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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674   
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Cheers 👍🏻 Nothing directly wrong with it but a few seals seeped and when I removed the twin carbs a fuel line snapped, I couldn't find the replacement pipe so I decided to upgrade, the rocker covers and sump came off as I wanted to just check the internals due to the new cam and carb. 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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14th Nov 2017 2:19pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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So if buggsy having an update was long overdue what is maggies?
Well I have been able to do a few bits to her this week so I’m back on the rebuild 
First job was to drop the gearbox and t-box:  Click image to enlarge A little bit of cleaning to remove 30 yrs of crud gave me this: Click image to enlarge Now I knew from the start a new chassis was going to be used for the project, it had a few areas that could of been patched and previously had a new rear crossmember, however I was not expecting this when I removed the gearbox crossmember: Click image to enlarge Click image to enlarge Click image to enlarge As you can see there is nothing left from behind the crossmember, I have never seen rot this bad so here is another place to check. With the box off I can start to overhaul the brackets/transmission brake etc: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge More updates to come and hopefully a lot more often  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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2nd Jun 2018 11:09pm |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10382 
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The chassis is a bit scary behind the crossmember, I've seen rust before, but not nothing!
Does this not make you stop and buy a galv chassis? I started to overhaul my handbrake, got bored and replaced it with an X-Eng version, even though it will never be used, it fascinates the MOT guy  |
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3rd Jun 2018 5:36am |
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| defender9 Member Since: 12 Mar 2016 Location: Fylde Coast Posts: 1629 
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My chassis was almost that bad when I removed the gearbox cross member. Once repaired the new galvanised cross member was bolted in with thick grease between the cross member and chassis.
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3rd Jun 2018 5:39am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Well to ensure my new chassis doesn’t suffer the same fate I have so far:
Galvanised 2 pk marine grade paint Internal dinitrol And now an external dinitrol Click image to enlarge So hopefully this means it’s as close to being Guernsey proof as practically possible. 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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3rd Jun 2018 6:41pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10756 
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Great update Mash
What about taking the gearbox cross member off every so often just to check to see whats going on ? 1996 Golf Blue 300Tdi 110 Pick up. Keeper. Clayton. |
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3rd Jun 2018 7:59pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Always a good idea to keep an eye on hidden areas Clayton
So a little more got done this weekend, she is slowly ( read very ) coming back together, a good rummage around found a few odds and sods I could move from storage and bolt on: Click image to enlarge Click image to enlarge Just waiting on some bolts to add a few more bits, it’s mad how you can have all the right bits, place them in a draw and for items to vanish into thin air 
Next on the list was the bulkhead, a few imperfections from the galvanising needed some filler: Click image to enlarge Now I have a very small tolerance to body work, I can manage a small bit at a time when it comes to it so I needed something to distract me in between filling and sanding, cue the heater matrix, now just about every rivet of which there are many had signs of corrosion, so out with the drill  :
Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge It’s amazing what protection a sticker offers: Click image to enlarge Click image to enlarge All disassembled, worst of the rust remover then a coating in rust killer before a rust inhibiting primer with a final coat of satin black: Click image to enlarge So slowly getting there 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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18th Jun 2018 9:45pm |
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| HK07 Member Since: 15 Dec 2016 Location: Hampshire Posts: 746 
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Been that, done that, got the dirty T-shirt.
Amazing how those bulkheads differ ever so slightly. Good fun ain't it? 2007 90 Puma - Love it - Best car I have ever owned. 1989 Ninety 200tdi - Love it - Second best car I have ever owned. 1951 80" Series 1 - Love it - Third best car I have ever owned. |
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18th Jun 2018 10:01pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Oh it’s all good fun, and watching filler dry is much more exciting than all those overpaid numpties kicking a bag of wind
 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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18th Jun 2018 11:36pm |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10382
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I take it a new matrix is going in too?
top job |
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19th Jun 2018 5:37am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Cheers Greeni
yes a new matrix will be going in along with some insulation. 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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19th Jun 2018 10:39am |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10756
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Nice work there Mash, always like a good cloths line full of landy bits
1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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19th Jun 2018 9:27pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Big news
I took this: Click image to enlarge Then I added it with this: Click image to enlarge And then I got this: Click image to enlarge Now I am a while away from dropping in the engine as I want to sort the fuel/brake lines etc first, does anyone know the distance from the front crossmember to the bell housing so I can correctly align it as I forgot to measure it  I would go off the diff using the rear prop but as I have changed the rear axle I’m unsure if this will of effected the distance.
I 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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15th Sep 2018 3:58pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10756
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Good feeling you get when adding stuff to the new chassis
 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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16th Sep 2018 7:20pm |
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