 | Home > My Defender > Rebuild of a 1985 90 |
 
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| trickster5000 Member Since: 12 Dec 2015 Location: East Yorkshire Posts: 502   
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So, this is my mates 90 I'm helping to rebuild and I thought I would share our progress here. It's in a shocking state on its current chassis despite the guy we bought it off insisting it "just needs a bit of welding" - somehow it still had a valid MOT...
I think it might be a converted van, but the main modification is the 300tdi lump and R380 box. It's a remarkably good conversion, and would be difficult to tell from a genuine 300tdi Defender except that it's a B reg. Anyway, we started the stripdown a few weekends ago, and made reasonable progress largely thanks to an angle grinder 
This is it when we first got it in the shed:  Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge The real state of the chassis was starting to be revealed: Click image to enlarge Click image to enlarge Click image to enlarge The remnants of the N/S outrigger was helpfully filled with expanding foam 
Click image to enlarge We then rolled it outside to blast off all the gunk: Click image to enlarge And by now the O/S outrigger had all but disintegrated: Click image to enlarge But we did manage to get the gbox looking shiny: Click image to enlarge Today we took the engine and gearbox off the chassis and started taking axles off (which again required the services of the angle grinder): Click image to enlarge Click image to enlarge The new Shielder chassis and bulkhead arrived the other day - it was very nice to see shiny bits instead of manky rusty stuff 
Click image to enlarge I guess next steps will be taking the back axle off tomorrow and then start cleaning bits up and putting them back on. We will be trying to save as much as possible but we really want to do this properly now rather than having to come back to replace some awkward part in a year's time. That's the progress so far but there may not be any significant updates for a while now as I'm off to uni so won't be able to work on it for a bit. Matt. '89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html |
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15th Sep 2018 8:59pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674  
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Excellent progress so far
 another rebuild to follow. 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 9:37pm |
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| LR90XS2011 Member Since: 05 Apr 2011 Location: bickenhill Posts: 3641 
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love these rebuild threads, there must be a good sense of achievement when people complete them, have done a couple of Mini's and kit cars and am 90% through a complete house renovation and although miserable hard work at the time the sense of satisfaction is great, and generally it is time much better spent than watching TV. DEFENDER 90 TDCI XS,
I hope everyone is well and your land rovers make you happy |
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16th Sep 2018 6:33am |
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| LR90XS2011 Member Since: 05 Apr 2011 Location: bickenhill Posts: 3641
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Greeni's comments are a good point, the classifieds are full off different cars that have had a lot more spent on them than people are willing to pay, especially when they are drastically modified, and generally that does not include peoples time. Not such a big deal if you plan to keep them though.
Anyway better go and start laying the patio would rather be at Eastnor with the MROC or Peterborough or Weston Park! DEFENDER 90 TDCI XS, I hope everyone is well and your land rovers make you happy |
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16th Sep 2018 6:56am |
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| trickster5000 Member Since: 12 Dec 2015 Location: East Yorkshire Posts: 502
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We're fully anticipating things to get expensive - there were a number of parts that didn't survive the strip down and disintegrated at the sight of an angle grinder so I suspect we'll be putting in a big order with YRM at some point.
Then there's all other little miscellaneous stuff that soon adds up like rads, fuel tanks hoses etc. The bodywork is mostly in good condition bar a few knocks and a gaping hole in the rear tub floor. To keep costs down we're hoping to respray parts ourselves with a compressor. The final goal is a nice classic bronze green finish with no exposed galv bits so the chassis will get a coat of Buzzweld Galv in One. There's no plans of selling any time soon so the final value vs amount spent is a less important consideration than the limits of the budget Matt.
'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html |
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16th Sep 2018 7:22am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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If she’s a keeper forget the budget
 keep all the receipts in a box and don’t even try adding them up, oh make sure it’s hidden from Swmbo 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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16th Sep 2018 8:23am |
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| Oldyellar Member Since: 04 Sep 2015 Location: Central Posts: 384  
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Brilliant project man
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16th Sep 2018 3:13pm |
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| trickster5000 Member Since: 12 Dec 2015 Location: East Yorkshire Posts: 502
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As promised I got the rear axle off this afternoon. Easier than the front axle, but the 2 bolts through the A-frame to axle bracket were a bit of a swine to get out
Click image to enlarge Click image to enlarge Click image to enlarge The rear diff appears to have a serious seal problem - I don't just mean a few drops, it was literally dribbling out in a continuous stream whenever the prop flange was face down so that will need to be investigated Click image to enlarge Not sure what extent we will go to in terms of rebuilding axles but certainly will be stripping swivels off the front and then inspect the state of half shaft splines etc and go from there Matt.
'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html |
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16th Sep 2018 4:01pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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A minimum of hubs off and check over the stub axles and bearings, all 4 can be done in a day. Budget for new seals and grease to re-pack the bearings, assuming yours is the 2 nut system and not a stake nut it’s less to buy. 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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16th Sep 2018 4:11pm |
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| Procta Member Since: 03 Dec 2016 Location: Sunderland Posts: 5166
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great progress there
Here looks like that's had a bum MOT, just to pass it on and get rid. I am sure mine had the same thing.
I hate it when people do that with the mots and bodge stuff! Defender TD5 90 ---/--- Peugeot 306 HDI hatch back Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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16th Sep 2018 5:49pm |
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| trickster5000 Member Since: 12 Dec 2015 Location: East Yorkshire Posts: 502
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I think this one's seen its fair share of bodges! Just goes to show an MOT isn't worth the paper it's written on in some cases. There's no way this vehicle should have been allowed on the road in that condition even a year ago - the rear crossmember actually partially detached from one of the chassis rails when we were lifting it today and the outriggers had no structural strength whatsoever! Matt.
'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html |
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16th Sep 2018 6:04pm |
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| Procta Member Since: 03 Dec 2016 Location: Sunderland Posts: 5166
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I could see looking at that, it should have failed big style. I remember one of the lads on an old metro forum nearly 10 years ago buying a car with an MOT, I think he bought it to break tbh, as he was like that. Anyway when he came to dismantle the car, he found out it was practically a death trap! The full floor was orange with rust! When he got the history up it had failed big style, but was passed just to get shot. He made a song and dance about it mind, but a few people said you should have checked the car over. The seller offered to buy the car back oddly enough, but that could have been to protect who ever MOTd the car. The lad got VOSA involved and got the garage suspended for doing MOTs. How true that was I couldn't say.
But the car was really bad, when he posted photo up, and the engine was practically on its last legs too. Which died while he had it on tick over. I cannot remember if he just weighed it in rather than break it. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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16th Sep 2018 6:39pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10751 
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Good progress Matt on the 90 will be watching with interest when the updates come
 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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16th Sep 2018 8:00pm |
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| shayes Member Since: 29 May 2016 Location: Devon Posts: 153 
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Great thread Matt. I echo Clayton's comments. I will be watching this re-build with great interest. Well done so far!.
Cheers, Simon |
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17th Sep 2018 8:04am |
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