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fathaggis

Member Since: 31 May 2015
Location: taynuilt
Posts: 385

this defender is in a league of its own .....

its should have one of the magazines do a spread on it .. its that good

16th Jul 2015 10:26am

Welkman

Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

I found doing electrics on yachts has helped no end with car electrics as everything has to be to a really high standard for insurance, also the systems for a small boat are similar in terms of aux fuse boxes, split charging and cable protection. I used this book to teach myself

28th Aug 2015 7:52am

need4speed

Member Since: 23 Nov 2012
Location: Kilmarnock
Posts: 746

That's a good shout Welkman

I'm pretty good mechanically but the one aspect of my build that I've needed a lot of help with is the electrics.

PaulMc on here has been a real life saver for me. I have a 4.6 V8 fitted with Megasquirt in my 110 so a lot of the TD5 loom was totally redundant. Paul told me what I could safely remove from my harnesses and even made up some custom ones for me for my engine and Raptor console etc etc.

Something like that book you refer to could really help me get my head around that aspect of things...

28th Aug 2015 1:21pm

Pickles

Member Since: 26 May 2013
Location: Melbourne
Posts: 3781

2013 Defender 90 Puma 2.2 CSW Keswick Green

need,...4.6 & "megasquirt"?.....excuse my ignorance, but what is a "megasquirt"?....anyway a "4.6" in a 110 sounds interesting (any V8 does to me!!)....any pics, engine bay etc?
Pickles.

28th Aug 2015 9:56pm

AndrewS

Member Since: 10 Apr 2007
Location: Hereford
Posts: 3707

2013 Defender 130 Puma 2.2 SW Rimini Red

Great build

130's have feeling's as well you know

29th Aug 2015 7:16am

need4speed

Member Since: 23 Nov 2012
Location: Kilmarnock
Posts: 746

Pickles wrote:
need,...4.6 & "megasquirt"?.....excuse my ignorance, but what is a "megasquirt"?....anyway a "4.6" in a 110 sounds interesting (any V8 does to me!!)....any pics, engine bay etc?
Pickles.

Here you go Pickles..

http://www.megasquirt-v8.co.uk/ms_what_is_ms.php

And a link to my build- it's easier than going over it again

http://forums.lr4x4.com/index.php?showtopic=46671

I really need to update the thread as lots has been done since but I'm in such a tight garage now taking decent pics is very difficult. It can be a challenge just getting round the LR to work on/in it....

29th Aug 2015 9:45am

Defender_Td5

Member Since: 20 Jul 2009
Location: Devon/Australia
Posts: 69

1991 Defender 110 300 Tdi USW Stornoway Grey

Over 20k views! Well I never, ever expected my thread to be so popular, thank you to everyone who has taken the time and effort to read the whole thing right the way through. I must apologise for being a little quiet on here recently, I have been flat out with work and also have taken on rebuilding a 1975 Series 3 SWB (owned by a friend, who is learning mechanics as we go) here in Australia:

As bought after part dismantling (rare chicken edition):

Click image to enlarge

The state of the chassis:

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Repaired Bulkhead and Chassis:

Click image to enlarge

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Bulkhead Repairs:

Click image to enlarge

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Core plug hole repaired:

Click image to enlarge

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Rebuilt Front and Rear Axles, including differentials as well. Every seal, gasket and bearing was replaced due to salt water damage (the vehicle had been used on the beach extensively by the previous owner) and lack of maintenance:

Click image to enlarge

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Currently as the project stands:

Click image to enlarge

Click image to enlarge

An order has arrived from the UK for the Overland 110 as well, consisting of the following:

- 6 x Wolf Tubeless Wheels (these will be fitted with 255 85 R16 BFG KM2s and used solely for off-roading)
- 1 x Blindo Wheel (to carry as an additional spare and will be fitted with the same General Grabber AT2 tyre)
- D44 front weld on aluminum housing protector (in black, red was a bit bright!)
- Full Superpro bush replacement kit.
- 1 x Ashcroft front diff locking unit
- 2 x Ashcroft HD CV joints
- 2 x Ashcroft HD front half-shafts

That will take care of the drive-train strengthening upgrades, given the rear axle is already done this will also future-proof the vehicle as well for a possible engine and gearbox upgrade.

I'll update the Defender build once I get my teeth stuck into it again.

Watch this space!

Cheers

Rob

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

Defender 300Tdi 110 Utility Wagon ROW Overland
Series 1 86"

Last edited by Defender_Td5 on 31st Aug 2015 7:45am. Edited 5 times in total

31st Aug 2015 5:51am

GREENI

Member Since: 22 Aug 2010
Location: staffs
Posts: 10379

Awesome. That is all.

31st Aug 2015 7:17am

rustandoil

Member Since: 08 Sep 2012
Location: Cotswolds
Posts: 736

2005 Defender 110 Td5 XS DCPU Bonatti Grey

Just read the whole thread from the beginning, your attention to detail is what stands out, well done

31st Aug 2015 7:58am

mrd1990

Member Since: 16 Aug 2012
Location: Wales
Posts: 600

You should do rebuilds for a living, I'd happy pay over the odds for your services

31st Aug 2015 10:14am

Oldyellar

Member Since: 04 Sep 2015
Location: Central
Posts: 384

2015 Defender 90 Puma 2.2 XS CSW Corris Grey

Amazing work

13th Oct 2015 4:13pm

T1G UP

Member Since: 08 Dec 2009
Location: Bath
Posts: 3101

2011 Defender 110 Puma 2.4 XS CSW Orkney Grey

Defender_Td5 wrote:
Hi All!

Finally an update! Sorry it took so long...

So, first on the list was the change out the front seats for some recently purchased Puma XS Heated ones, these where bought over from the UK and had only done delivery miles before being removed for an upgrade by the previous owner:

"Old" Outlast Covered Standard Tdi Seats:

Click image to enlarge

New Tdci Seats all fitted:

Click image to enlarge

I got lucky with an eBay purchase of some second row XS Puma covers to match the fronts, I have now fitted these thanks to an excellent guide on this forum:

Click image to enlarge

Front and Rear Anti Roll Bars Blasted back to bare metal:

Click image to enlarge

Back from the Powdercoaters (satin black in place of the original bright orange), I also took the opportunity to have the mounts blasted and galvanized at the same time:

Click image to enlarge

Both rock sliders were removed and had jacking points installed, this involved taking out a "half-moon" shape and welding in some 4mm tube that was cut to fit:

Click image to enlarge

Click image to enlarge

Both were then blasted:

Click image to enlarge

And galvanized:

Click image to enlarge

Click image to enlarge

I then tried them out on the Defender, but decided I preferred them powdercoated as they were originally, so I am having these done as well:

Click image to enlarge

The front propeller shaft came back from reconditioning, the splines were excessively worn, which has me a bit perplexed as the vehicle has only done 14,000 miles and I had been greasing both front a rear prop-shafts regularly. As a matter of course they also replaced all three UJ's and rebuilt the center cardon joint as well.

Click image to enlarge

All five Blindo wheels were reconditioned as they had gotten pretty scratched up by offroading, the BFG KM2's were removed and replaced with some General Grabber AT2's in 265 75 R16 size, I'll keep the KM2's and mount them on a set of Wolf rims that I have purchased. It's amazing the difference between the KM2's and the AT2's on the road in terms of noise reduction and steering vibration.

Click image to enlarge

I also removed the front and middle head-linings and tidied up the wiring with some self adhesive clips:

Click image to enlarge

That's where I am currently, a bit more to follow in a few weeks. Here is my other toy when it was in for a full dyno tune, it's a KTM 990 Adventure.

Click image to enlarge

Cheers all.

Rob

you must be my brother from another mother! i have an orkney grey 110 ( utility sides now fitted ) with black blindos and a 2009 white ktm 990 adventure with akro cans and a remap!

another man of great taste :bow:

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

13th Oct 2015 4:28pm

T1G UP

Member Since: 08 Dec 2009
Location: Bath
Posts: 3101

Defender_Td5 wrote:
Hi All!

Finally an update! Sorry it took so long...

So, first on the list was the change out the front seats for some recently purchased Puma XS Heated ones, these where bought over from the UK and had only done delivery miles before being removed for an upgrade by the previous owner:

"Old" Outlast Covered Standard Tdi Seats:

Click image to enlarge

New Tdci Seats all fitted:

Click image to enlarge

I got lucky with an eBay purchase of some second row XS Puma covers to match the fronts, I have now fitted these thanks to an excellent guide on this forum:

Click image to enlarge

Front and Rear Anti Roll Bars Blasted back to bare metal:

Click image to enlarge

Back from the Powdercoaters (satin black in place of the original bright orange), I also took the opportunity to have the mounts blasted and galvanized at the same time:

Click image to enlarge

Both rock sliders were removed and had jacking points installed, this involved taking out a "half-moon" shape and welding in some 4mm tube that was cut to fit:

Click image to enlarge

Click image to enlarge

Both were then blasted:

Click image to enlarge

And galvanized:

Click image to enlarge

Click image to enlarge

I then tried them out on the Defender, but decided I preferred them powdercoated as they were originally, so I am having these done as well:

Click image to enlarge

The front propeller shaft came back from reconditioning, the splines were excessively worn, which has me a bit perplexed as the vehicle has only done 14,000 miles and I had been greasing both front a rear prop-shafts regularly. As a matter of course they also replaced all three UJ's and rebuilt the center cardon joint as well.

Click image to enlarge

All five Blindo wheels were reconditioned as they had gotten pretty scratched up by offroading, the BFG KM2's were removed and replaced with some General Grabber AT2's in 265 75 R16 size, I'll keep the KM2's and mount them on a set of Wolf rims that I have purchased. It's amazing the difference between the KM2's and the AT2's on the road in terms of noise reduction and steering vibration.

Click image to enlarge

I also removed the front and middle head-linings and tidied up the wiring with some self adhesive clips:

Click image to enlarge

That's where I am currently, a bit more to follow in a few weeks. Here is my other toy when it was in for a full dyno tune, it's a KTM 990 Adventure.

Click image to enlarge

Cheers all.

Rob

you must be my brother from another mother! i have an orkney grey 110 ( utility sides now fitted ) with black blindos and a 2009 white ktm 990 adventure with akro cans and a remap!

another man of great taste :bow:

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

13th Oct 2015 4:28pm

Defender_Td5

Member Since: 20 Jul 2009
Location: Devon/Australia
Posts: 69

Hello!

Merry Christmas to all! I am finally back with an update....so read on and hopefully enjoy.

Breathing Issues:
The Wolf Army spec Donaldson filter that I had fitted to the truck has performed very well, however during a routine service the plastic mounting band which holds the filter to the engine mount snapped in half. I wasn't very impressed by this and set about sourcing a metal band from Donaldson directly.

[URL=]

Click image to enlarge[/URL]

Removal of the housing also showed that the inlets and outlets had been overly compressed by the hose clips, I addressed this issue by sourcing some slightly undersized aluminum tubing and then inserted into both the inlet and outlet, securing them in-place with Araldite two part slow setting epoxy glue:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

A new mounting system had to be made up to mount the different metal securing band, the old plastic mount was bolted to the original 300Tdi flexi rubber mounts, however the new system is hard mounted to the air filter support bracket, it gives a much stronger mount that is now lease prone to flexing and rubber deterioration.

[URL=]

Click image to enlarge[/URL]

A piece of 3mm aluminum was then used to direct mount the new metal band:

[URL=]

Click image to enlarge[/URL]

However with the new steel air filter box mount in place, this altered the alignment of the air-intake hose which meant the Land Rover offering was no longer, long enough without putting undue stress on the mounts:

[URL=]

Click image to enlarge[/URL]

So the hose was split at the joint and a insert piece was purchased in three ply silicon, again the flanges were strengthened with aluminum tube inserts which were Araldited in place and then the extension piece was hose clamped together, one more hose clip still to go on in this picture:

[URL=]

Click image to enlarge[/URL]

While on the subject of breathing, I also purchased a MANN Provent 200, this will be fitted soon and will hopefully address the 300Tdi crank case breathing issues which all the engines suffer from to a degree:

[URL=]

Click image to enlarge[/URL]

Following on from a slightly enthusiastic off-roading expedition, I ended up with quite a large amount of muddy water in the truck, this time it had got into the carpets, so everything had to come out for a proper clean up, including the rear storage chests:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

Bits of Land Rover everywhere:

[URL=]

Click image to enlarge[/URL]

I took the opportunity to address some slight aluminum corrosion that had started around the mountings for the rear seats and the rear storage chest:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

The rear floor was then covered in Dynamat:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

Carpet re-installed:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

New BFG KM2s in 255 85 R16 mounted on Genuine Land Rover Wolf Rims. These are now my off-road wheels and tyres as I was fed up with trashing my rather nice Blindos!

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

Out for an adventure with some friends:

[URL=]

Click image to enlarge[/URL]

Defender wins!

[URL=]

Click image to enlarge[/URL]

Awesome day in the mud:

[URL=]

Click image to enlarge[/URL]

New air-intake hose got tested:

[URL=]

Click image to enlarge[/URL]

Twin ARB compressor purchased and awaiting installation:

[URL=]

Click image to enlarge[/URL]

What to do with the old ARB compressor? Make it into a mobile air source of course, mounted into a Spacecase:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

I was still suffering from a slight drive-train vibration and was convinced it was propshaft related, so a call to Gwyn Lewis in the UK and one of his amazing double cardon HD props later and guess what, no drive-train vibration at all:

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

Still yet to be fitted is my D44 HD front Diff guard, this will go on when I pull the front axle off to add the Ashcroft Halfshafts and CVs:

[URL=]

Click image to enlarge[/URL]

Finally got around to fitting my Madman Engine Monitoring System, more on this in the future:

[URL=]

Click image to enlarge[/URL]

EGT Probe install as a part of the Madman kit:

[URL=]

Click image to enlarge[/URL]

The clutch master cylinder gave up the ghost and dumped all its fluid all over the housing, which kindly stripped all the paint off, so that had to come out for a re-paint and fitting of the new cylinder. I also fitted a later cross drilled clutch pivot pin that has a grease nipple in the end, the result is a clutch that now doesn't squeak!

[URL=]

Click image to enlarge[/URL]

[URL=]

Click image to enlarge[/URL]

Resting up before the next trip!

[URL=]

Click image to enlarge[/URL]

Cheers all and here's to wishing everyone a Happy New Year!
Rob

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

Defender 300Tdi 110 Utility Wagon ROW Overland
Series 1 86"

Last edited by Defender_Td5 on 28th Dec 2015 6:03am. Edited 1 time in total

26th Dec 2015 4:14am

Enid_Puceflange

Member Since: 25 Oct 2014
Location: edinburgh
Posts: 1172

Brewstop wrote:
This thread is comprehensive land rover porn for me - Thank you!

What he said!!^^^^^

Merry Christmas My confidence has been writing cheques that my abilities can't cash for years.

26th Dec 2015 1:17pm

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