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Badger110

Member Since: 06 Feb 2018
Location: South hams
Posts: 1039

2011 Defender 110 Puma 2.4 USW Buckingham Blue

' Sally ' the 110 USW official work thread

Hello!

Here's my new addition to the family, ' Sally '. A 61 plate USW XS spec in Buckingham Blue with FSH and 140k on the clock.

We are coverting her to a camper for our ' holidays ' as standard holidays dont work for us due to work commitments and having 5 horses and 4 dogs...getting a baby sitter for that lot is not easy! So she will be converted to sleep my wife and me and 4 dogs, as well as having cooking/washing facilities and eventually being completely self sufficient ( We enjoy just stopping and camping, not really into camping sites etc ).

Click image to enlarge

This is the shot taken when i picked her up 240 miles away in Stafford. She belonged to a farrier before me and the rear had been converted to take his forge and tools, hence the side opening on the near side.

It had been done quite well with a finished bulkhead between the rear seats and the load area

Click image to enlarge

So my first job was to replace the central locking actuator on the rear O/S door as it wasn't working on the button or the keypad. The dealership sent me one down

Click image to enlarge

After stripping the door panel and plugging in the new actuator, that never worked either. So it's either 2 duff ones or i suspect the problem could be elsewhere. The dealership did say to get it done and send them the bill, so i may book it in with some other bits, at least they will have a better idea than i

The first major job was to remove the rear seats, carpets, headlinings and the forge set up in the back ready for fitting stage 1 of the sound deadening.

Underneath the carpet in the footwell of the rear seats is a panel, which typical of LR, has steel bolts to the underside of the body, and so they rust from the bottom up and react with the aluminium. I'm off to the local tool shop tomorrow to swap these out for stainless.

Click image to enlarge

So everything was stripped out and we're left with a large space

Click image to enlarge

The side opening looks like a homemade affair, but isn't too shabby. However it locks from the inside via 2 small clips and the rubber at the top has melted from the forge fitted, so i'm un decided as to what to do with it just yet. I may turn it into an opening window or repair and leave as it...until i decide on how the interior will look/be built, i don't know it's future just yet.

Click image to enlarge

Click image to enlarge

Onwards with the sound deadening. For stage 1 I used a pack of 40 Silent Coat sheets and this covered the rear tub area, roof but not the floor. It's great stuff and although i didn't cover the entire area,( you really don't need to! ) the difference is very noticable within the rear area and tapping the panels with a rubber mallet tells you that it's working well. I used scraps/off cuts to fill in areas here and there.

Click image to enlarge

Half way through, my lovely wife arrived with lunch to keep me going

Click image to enlarge

After i had fitted the silent coat, it was onto stage 2 of the deadening and i used a 5kg per sqm 2.2mm rubber sheet with a -28db rating for the wheel archs, sides and floor of the tub itself. This stuff is a nightmare to stick down, taking plenty of contact adhesive to keep it in situ ( as well as breeze blocks ) but it adds so much more to the ambient noise reduction. Sitting in the rear you notice the flatness of sound when talking and although there is still the final cover of 10mm close foam to go over the top of this, already it's a massive improvment. The rubber sheet is on the areas i feel make the most noise, ie the wheel arches, side panels and floor. The roof will evetually have a roof tent and solid rack so i'm not inclined to run the gauntlet of trying to keep the rubber stuck to the roof!

Click image to enlarge

The gaps will be filled with black silicone when the glue has gone off and before the 10mm foam is fitted on top.

So that's it for today but there is a huge list of stuff to be done including;

2nd battery and set up via solar/split charge
Fridge install
Cooker install with possible LPG tank for this and heater
Heater install
Roof tent & Rack
Porter loo
Upgraded stereo
Awnings
Units built inside to accomodate 4 travelling dogs as well as the above ( think tardis as we have a Collie, Lurcher, Old English Sheepdog and a Basset Hound)
Injector seals
Wheel bearings
Remap
And much much more!

thanks for reading

18th Feb 2018 7:12pm

familymad

Member Since: 13 Dec 2011
Location: Bucks
Posts: 3481

2016 Defender 130 Puma 2.2 HCPU Santorini Black

Looking good. I love the USW. When our kids have flown that's what I'll trade the 130 for

1951 80" S1 2.0
1995 110 300TDI
1995 90 300TDI

18th Feb 2018 7:17pm

ARC99

Member Since: 19 Feb 2013
Location: North Yorkshire
Posts: 1831

2008 Defender 110 Puma 2.4 USW Cairns Blue

I had a problem with the rear door not locking on my USW. The problem was traced to one of the cables behind the door panel had snapped. Don't make old people mad.
We don't like being old in the first place,
so it doesn't take much to

us off.

Richard

18th Feb 2018 7:40pm

Badger110

Member Since: 06 Feb 2018
Location: South hams
Posts: 1039

Quote:
I had a problem with the rear door not locking on my USW. The problem was traced to one of the cables behind the door panel had snapped.

I'm thinking it's probably something simple like this, anything else would likely cause am issue on all the locks, however it's going in soon for injectors seals so i may get them to have a look at this issue as it's covered from the dealer.

I did notice the doors already have sound deadening installed from the factory as well...

Click image to enlarge

18th Feb 2018 10:11pm

Badger110

Member Since: 06 Feb 2018
Location: South hams
Posts: 1039

familymad wrote:
Looking good. I love the USW. When our kids have flown that's what I'll trade the 130 for

It's a shame they didn't do a 130 version of the USW...imagine all that room in the back!

18th Feb 2018 10:13pm

L110CDL

Member Since: 31 Oct 2015
Location: Devon
Posts: 10742

Very nice landy and a great start to your camper conversion

1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.

18th Feb 2018 10:15pm

Crossfit_Pete

Member Since: 07 Feb 2018
Location: N.Essex
Posts: 168

2007 Defender 90 Puma 2.4 CSW Firenze Red

Will be interested to see what you have planned

18th Feb 2018 10:21pm

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Door not unlocking will be broken wires in the rubber boot between pillar and door. It's a very very common fault. Ray
My build thread
http://www.defender2.net/forum/topic17615.html

18th Feb 2018 11:50pm

ozzie1989

Member Since: 25 Feb 2009
Location: Wales
Posts: 282

2010 Defender 110 Puma 2.4 USW Bonatti Grey

Second that, I changed both my rear doors not so long ago for thicker wire encased in an outer PVC sheath where it goes through the rubber boot and ones gone again! Now: 2010 2.4 TDCi 110 Utility Wagon
Then: 2004 2.5 TD5 90 Hard Top (X-Tech Edition)

19th Feb 2018 9:25pm

LandRoverAnorak

Member Since: 17 Jul 2011
Location: Surrey
Posts: 11324

Badger110 wrote:
It's a shame they didn't do a 130 version of the USW...imagine all that room in the back!

Years ago, I knew a guy that had a 130 USW that was built by Foleys. The back was truly cavernous. Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia

19th Feb 2018 9:57pm

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