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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415

United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
1989 Eastnor Green 90
Bought my 90 back in 2007(ish) from a family member.

It's done around 110k from new and is sat on a galvanised chassis.

In 2010 I installed a 200tdi engine, which came out of a RRC, luckily with the same mileage as the 90, give or take a couple of hundred miles!

The 90 has started to look a bit tired; doors rotting away, rusty bulkhead and body cappings, the usual things, so I've been accumulating parts as and when I find them.


Click image to enlarge


So with having a couple of weeks free, due to Covid-19, I thought now would be as good a time as any to start on a bit of a restoration project! So I've started to strip the 90 down.

So far, roof, side panels, bonnet, wings, doors have all been removed.



Click image to enlarge



My to do list got longer and longer with removal of each component Crying or Very sad . So as it stands I need to do the following:

- remove and repair seatbox (currently having much fun removing this)
- repair or replace bulkhead (not sure which way to go yet)
- replace front doors (doors already sourced - door cards and accessories still required)
- various panels for front wings need sourcing and replacing
- repair rear tub (unsure if this is possible - photos to follow)

Important points I'm yet to decide:

- keep the Eastnor Green or changed to Keswick Green?
- keep the 200tdi or swap for something else? Td5?

More posts to come!
Post #827700 25th Apr 2020 11:11pm
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LR90XS2011



Member Since: 05 Apr 2011
Location: bickenhill
Posts: 3641

United Kingdom 2011 Defender 90 Puma 2.4 XS CSW Galway Green
GOOD LUCK

looks like one of those to do lists that could just get longer and longer DEFENDER 90 TDCI XS,

I hope everyone is well and your land rovers make you happy
Post #827709 26th Apr 2020 6:48am
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discomog



Member Since: 09 May 2015
Location: Notts/Lincs Border
Posts: 2526

United Kingdom 2015 Defender 90 Puma 2.2 XS CSW Santorini Black
Looks like someone is going to be busy. Personally I'd keep to Eastnor Green. Defender 90XS SW
Mini Countryman Cooper S
Morgan Plus 8
Post #827711 26th Apr 2020 7:15am
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jeffersj



Member Since: 23 Jan 2015
Location: Near Preston
Posts: 431

United Kingdom 1996 Defender 90 300 Tdi HT Bronze Green
Mine is Eastnor green, it had been resprayed by the previous owner but when I asked him what colour it was he just said it was Land Rover Green?

I tried Land Rover Green (Bronze Green) but this is too dark but when I sourced some wheel arches on FB Marketplace they turned out to be the same colour Eastnor green. The paint code for this is PRC419 I think from memory which is still available (it later became Eskdale Green). These were colours used on the classic Range Rovers.

So you could keep it this colour knowing paint is available. If you are going to have it resprayed then i would opt for one of the modern Greens, Keswick is nice. Jeff
Ex 1968 Series 2A
Ex 90 TD5
Ex D3
Ex D4
Post #827723 26th Apr 2020 8:34am
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mini Anaconda



Member Since: 23 Aug 2016
Location: Thames Valley
Posts: 783

United Kingdom 
I also have a 1989 Ninety in the same colour with a 200tdi.

Keep the original colour. Keswick Green looks too modern for that age in my opinion. Thumbs Up BORG - Bucks & Oxon 4x4 Response Group
Post #827780 26th Apr 2020 2:50pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10742

England 
Great project to do now and will be watching this thread Wink

I would keep the same colour Very Happy 1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.
Post #828084 27th Apr 2020 8:47pm
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Rosco



Member Since: 03 Dec 2010
Location: Burntwood
Posts: 1833

United Kingdom 2015 Defender 110 Puma 2.2 XS CSW Montalcino Red
Watching and will follow with interest. Thumbs Up

Personally I'd look to keep the 200tdi if its in fine fettle as they are a decent old school engine. Not that I'm against the other choices, the TD5 Disco I had was fantastic, but the simplicity of the tdi's will always endure for me. Provided parts dont become to expensive/rare obviously. 2007 - Stornoway Grey 90 XS SW - Gone
2002 - Black Discovery II - Gone
2014 - Montalcino Red 110 XS SW
Post #828180 28th Apr 2020 10:03am
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Neilios



Member Since: 01 Nov 2017
Location: Co. Durham
Posts: 169

England 1997 Defender 110 300 Tdi HCPU Keswick Green
I agree, keep it the same colour and 200tdi, good combination had one retrofitted many moons ago using a 1989 90. ๐Ÿ‘Œ 1997 110 Hi-Cap Keswick Green
1997 90 Truck Cab Blue
1996 Discovery Pickup
Post #828362 28th Apr 2020 9:02pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415

United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
Thanks for the replies chaps.

After careful consideration, I've decided to keep with Eastnor Green. The 200tdi is going to stay for now too. I do tow occasionally, so some extra grunt would have been nice. Having said that, it's a keeper, so looking long term, should the 200tdi last at least another decade, I guess the next conversion will be to electric.

Anyway back to the present...

Just got the bulkhead to remove now (the rear tub will be repaired insitu). I'm at a crossroads with the bulkhead. I have three maybe four options.
Option 1 - repair and galvanise existing bulkhead, which is straight, but gone on the corners and footwells
Option 2 - repair and galvanise a Td5 bulkhead that I have which is rust free, but buckled, with accident damage on the o/s door pillar and corner.
Option 3 - buy a new galv'd bulkead at ยฃ1650 Shocked
Option 4 - find a straight, honest bulkhead and galvanise it myself.

Photos to follow, but thoughts on the bulkhead options would be much appreciated!
Post #828738 1st May 2020 12:39am
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Co1



Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3674

United Kingdom 2013 Defender 90 Puma 2.2 HT Loire Blue
Are you doing the repair work? If so Iโ€™d go down that route purely from a job satisfaction perspective and pick option 1. Also is the most original option.
Post #828740 1st May 2020 4:59am
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Neilios



Member Since: 01 Nov 2017
Location: Co. Durham
Posts: 169

England 1997 Defender 110 300 Tdi HCPU Keswick Green
I agree option 1 would be the best, but if you wanted you could have that one galvanised, I did that with mine, repaired it with H/D foot wells and new feet and a few minor repairs and it looked great. 1997 110 Hi-Cap Keswick Green
1997 90 Truck Cab Blue
1996 Discovery Pickup
Post #828744 1st May 2020 6:28am
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Neilios



Member Since: 01 Nov 2017
Location: Co. Durham
Posts: 169

England 1997 Defender 110 300 Tdi HCPU Keswick Green


The finished item prior to preparing and Galvanising and paint, came out great and should last and itโ€™s the original 1996 item as well. ๐Ÿ‘ 1997 110 Hi-Cap Keswick Green
1997 90 Truck Cab Blue
1996 Discovery Pickup
Post #828745 1st May 2020 6:38am
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415

United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
The bulkhead is finally off!


Click image to enlarge


Hopefully I've labelled all the wires up correctly!

I've started to clean up the chassis, engine and drivetrain too.

Before:


Click image to enlarge


After:


Click image to enlarge


Next steps:

I'm going to shotblast both bulkheads to see what I'm working with - luckily my mate has a shot blaster, I just need to buy the media. I need to do some research, but I think I'm going to be using 0.2-0.5 crushed glass grit. Has anyone done this before and can offer any advice?

Regarding the only welding, I've only ever done stick welding on bits that wouldn't be seen, and while I managed to successful stick two pieces of metal together, I think welding up the bulkhead with a mig is a step to far for me...

The shopping list is getting rather long!
Post #830398 10th May 2020 11:45pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415

United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
A bit of an update, well more ramblings...

Not much has changed as I've just come home from an unexpected stay in hospital!

The current situation:

My heart is now set on replacing the 200tdi with a td5.

Just order some media for the sand blaster. Hopefully 0.2-0.5 glass grit is ok for stripping the bulkheads!
Post #832115 19th May 2020 9:56pm
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Procta



Member Since: 03 Dec 2016
Location: Sunderland
Posts: 5164

United Kingdom 
yeah when you start a job like this, the list just sky rockets up! From what i watched on youtube, ( Britannica Restorations Ltd) he states when you put the body back on, he states to put the rear tube on 1st so that you can line up the rest of the bits. Have a look at his videos Thumbs Up Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

Success is 90% Inspiration and 4 minutes Preparation # you can make it!
Post #832117 19th May 2020 10:01pm
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