 | Home > My Defender > Defender 90 TD5 Rebuild / Tribute Build Thread |
 
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130   
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My 1999 Defender TD5 90 was beginning to look a little tired, it's been my runabout for over 5 years and after a lot of hard winters up north - it's definitely suffered.
With the Defender production coming to a halt soon, I've decided to create my own tribute to the Land Rover itself. To take the most iconic elements from previous Land Rover vehicles and combine them with the Defender to produce my own ideal Land Rover. I was a little underwhelmed by the Land Rover heritage special edition, so in effect, this is my interpretation of that concept. Any work carried out, the goal is to make it better than factory wherever possible. I've been busy filming videos on the build too, you can watch how things have progressed so far: https://www.youtube.com/playlist?list=PLhy...QhEXkyfN6y So, I found a small lock-up in early 2014, it had everything I needed (room for 2 Landy's, plus space for tools and body panels e.t.c).  Click image to enlarge I started stripping down the Defender in January of that year. Then, my parents had their car stolen from their drive, so the Land Rover was hastily rebuilt and loaned to them for several months. After getting it back in one piece, I began removing panels (again) and assessing the general condition: Click image to enlarge After painting the vehicle with Plastidip to use as a wedding car, I had to remove the film first. Click image to enlarge Then began removing panels, when removing panels, you slowly reveal hidden corrosion and rust :S Click image to enlarge In the meantime, I bought the wife let me purchase this 110 Puma, which has been a fantastic Land Rover! Click image to enlarge Removing panels like the roof and wings is very quick and good for morale - progress is rapid at this stage. Most of the panels are in good condition, the roof will be replaced with a soft top so I'll lose my webasto sun roof  But gain a canvas top. 
Click image to enlarge The sunroof was fitted at Land Rover Special vehicles - the 90 was originally owned by the National Grid who would drive up and down power grids with a hefty thermal imaging camera poking our the roof. It was also used as a driver training vehicle, shown here at 2 Dales 4x4 training centre in Derbyshire. Apparently, as it had road tyres fitted, the instructors preferred this Land Rover over others available, it helped install off-road driving techniques. Click image to enlarge The windscreen surround and hard top sides are gone! The whole lot will be stripped back so I can paint them later.I also spent time carefully drilling out rivets so I can get the capping galved. Upon refitting, I'm going to take measures prevent galvanic reactions from taking place ever again! Click image to enlarge Then, the gearbox and engine needed to come out. The TD5 unit we have is low mileage and a really sound power plant. I love them! My plan is give this a good clean, perhaps a tasteful tune by Alive Tuning but that is all by way of modifications. Click image to enlarge Click image to enlarge Then, the tub was removed, along with the bulkhead. The chassis was shifted to the side of the workshop to give me a little space. I then began experimenting with electrolysis to remove rust. My experiment was working well, until the power supply exploded! Will come back to that at some point: Click image to enlarge Underbody components were as expected for a 16 year old Landy - these are all at the shot blasters along with the bullhead as we speak. Click image to enlarge Then, it's time to start rebuilding! A shiny new galv chassis came by way of Richards Chassis at Doncaster. I've been very impressed with the build quality and finish this chassis! Top notch product, should mean this Land Rover lasts a long time. Click image to enlarge This was promptly sprayed black using a T-Wash solution, followed by etch primer and then an acrylic based top coat from Frost Autos! Looks very good now! I'm aiming for a factory finish so this extra work was worth the effort Click image to enlarge And that brings you all up to press, with the chassis painted - I'm hoping to get the whole lot built by January 2016. I'm carrying out any work I can in the shop, including a paint job, so stay tuned! Click image to enlarge Editor of FunRover - One blog. Read it! Land Rover rebuild video series here: |
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23rd Sep 2015 9:30am |
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| Browny90 Member Since: 20 Jul 2015 Location: Derbyshire Posts: 183 
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looks like it will be worth the effort in the end, I've tried to do the same, but skipped on the galv chassis as I didn't have the cash at the time.. maybe I'll treat myself in a few years and do the chassis,
I went for a slightly older version fitting a 200tdi to a TD5 chassis with TD5 body, rear fuel tank and TD5 dash and bulkhead. Question is, what do YOU think are the most iconic elements of the defender over the years? obviously everyone has their own opinion, I really wanted to keep my 200tdi alive, once the car is up and running (hopefully by xmas) I will pull out the engine and box next summer and have them fully rebuilt so that they last a whole lot longer. I'd be interested in seeing peoples list of what they think is the Ideal truck using any part you like between say 1985 to present.. I think they have to be actual possible ideas i.e. an engine and gearbox combination that could actually fit together.. This was mine last weekend, I haven't done much work forward of the bulkhead, the wing is just there for storage, new wheels & tyres on the way, Heated windscreen to fit and been toying with the slide open panoramic windows, but still undecided, Obviously the bulkhead still needs painting to. My 1986 90 is currently on a full rebuild, with new chassis, Paint etc.. Very much a hybrid, TD5 Chassis, tub & bulkhead with a 200TDI and LT77 GB Painted in Stornoway Grey  2 years off the road, but getting close to completion now |
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23rd Sep 2015 9:53am |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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Hmmm, good question.
The TD5 for me is a good all rounder, but of course for a true iconic engine - it would be a 200/300. Or maybe the ROW TGV - though I've never driven one of those. Money no object, V8 - but a diesel one from the Range Rover. It will fit in there, it's been done. The iconic parts of a Land Rover are for me atleast, exposed rivets, the front end (with elements mixed in from the 2a and Series 1) and galv cappings. I'm also switching to older Series 2 / 3 doors with removable tops. The colour I choose should tie it all together, don't want to give too much away, but... it's not a Defender colour. Editor of FunRover - One blog. Read it! Land Rover rebuild video series here: |
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23rd Sep 2015 10:01am |
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| Browny90 Member Since: 20 Jul 2015 Location: Derbyshire Posts: 183
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A diesel V8 would be great but will probably leave the rest of the truck standing still as the engine box and wheels shoot off down the road on their own
I think to make it fair the parts have to come from a defender/ series but don't necessarily have to be genuine LR i.e. panoramic windows etc.. Also if someone thinks they already have The Ultimate Defender then post a pic and see how they compare? I know there will be lots of variations depending on what you actually use it for etc, but will still be interesting to see what people think are the best/ strongest/ long lasting/ best looking parts from the last 70 odd years.. My 1986 90 is currently on a full rebuild, with new chassis, Paint etc.. Very much a hybrid, TD5 Chassis, tub & bulkhead with a 200TDI and LT77 GB Painted in Stornoway Grey 2 years off the road, but getting close to completion now |
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23rd Sep 2015 10:18am |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10381
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I once owned an 100" galv chassis/bulkhead, front and rear Salisburys, with a GM 6.2 V8 diesel.
It was great. Sorry to bust your topic Funrover |
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23rd Sep 2015 10:30am |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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This will be my daily driver too when it's finished  I'm aiming to make a proper, stripped back tribute - I should have made that clearer I do not believe in lowered suspension or performance steering wheels  Editor of FunRover - One blog. Read it!
Land Rover rebuild video series here: |
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23rd Sep 2015 10:42am |
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| me@td5.org Member Since: 16 Jan 2011 Location: Warwick Posts: 856 
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Nice to see this getting a new lease of life. I too drove a Special Vehicles 90 (300 taxi) built for the same purpose although mine came in ford signal green from the factory and had 2 removable glass sunroof. They where hardly used for the task they were designed, the cameras were quickly replaced with much lighter versions which didn't require the accompanying gas cylinder. They therefore had very low mileage and had never been worked by the line gangs. www.td5.org
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23rd Sep 2015 1:45pm |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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Good bit of info there
Out of interest, has anyone ever had a bulkhead galvanised? I'm looking at knocking up a jig to stop it from warping Editor of FunRover - One blog. Read it! Land Rover rebuild video series here: |
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23rd Sep 2015 2:03pm |
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| mikeh501 Member Since: 07 Jan 2013 Location: United Kingdom Posts: 1142
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great job in progress! im in the process of building up mine. hopefully ill get the gearbox and tbox in this week/next.
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23rd Sep 2015 3:26pm |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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Thanks for the nice comments everyone!
@Mikeh501, hope all goes well this weekend
Here's what I got up to yesterday: Click image to enlarge Using a twisted wire cup, started removing the worse of the rust. Really impressed with the cups, they work pretty quickly! A friend removed the superpro bushes using threaded bar - as they are a one piece construction, you'd need an 8" vice and suitable drifts e.t.c. Today, I'm hoping to go collect my bulkhead and axles: here's a sample from the video I shot whilst I was there on Monday Click image to enlarge It's brought it up lovely! Much less welding needed than I thought, then off to galvanisers  Editor of FunRover - One blog. Read it!
Land Rover rebuild video series here: |
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24th Sep 2015 6:51am |
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| AndyTunn Member Since: 10 Jan 2015 Location: Auckland Posts: 313 
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Hi, just checked out all the videos so far on YouTube - really great stuff!!
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24th Sep 2015 7:18am |
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| fathaggis Member Since: 31 May 2015 Location: taynuilt Posts: 385 
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looking great mate ..... ill be watching . my 90 was a total stainless rebuild with a 300 tdi . no galvi as it didn't need it . it may export some day
http://www.defender2.net/forum/topic37584.html my car |
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24th Sep 2015 11:31am |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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Very smart Landy fathaggis! Editor of FunRover - One blog. Read it!
Land Rover rebuild video series here: |
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24th Sep 2015 9:19pm |
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| funrover Member Since: 12 Dec 2010 Location: Yorkshire Posts: 130
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More progress made, a little gutted that my axles and bullhead won't be finished till next week - could slow me down a bit. I had help off my mate last night, but we didn't have tonnes to do.
Click image to enlarge The gearbox crossmember is in. These require a slight spreading of the chassis. I do not like farm jacks but it's all that was to hand, so packing it out with wood to protect the chassis and one man operating the jack whilst another hammers the gearbox in. The ends we're coated with grease to make the job a bit easier. Glad to be able to put the farm jack away again, no incidents
Click image to enlarge I took delivery of this fantastic bit of kit from SIP Industrial products. It cut right through the CV shaft grease and means they are ready for rebuilding. Click image to enlarge I've filled it with paraffin for now, am waiting on some proper parts washer fluid for items I want to paint afterwards. The rear upper link arms still had metaplastic bushes fitted. These were totally shot, they were burned out: Click image to enlarge Then it's a case of cleaning off all the cast parts, going from this: Click image to enlarge Using a twisted wire cup Click image to enlarge Was a late night for me. Here's how they looked afterwards. I'l treat them to some anti-rust agent then etch prime and paint them satin black to match. There'll be no blingy bits underneath. Click image to enlarge Also, couldn't wait to start fitting new bits and bobs, so.... Click image to enlarge I'm going with a standard suspension set-up. Editor of FunRover - One blog. Read it! Land Rover rebuild video series here: |
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25th Sep 2015 9:37am |
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