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tdfan

Member Since: 15 Dec 2012
Location: N wales
Posts: 15

Bonnet help

My 300 Tdi is having a light renovation and I've been given a mint condition Td5 bonnet as my original one needed a lot of work before painting. I'm aware that there are differences between a 300 ad the Td5 bonnet and i have moved the expansion tank to accommodate the ribs so that's ok. When test fitting though I've realised that it still won't shut because of the the two upright lugs that are on top of the radiator frame ( the ones that the rubber part of the front brackets locate onto)I'm sorry if I'm not explaining this too well! As it stands the bonnet is still about 12mm too high at the front. Has anyone experience of the best way of getting round this problem? The only way i can see is to drill two holes in that first skin on underside of the bonnet so that it passes over those lugs or cut those lugs down so that they do not protrude past the rubber bushes? If I get round this problem then i know that the bonnet stays are different, how have people got round that ? I might be missing something completely and making a right mess of this , so any help would be appreciated.

1st Jan 2021 5:18pm

Oldowner

Member Since: 26 Dec 2018
Location: South west
Posts: 627

2007 Defender 90 Puma 2.4 HT Aintree Green

I have fitted plenty of td5 bonnets to 300tdis. You only have to move the expansion tank outwards 10mm and then fit the td5 bonnet / Puma bonnet stay / intercooler brackets. Never had any interference with the radiator frame - possibly someone has fitted a discovery 300tdi radiator frame?

If you source the td5 / Puma bonnet stay / intercooler brackets and prop then you can trim the majority of the brackets away leaving just the stay and clip parts. They then bolt into two predrilled and tapped holes that are already present in your 300tdi wings.

I have found this old photo of a 300tdi hicap I rebuilt some years ago showing the modified td5 bonnet stay brackets. This had no issues with the radiator when fitted with td5 bonnet.

Click image to enlarge

2nd Jan 2021 3:14am

tdfan

Member Since: 15 Dec 2012
Location: N wales
Posts: 15

Thanks for taking the trouble to reply. I'm still scratching my head. Everything you say is right, it should fit but it doesn't! I've compared my defender to another 300 and to your picture. my rad frame is the same, an original 300. I've put plasticine on the underside of the bonnet so i can clearly see that is those two lugs on top of the frame that are contacting the underside of the bonnet, but why???the only other thing I've noticed is that the bonnet is sitting a smidge too far forwards , the striker is about a quarter of an inch out as it goes down onto the catch , but I'm hoping that there's enough adjustment on the hinges to sort that? For my last stupid questions, do you happen to know if all Td5 bonnets are the same or are there different variants at all? Again, thanks for all your help, really appreciated.

2nd Jan 2021 5:19pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 534

Have you fitted the bonnet hinge bushes the right way round?

2nd Jan 2021 5:55pm

tdfan

Member Since: 15 Dec 2012
Location: N wales
Posts: 15

You've got me thinking. I think so but I'll double check in the morning. I think I put them in with the thinnest side towards the bulkhead. What effect would it have if they were the wrong way round? Thanks.

2nd Jan 2021 6:03pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 534

Thats the way both my 300tdi and TD5 are. Just if wrong way round it changes slightly the angle the bonnet sits at, if IIRC back edges closer to wings and sometimes scrape.

2nd Jan 2021 8:42pm

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