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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347   
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Thank you Pickles glad your enjoying it
Good to know my ramblings are being read and hopefully people will learn from my mistakes or even just have a better idea of what makes up your vehicle. Early start this morning saw the rear seat belt bottom mounting point removed. This was a bit of a sod as the nut broke free from its spot welds so i had to jam a breaker bar on the top and then swing underneath with another breaker bar to unwind it. After a bit of a wrestle the roof and body were now completely free!  Click image to enlarge Then with some wiggling, a slice through the top seal and help from a very keen helper (Mum  ) the windscreen was swung free and then stored somewhere safe and out the way.
Click image to enlarge This revealed the top of the bulkhead. Much to my joy it was surprisingly dry and complete! I was expecting carnage so this is really a welcome boost! Click image to enlarge Next out came the passenger side vent and the bracket that holds it. Note the very interesting spot weld pattern  How the hell Land Rover put the vent on I will never know. I can only assume in the 80s-90's they had an employee with tiny tiny hands who could fit between the vent and the grill and bolt it to the operating lever. He must have left in 2006 and they had to redesign the dash and bulkhead to accommodate this. That's my theory anyway 
Click image to enlarge Offering up the repair section I bought just in case, I don't think it will be a simple case of just tack it then weld it in...... Click image to enlarge Deep breath..... Click image to enlarge First cuts...... 
Click image to enlarge So much rot. So so so much rot. Some bit are worse than others but overall I think it could be worse.
I must admit I did have to tell myself "dude...stop" before I ended up with no bulkhead at all. Click image to enlarge Bit of a go over with a wire wheel attachment and a bit of a better picture. Now for the card templates and spitting and crackling welding stage. Not going to lie it is a very daunting process and I am starting to wander if my decision to DIY was better than to spend the £2k to have had it done professionally. But then where is the fun in that! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter  |
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28th Oct 2014 1:25pm |
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| Go Beyond Member Since: 30 Jan 2012 Location: Headcorn, Kent Posts: 6678
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Wow
Good for you |
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28th Oct 2014 1:38pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Thank you Matt
Must say your 130 is looking much more tempting than it already does as it has got no rusty bits at all! Must see that bank manager, maybe we can do a 3 way swap! Click image to enlarge As with all rebuilds, it starts with a card template. My preference is the card that comes on the back of a note pad as it is thin enough to be cut with scissors, yet strong enough to be used as a template. As you can see, the old material is cut away and the new cardboard let in. Click image to enlarge Some people use pens, I prefer to use blue pencils. They seem to show up on all materials quite well and are soft enough that they mark most things too. The template is transferred onto a suitable bit of plate. I used 1.5mm throughout this project as it was what I had lying around and about the right size. Click image to enlarge Brand new bits! Well not brand new but new replacement. The edges are given a once over with a flap disk to take off any sharp edges and prepare for welding. Click image to enlarge Snap, Crackle, Pop! Welding anywhere near rust is always a pig to do as it will pop and fizz at you as well as be a pain to get a good weld. There are many ways to do it but I always do a series of small tack welds, then join them up. This has always served me well and seems to have worked here. The downside is, it looks like  !
Click image to enlarge However after an attack from a flap disk and a wire wheel it does look a bit better (not that it matters at all because it is being well hidden) Much better. Click image to enlarge The front face was then started on. This was a bit of a faff as I'm not 100% sure that the shape of the patch is correct. it looks about right but the angles on the side look a bit suspect. I suppose it doesn't help that the original plate work was so far rot that it all had to be cut off so I don't have any reference. Still, getting tantalisingly close to finished! Click image to enlarge The rear of the panel. The lipped flange part was also rotted out so had to come off. This bit in particular is a pain in the arse as it is a very complicated shape to replicate. In hindsight a whole doorpost would have been a better bet though this would not have helped the area with the most rot and would have meant the wing and heater box would have had to come out. Anyway, enough for tonight, time for a beer!  Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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28th Oct 2014 7:01pm |
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| Venomator Member Since: 25 Aug 2014 Location: Peterborough Posts: 2087
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What a scary but awesome project you are undertaking...
I can only say I am totally in awe at your courage in taking on such a task! Thank you for sharing it with us normal bods and the brilliant photo-story that accompanies your endeavours... Rog... 
The GREEN One... MY2016 Urban Truck Build Thread - http://www.defender2.net/forum/topic40548....al[/color] |
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28th Oct 2014 7:12pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Thank You Venomator!
Its quite good fun really. I started planning this in August with what bits to get, what needs to be bought and what needs to be ordered. Mostly it is what needs to be done! It is very easy to get carried away! I think the scariest bit so far was getting the roof off. Its very heavy and cumbersome especially when you are on your own. Though I must say the minute the windscreen was off it made it much easier to maneuver
Fingers crossed will get a good days run at it tomorrow and knock all the welding on the head so I can get stuck in on rebuilding
Will be happier once the roof is bolted back on and everything is back where it should be. Glad your enjoying my journey though! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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28th Oct 2014 9:00pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Hi Guys!
Today started well with a cooked breakfast and a slice of birthday cake yum yum! I then waddled into to workshop to carry on where I left off yesterday. I must admit photos of this stage are a bit sparse and poor quality as its quite difficult to photograph. Click image to enlarge The front was loosely clamped on and the fillet then welded in. This was a massive pain as none of it seemed to want to line up correctly and just in general be a pain but with a mix of weld, hammer, grind weld , hammer, grind I seem to have sorted it. Click image to enlarge This then left the front. Its not very pretty at this stage and I have a horrible feeling I'm going to have to use some plod to smooth it all out again but its not the end of the world as I know there is good solid metal underneath. Click image to enlarge The door post side. Fingers crossed i have got it close enough in the right place. Luckily land rovers being what they are there is more than enough room for adjustment (I hope  )
Click image to enlarge The vent seal was loosely fitted and much to my surprise, I mean Joy it doesn't look to bad as the seal hides a quite lumpy grind. Just got the top to do now and hopefully should be the end of the big welding bits. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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29th Oct 2014 1:21pm |
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| gilarion Member Since: 05 Dec 2013 Location: Wales Posts: 5111  
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Brilliant thread. I love to see Defenders being brought back to life and done with care. Non Defender owners have no idea why we care for them so much and form a bond with our vehicles, but when you restore one it sort of becomes part of your DNA if you know what I mean!
Well done that man. |
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29th Oct 2014 2:11pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Thank you Gilarion!
I'm very much the same I love to see landys restored! There are very few vehicles which you look at when in a forlorn state which make you think...humm not to bad, just needs x and y and z! I know exactly what you mean, I have driven lots of vehicles but my 110 is the only one I would comfortably take with me around the world. Its not my Car, its another part of me, like my foot but more practical. This evenings update comes with a bit of a bang! Quite literally, I can only assume that the RAF knew it was my birthday as they did a Supersonic Flyover which shook the house and brought everyone outside to say "what on earth have you done now" humm, I feel the cold fingers of blame but this time I was completely innocent!
But progress has been made none the less! Click image to enlarge The front face and the top rail bit have now been welded in and with a sigh of relief it signifies the last of the welds to this side of the bulkhead. Click image to enlarge Still a bit rough, in fact very rough but its a bit of an agricultural repair with a welder which waited until the only visible bit to start playing up! Click image to enlarge I couln't wait to give it a light dusting of etch primer and refit the seal to see how it looks. Honestly, could be better, but for a first shot its not too bad. Nipped out with dad to Halfrauds to pick up some filler and misc bits so tomorrow will be the day of filling and sanding and spraying! Also while out I picked up some pop rivets to do the reinforcing plate for my bonnet spare. I know I am in a bit a minority with my bonnet mounted spare but to me it is the only place I would have it! helps to counter act any weight you have in the back (not that I can tow much yet  ) but its reassuring to know you can load the rear up with a ton of stuff and the steering not disappear off a cliff. Plus it works very well. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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29th Oct 2014 7:44pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Sorry for missing the lunchtime update, its suddenly all got very busy today!
First the bulkhead had a quick wipe over with some filler to smooth out any odd lumps and bumps and was given a spray over with some etch prime. All was going well and I was getting ready to give it a final going over untill disaster stuck. Click image to enlarge Spot whats missing  so to console myself I decided to turn my attention to the bonnet - at least that can be done fairly quickly!
Click image to enlarge The supporting plates were bolted on with the 3 small bolts in the centre then the holes for the rivets drilled through. Top tip! put the rivets in to the holes you have drilled as you go, this will stop it from wandering or moving and meaning none of the holes line up. Click image to enlarge The centre plate was then whipped out and given a coat of Etch Primer. Although it is 3mm steel I wanted to make sure it outlasted the rest of the bonnet! Click image to enlarge While the etch primer was out I also treated the new bulkhead hinges. Making sure to treat the rear thoroughly to prevent any worry from the inevitable water ingress! Click image to enlarge Once the etch primer was dry I gave it a good going over with some black paint just to give it some further protection. Click image to enlarge This is where it starts to get very exciting....The hinge blocks getting some Arles Blue Click image to enlarge I must admit (though this is a horrendously bad photo) the colour match is very good! the only problem being the new paint is going to be a very stark contrast to the old very flat and dull paint. But it is the same colour so maybe a good polish is in order. Maybe. Click image to enlarge Dead posh Getting very excited now to start bolting it all back together! (though have just spotted the lumps in the paint ) The perils of spraying outside!
Click image to enlarge Away from going ohhh at the new paint, with a little help I got all the reinforcement plates riveted and sealed in place. The result is a far more stronger and resilient bonnet much better suited to taking the weight of my spare wheel! The steel frame had also had any rust wire wheeled off and given a good doshing of Krust in preparation for some paint. Click image to enlarge I say helped, Our resident ferocious layabout Teddy kept coming over and dropping his ball with an expectant look of "well? it wont throw itself you know?" Love him though this is all very exciting for him! Click image to enlarge After I had calmed down I rubbed back (what was typically the nicest bit of the repair) and welded on the tag which holds the vent flap in place. Still spitting feathers about it but much rather find it now rather than once it was all painted. Click image to enlarge This was then sanded back and filled and primed. Click image to enlarge Which was then in turn filled and primed and filled and primed and sanded. Photos of the undercoat to follow Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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30th Oct 2014 10:36pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Very very excited to see this finally come to fruition!
Click image to enlarge View from behind. Not the best but I can live with it! Click image to enlarge Click image to enlarge So So So pleased with how this has turned out. Yes I know it is a bit lumpy bumpy but thats now just another page in her history. I reckon the repair will probably last about 2-3 years before the rust worn appears, most likely in the bit next to the bit you have just repaired but a lot can change in that time so I will cross that bridge when it comes to it. Final paint tomorrow then cappings off, galvenised cappings in, then roof down windscreen in bonnet on and find where all those tiny bolts shot off to.... Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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30th Oct 2014 11:35pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Slower start today, went out for a very nice dinner and rolled home so a very slow and heavy start to the morning, but one that picked up quickly!
I had a good look over the capping's and decided to hold of for now. There are some bits I didn't have and I didn't want to get it all apart and then have to wait for the postman. So they are on hold, if only temporarily for now. Click image to enlarge The bonnet is now finally finished! Very happy with how it has come out. Hopefully should now last miles of lumpy bumpy Kentish (and further afield!) roads! Click image to enlarge The next stage was then very quick and I didn't have a chance to get many photos. The windscreen seal was stuck down and then the windscreen offered up (though I'm still not convinced it is quite in properly) and given a good coating of sealant. The roof was then gently dropped down and the bolts wiggled back into place. Much to my surprise they all lined up which makes me worry I have forgotten something. I worked back progressively from the Windscreen to the B-posts, to the C-posts, to the little L section bracket with the stupidly tiny nut and bolt and then finally to the rear corner capping's and the rear door L sections. All seems to have bolted down well, so now just have to bolt in the windscreen hinge blocks and then the front doors and we will be free to roll outside into the sunshine for the first time in a week! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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31st Oct 2014 1:14pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Well, mostly back together. The important bits are all back together.
Click image to enlarge The drivers side hinge went back together in a sort of fashion and the block went on. I think the best way to describe it is trying to thread a shopping trolley through a porthole with a bicycle in the way. Just all kinds of faffing around. The passenger side one also had a bit of a faff around but it was sorted in the end. Click image to enlarge The finally dressed, repaired and sorted (for now) bulkhead. Very happy with how it has turned out, Needs a little more fettling and a good all over polish to smarten things up but I'm sure it will look fine once finished. Click image to enlarge Refitting the doors was a bit of a stress and now nether of them line up properly and will need adjusting. This isn't the end of the world, but a bit beyond my patients at this time, Mainly because the doors are heavy and I don't want to bend or buckle anything. Click image to enlarge Still very pleased with my efforts.
Click image to enlarge Work then turned from mechanical to electrical and the mess of wire that lives behind my radio. Can anyone tell me what these are? They aren't plugged into anything but I don't know what they are for? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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31st Oct 2014 7:30pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Well, nearly finshed....Land Rovers rarely are ever finished.
What do we think? Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge All door hinges replaced and bulkhead now all patched up and looking good as new
Now just got to keep it looking reasonable. Next thing on the list is removing the rear windows to convert it into a Utility Station Wagon, then next summer if it is warm and dry enough for a weekend to jack up the roof again and replace all the cappings with galvanised. If I'm feeling particularly flush I might invest in a winch for Christmas, or maybe New Years. Probably Easter
Otherwise its just doing some fairly complicated electrical modifications to add in some mod cons. But for now, she starts, she drives, she lives
What do you think? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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16th Nov 2014 1:34pm |
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| Hazza Member Since: 10 Jan 2011 Location: North Yorkshire / Leeds Posts: 219 
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Landy looks great, isn't it the best feeling when you're driving it again!? 1990 Defender 110 200TDI Camper - now converted to Td5 power
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16th Nov 2014 1:52pm |
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