 | Home > My Defender > Time to get round to the rebuild....open diary with pics. |
 
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49   
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I have a dream... a dream to drive a Defender that doesn't rain on the inside, isn't colder than the outside, is quiet enough for me to listen to radio2 and has an interior that rivals a 1940's John Deere.
The thing is, I don't have a budget for a new one, so I'm going to have to do it myself........ It all started with the need for a bulkhead replacement, then I thought 'whilst I'm at it, I might as well rebuild the engine, gearbox, drivetrain, steering, bodywork, electrics, brakes....' and so it goes on. Today I've made a start whilst it's not raining, then I can still get on with things in the shed when the weather is poor.  Click image to enlarge As you can see, I don't have the luxury of a garage, so I'm doing it on the driveway..... in the winter? I must be mad... I know my ambitions may be high, but when you get down to it, there's not much to a Defender. So 6 months should be enough time for me to make the dream a reality? Just about every system has been or will be modified, starting with the existing stretched (12") 110 chassis. HB  Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first!
http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." Last edited by Hairy Beekeeper on 17th Nov 2015 12:25pm. Edited 1 time in total |
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16th Nov 2015 2:28pm |
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| GSLRO Member Since: 13 May 2012 Location: Tyne and Wear Posts: 499 
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Oh good luck! Will get the popcorn ready for sitting back and watching a rebuild thread. Just wonder if it will be cheaper to buy a new one, even though new ones do also leak!
Adventure isn't paved! |
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16th Nov 2015 4:18pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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I'm probably going to use this thread as a diary as well as sharing. If there's some boring bits, then I apologise!
The engine is covered in about 10+ years of work and off road fun, I've just spent the last week or so 'finding' the workshop floor and bench! Before.... Click image to enlarge It's amazing what you can achieve with just a domestic cold jet washer. Most of the mud has come off, but a lot of greece remains. Click image to enlarge It's now clean enough to take into the workshop and start stripping. Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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17th Nov 2015 12:10pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674  
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Looking good so far, will follow this thread. Oh and brave man for doing it in this weather
90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html 110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html 52HG25 lightweight https://www.defender2.net/forum/topic72342.html D3 Hse - Fiona Capri 2l S - Anna Think I might have a problem............ |
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17th Nov 2015 12:48pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347 
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Give the greasy bits a good coating with gunk and agitate it with an old toothbrush then just pressure wash off. Works brilliantly!
Good luck your a brave man doing it over winter! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter  |
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17th Nov 2015 12:59pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Thanks, I plan to take the bulk of the dirt off outside then clean each individual part as I strip down, inspect and rebuild.
The engine is having new main bearing shells, piston rings, piston bores honed, minimal head skim, valve seats reground, new water pump, glow plugs, injector heads, turbo seals and bearings, valve caps and anything else I find that is either worn or might as well be changed whilst it's in bits. Along with all of the obligatory seals, belts, gaskets and filters. I am also considering port and polishing the head too, anyone have any experience with this? oh yes, and shiny bits. A recon engine should look like one from the outside, and have shiny bits on it too! Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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17th Nov 2015 1:24pm |
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| JAY BOY Member Since: 04 May 2010 Location: Not here Posts: 1706 
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Good luck with the build.
I'm looking forward to your journey |
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17th Nov 2015 7:53pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Sounds very thorough, I'm surprised your going that deep into the engine, I have never known a 200Tdi need new bearings or cylinders re-honing. Is it very very smokey?
I would caution you to give Frida at Turner engineering a call first as you may save yourself a lot of time, hassle and money by letting sleeping dogs lye. With regard to performance head, I have literally just fitted one to mine
Bit of a write up here... http://www.defender2.net/forum/topic40214.html To be honest yes there is a slight difference, is it £100 different, not really. Having just had an absolute nightmare with my head just get it inspected and bolted back down and running. Defiantly worth doing clutch, inspect the flywheel, change gaskets where needed and doing the timing belt. Best of luck and keep us posted! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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17th Nov 2015 8:12pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10728 
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good luck with the rebuild, will be watching your thread with interest
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17th Nov 2015 9:37pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Thanks for all of the genuine interest, my wife is very relieved to not be the bearer any more!
I read your thread with interest Shaggydog, thanks for the link. The 200tdi in my Defender is a retrofit from a c1993 Discovery with unknown mileage on it. I did the conversion myself about 10 years ago and should have written it down (I probably did at the time, but who knows where). I think it was in the region of 180k, and came out of a scrapper with the usual rotting floor issues. It was a straight swap for my SWB shogun that I had at the time. We both felt like we had a good deal out of it! 
The poor girl (she called Clara BTW) has had many years of off roading abuse from me ever since and if I'm honest, not been looked after very well with servicing and the like. Most things being done because they were necessary, rather than out of routine servicing. she was stood for well over a year and with a quick prime she instantly fired into life, even with old fuel and stale vegetable oil in the tank. I'm inclined to agree that there may not need to be such a comprehensive rebuild of the engine, but I feel I owe it to her after all of the 'that'll do for now' bodges I've done over the years. - I remember one occasion where the exhaust port had gone on the head gasket and it took me at least 6 week of driving what sounded like a steam engine before I found time to fix my working vehicle. 
I also feel like I might as well do as much as possible when it's in bits, it's much better than wishing you had afterwards, 50k down the line. Anyway, back to the workshop. I'm going to strip the ancillaries off and start making lists..... HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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18th Nov 2015 11:20am |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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I finished early today, so I managed to squeeze a couple more hours in the workshop before kitchen duties.
Yesterday I started stripping the block of it's ancillaries, labelling the bit's that could be put in the wrong place and putting the nuts and bolts for each item in a marked envelope to keep them together. I have taken a few pictures of bolt locations on the way, mainly for the water pump and the timing belt cover that both use different sized fixings. Click image to enlarge Click image to enlarge I got stuck on a tricky bolt, whilst trying to remove the timing belt cover, the one right at the top that has a nut on the end, and also tightens the water pump. I decided to give it a soak in WD40 overnight and go and order parts instead. The crankshaft pulley was easier than expected, the last one I did necessitated a visit to the garage and borrowing the 1" drive big bertha to impact the nut off, But that was a 300tdi, and apparently done to a much higher torque. I removed the clutch and bolted a piece of angle iron to lock the crankshaft, and then got my telescopic ratchet on it and hey presto, off it came!
Click image to enlarge Today got me doing a lot of work, but achieving little! The parts for the turbo are shown as different things in different places, so I thought I'd strip it and have a look for myself. The turbo (Garrett T25) isn't looking too good, the inside is very dirty. Probably all those dusty miles with just a snorkel for an air filter. The shaft still spins freely, with no grinding or tightness. Click image to enlarge I had a lot of trouble trying to undo the bolts that had seized and rusted. 3 of them came out with me grinding a couple of mm from the side of my spanner, so it'd fit in the tight gap and then tapping it on. Then using pressure and heat to get them going. The last one wouldn't budge, and despite me trying not to, started rounding off Argh! 
I shifted it in the end by welding a scrap bolt on and rocking it back and forth with a pair of mole grips. Click image to enlarge Once the bolts were loosened, it was evident that more penetrating oil is needed to free the housing, so that's where that is at the minute. I then went back to the timing belt cover and had a go at that. After tapping and levering (being careful not to bend or damage the aluminium) and applying heat, the flipping thing still didn't budge. I guess it'd corroded together, so I welded a bar on that too. -It didn't quite go to plan, it sheered off, but in a position that wasn't too inconvenient. Click image to enlarge Fingers crossed that I'll be home by lunch time again tomorrow, then I can see if the turbo will separate and finish stripping the other side of the block. HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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19th Nov 2015 9:10pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Hi Rosco, thanks for the interest.
I did the stretch about 3 computers ago, so I'm not sure if I still have access to the pictures. There is a chance that facebook holds the evidence somewhere! It started out in life as a 110 CSW, and was great at doing what it does. Nicknamed red leader one when leading convoys across the Peak District. I'd always fancied a double cab, it suited my lifestyle, and I didn't really need the seats in the back (at the time I didn't need the second row either), only being used to it's full potential when I went back to college (mature agricultural student), and we needed to move half the class to the BBQ area.... that's another story! anyway, I digress. The pickup bed in the back of a 110 is pretty shameful, and not really much use for more than a sheep dog to be fair, so that's when the plan came into action. The rear cross member was rotten, and I had access to a rear half that was in good condition. I cut the rear of the chassis off and welded on the other one that was cut 12" longer. My chassis currently has 2 rear radius arm mounts, where the joint is. I welded angle iron on the inside corners of the replacement chassis, and used that to slide it together and hold it in place whilst lining it up and making measurements. The receiving chassis had holes drilled into it, and then welded through the the angle iron below. the seam was welded, and then bracing was welded across the joint to strengthen it even more. My next focus was extending the propshaft. I ground off the weld at the UJ, and removed the pipe. The UJ piece had a tapered end and fitted very nicely into a scaffold pipe, then welded back together. Not knowing what travel was required, I used the telescopic ends from 2 shafts to make up each end. I think myself lucky that It didn't need balancing and it seemed to work first time! the exhaust was separated at a joint, and then a joining pipe 12" long was made to fit in the gap. This ensures that I can still use standard replacement parts. I also did the same thing with the brake lines. The fuel line was replaced with 10mm copper pipe from front to back, and the electrics extended with connector blocks covered in vaseline and placed in a box. The bodywork was cut down into a double cab and a rear 109 tub was modified to fit into the gap between the back of the rear seats and rear cross member. The MOT man was happy with the modifications, and stamped a report that I'd already prepared for him to sign, confirming the work being satisfactory. He said as far as he was concerned, it was just the same as a rear chassis section replacement, but better. So, that's a long story shortened about a chassis lengthened. I don't have a garage so had to do it on my driveway, and it took only a week from start to finish. All that was left was to wait for the weather to brighten up, then I got my gloss roller out and matched the panels with dark green paint. Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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20th Nov 2015 7:06pm |
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| Hairy Beekeeper Member Since: 16 Nov 2015 Location: leicestershire Posts: 49
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Christmas came early today!
When I came home early afternoon, the postman had filled my porch with lots of parcels containing new parts for the 200tdi. I didn't take the camera into the workshop, as my hands were black most of the time. I spent the next few hours stripping. The crankshaft drive for the timing belt was seized and took a while to persuade to to move without damaging it, or the aluminium timing belt housing. The head was separated, assistance was needed to keep the engine steady whilst cracking the bolts off. Maybe loosening it when it was still in the truck would have been easier? The Head presented me with a few problems, 2 of the injectors wont move. I've left them soaking for now. I also have a problem with the glow plugs. they have broken and left the ends inside when unscrewed. It's a good job that I was stripping the engine anyway, I think I'd have to take the head off to solve that one. Cam lifters and camshaft removed and in good condition, and no scoring apparent damage to the pistons or bores. There is heavy coking, likely to be the reason why the injectors and glow plugs are giving me hassle. The piston bore is smooth and shiny, a honing will be useful. Tomorrow I'm off to get some front doors and do family stuff, working all day monday and doing a couple demonstrations in the evening, so Tuesday should be my next workshop session. Now to open my presents, and check the parts are the right ones! HB Currently rebuilding my stretched 110 (now 122) to personal spec, probably going to be a double cab dropside, but not fully decided yet. So I've started at the front end first! http://www.defender2.net/forum/topic41658.html "Sorry love, don't make me choose between you and my Lanny. You won't like the answer....." |
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21st Nov 2015 9:26pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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I had 2 stuck injectors on my head.
In the end I soaked it with a mix of wd40 and diesel for a week and then on the last day used a very very tight fitting spanner and a piece of scaffold bar and gently wiggled it back and forth until eventually I could get a full rotation. Once I could get a full rotation I clamped the injector in a vice and then holding the head I pulled and wiggled it off. Be very careful as it is very easy to damage the very soft aluminium casting. As for the glow plugs again soak them and if they have snapped past the threaded section then just tap them out from underneath gently. Your not going to be able to reuse them! Stick some pics up will be very interesting to compare them with mine Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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21st Nov 2015 10:49pm |
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