lowest point on my landie. I want to increase the vehicle ride height so im planning to get taller tyres and not use the diff protectors as they reduce the ride height by about 1/2". So coupled with taller tyres id be looking at maybe a 2" increase in height under the diffs. I dont think 2" has ever cost so much lol..... but you know every inch counts lol Rolling with laughter

So 2 new axle cases later...


Click image to enlarge


A nice man with a plasma cutter and excellent welding skills later and you can see through both ends lol

Click image to enlarge


certainly going to look great with these covers on Thumbs Up

Click image to enlarge


next its time for paint. prepped with Dinitrol RC900 rust convert. then sanded all over with an air sander.

Click image to enlarge


Then epoxy mastic 121, and its all painted up nicely. really recommend this stuff, its got excellent adhesion. its like some kinda paintable sikaflex in consistency and hardens to a semi-flexible semi-gloss finish.

Click image to enlarge


Tada! Word of caution, dont use your engine lift as a work area! the lift made it really easy to paint them, but when i came back the next day the axles were on the floor! Mr. Green

Click image to enlarge
Post #430955 14th Jun 2015 9:28pm
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