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Cubflyer

Member Since: 25 Sep 2021
Location: Suffolk
Posts: 278

Defender 90 300Tdi Sill replacement

Hi folk ...

Hope this is a "Simple" question:

What time (hours of work / worst case) would you estimate it would take to fit new sills (both sides) please?

Looking underneath, they don't look too bad but the screws/nuts look corroded.

Many thanks

John 2010 Defender 90 300Tdi CW (White/1994)
2021 Defender 90 300Tdi SW (Blue/1994)

24th Apr 2022 6:44pm

I Like Old Skool

Member Since: 23 Feb 2015
Location: Manchester
Posts: 814

1994 Defender 110 300 Tdi ST Coniston Green

All the bolts will snap, but this is good because it saves you trying to wind the nut off over the rusted threads.

Buy yourself a bag of M6 x 20 bolts, nylock nuts, washers and oversize washers ready for refitting the sills. Plenty of grease on the bolts incase you need to take them out again in the future.

24th Apr 2022 7:56pm

Cubflyer

Member Since: 25 Sep 2021
Location: Suffolk
Posts: 278

Thanks for that info ... and "If" you were doing it ... how long for both sides?? 2010 Defender 90 300Tdi CW (White/1994)
2021 Defender 90 300Tdi SW (Blue/1994)

24th Apr 2022 7:58pm

I Like Old Skool

Member Since: 23 Feb 2015
Location: Manchester
Posts: 814

Just a thought, are we talking about the aluminium dresser panels or the steel u-channel that holds it all together?
If the latter the same still applies but there is a bracket at the front that bolts to the bulkhead with an insert that has 2 captive bolts on a plate. The plate will be corroded wafer thin and twist/snap so you either need to make or buy a new one.

Either way 1-1.5 hrs per side maybe? These jobs take as long as they take and you usually find something to tinker with as you go.

24th Apr 2022 8:13pm

I Like Old Skool

Member Since: 23 Feb 2015
Location: Manchester
Posts: 814

From memory I think the steel channel brackets front and rear are M8 nuts/bolts.

24th Apr 2022 8:16pm

Dinnu

Member Since: 24 Dec 2019
Location: Lija
Posts: 3425

2012 Defender 90 Puma 2.2 CSW Santorini Black

On later Defenders, the rear U channel bolts (talking about the bolts that attach to the tub on a 90) are M6 into a captive square nut that spins with the minimal effort. I do not know when the change to M6 was done, possibly when the seat belt lower mount was eliminated and moved to the same bracket as the retractor? 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black

25th Apr 2022 5:56am

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