 | Home > My Defender > Ex utilities Defender 110 from farm hack to pop top camper |
 
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162   
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After 10 years of playing around with Discovery 2s I had decided that it was time to find a new project to sink my teeth into as life is changing and after someone decided to drive into my much beloved Discovery 2 Commercial its replacement never bonded with me. With this in mind i idly decided to look through listings of Defenders and seeing what was out there and what i could afford if any! Well after a few months of scrolling the internet i found a 110 Defender ex utilities for sale not a million miles away for an agreeable price and also being the cheapest 110 Td5 available with an MOT and a full tank of fuel too i knew it was the one.
So off we trundled 2 and a Half hours North to go and have a look, now i must mention that it does have some damage after a cow had tried to rather enthusiastically show jump the bonnet in a previous life not that it bothered me particularly as its only panels. After an inspection vehicle check online and the most important test drive i decided that it was the one for me and so began my Defender ownership becoming my 7th Land Rover owned.  Click image to enlargeDefender July 2022 by Tom Bayford, on Flickr Click image to enlargeDefender July 2022 by Tom Bayford, on Flickr While it is not a mint example i had been looking at pop top converted Defenders as i fancied a more enjoyable and indoor space available camper but i refuse to get a van because they aren't as cool and you cant harrow fields tow horses go through deep floods and all the other country bumpkin stuff. So between me and my wife we stripped out the knackered and rather smelly interior to work out what was needed to happen to make it into a camper and working out our needs and also the Defenders needs too! If people are interested i have 18 months of Defender tinkering i can post  110 Td5 Ex Utilities slowly converting into a pop top camper one day
Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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13th Feb 2024 10:50am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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Thanks there is alot to post about as it has been quite the rebuild
110 Td5 Ex Utilities slowly converting into a pop top camper one day
Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 7:16am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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So with buying a cheap utility which in the last few years had been used by a vets to tow a hoof trimming machine around and had visited many the cow farm well you can imagine the smell during the heat of the summer of 2022
 On investigation using my nose alot of the smell was coming from the back and unfortunately the roller shutters had let in quite a bit of water into the back and rotted the floor and the racking inside so it all had to be cleaned out.
Click image to enlargePXL_20220721_140133520 by Tom Bayford, on Flickr Click image to enlargePXL_20220721_150227084 by Tom Bayford, on Flickr Click image to enlargePXL_20220722_120516526 by Tom Bayford, on Flickr Click image to enlargePXL_20220722_135232221 by Tom Bayford, on Flickr After cleaning it through and having a good base to work from it was time to decide on which way to go with starting a camper build as i soon had the realization i may of bitten off more than i could chew but nothing is impossible if your crazy enough
During this time i had a Discovery 2 that was my other toy so i just plodded on with the defender using it now and then and doing some basic maintenance to fix some issues mainly the crusty expansion bottle and the extremely crusty coolant elbow on the side of the head Click image to enlargePXL_20220727_101244320 by Tom Bayford, on Flickr Click image to enlargePXL_20220727_101248498 by Tom Bayford, on Flickr I also decided to give the interior a good scrub as it was well used... Click image to enlargePXL_20220728_150159008 by Tom Bayford, on Flickr Click image to enlargePXL_20220728_150310550 by Tom Bayford, on Flickr Amazing the difference that made! After spending a bit of time and love on the Defender i went out with some mates for the first green lanes trip in it which was extremely exciting as i hadn't checked the tyres over before hand and they where all inflated to 60 psi which made for a interesting ride  also make sure your battery is clamped down and terminals tightened as that can be a real pain when climbing up a steep lane!
Click image to enlargePXL_20220730_133632081 by Tom Bayford, on Flickr I also managed to cheekily during a course for work while working from home change the vent pins over
Click image to enlargePXL_20220824_154134293 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 7:40am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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As with any cheap project you have to expect problems and sometimes alot of them
 Driving the defender around i had noticed she kept wanting to almost fall over after cornering to the left and then something became very apparent.
Click image to enlargePXL_20221004_111933357 by Tom Bayford, on Flickr Looking at the tyre and wheel they didn't sit right a quick jack up then meant i was going to be doing an axle rebuild as both swivels where rather life expired but not to worry it made for an interesting job and it does drive alot better now! Click image to enlargePXL_20221011_120037190 by Tom Bayford, on Flickr The two stable mates at the time Click image to enlargePXL_20221004_111819842 by Tom Bayford, on Flickr So carrying on with the theme of doing more work as i like to have my vehicles to a standard of not loosing coolant as that is problematic i kept loosing coolant and tracked it to the core plug behind the manifold so off came the manifold a new skimmed one was put on along with a new core plug and some wurth studs Click image to enlargePXL_20221018_113914932 by Tom Bayford, on Flickr Click image to enlargePXL_20221116_130023582.MP by Tom Bayford, on Flickr Click image to enlargePXL_20221104_122501722 by Tom Bayford, on Flickr Click image to enlargePXL_20221104_122456458 by Tom Bayford, on Flickr Click image to enlargePXL_20221104_121021930.MP by Tom Bayford, on Flickr Click image to enlargePXL_20221104_121021930.MP by Tom Bayford, on Flickr I also in my experience of Td5 exhaust manifolds while i have them off i put Helicoils in the rotor filter housing as this greatly improves the reliability of not loosing all your oil very quickly on the way to work one morning 
After all of the work in the engine bay my attention turned to the interior once more and as i was instructed to sort the seats out by her indoors the next mini project began
So on the recommendations of Chris from Offroad consultancy i decided to use a britpart seat retrim kit which was pretty good apart from the herculean strength needed to fit the new vinyl over the seats but after some choice words it both seats where done including new heater elements for the factory fitted heated seats. Click image to enlargePXL_20221204_124538666 by Tom Bayford, on Flickr Click image to enlargePXL_20221203_174217515 by Tom Bayford, on Flickr Click image to enlargePXL_20221204_140623020 by Tom Bayford, on Flickr Click image to enlargePXL_20221204_143007689 by Tom Bayford, on Flickr After the seat upgrade i was using the Defender more and noticed the lack of illumination from the two glow worms going at it behind some foggy glass for headlights so an LED upgrade was to be made to improve visibilty and also safety of other people seeing me! Click image to enlargePXL_20221206_132131859 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 8:03am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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And just to prove during this time it did leave my driveway once
Click image to enlargePXL_20221014_165400093 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 8:05am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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With most winters now being very wet the local roads tend to develop some slight problems unless you are of course in a boat or a land rover!
Click image to enlargePXL_20230116_161633857 by Tom Bayford, on Flickr This of course meant it was time to fit a raised air intake or at least my excuse Click image to enlargePXL_20230207_150714014 by Tom Bayford, on Flickr Then began the tub saga of which youll hear more about later on in the story! So the realisation of my rear tub being somewhat damaged and also having some very rusty roller shutter frames i found a newer one near home for sale with aluminium shutter frames and my idea is to build some gullwings for them Click image to enlargePXL_20230224_144458102 by Tom Bayford, on Flickr Also used the defender for harrowing the fields of which it did a good job Click image to enlargePXL_20230302_172641488 by Tom Bayford, on Flickr Then some old friends got in touch as they where coming up to Salisbury plain for a holiday so they got in touch with their local tour guide
Click image to enlargePXL_20230409_133146239 by Tom Bayford, on Flickr And then the worst part of any Plains trip the cleaning up! Click image to enlargePXL_20230417_094815160.MP by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 8:28am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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In between using the Discovery for holidays my lovely wife treated me to some Mud stuff defender arm rests which are an absolute god send
Click image to enlargePXL_20230608_112301820 by Tom Bayford, on Flickr I also spent some time chasing a persistent coolant leak and decided it was time to tackle the Water pump as it was leaking through the weep hole. Now with this most people will tell you that you have to take off the rotor filter assembly and its really difficult you'll need all these gaskets etc... I find it easier to remove the accessory block of the side of the engine pull the power steering pump forward disconnect the air con pump and flex it out the way and support (If your posh and have AC!) and remove the 5 bolts and 1 nut. you can then do the water pump and cover on the bench with amazing access! Click image to enlargePXL_20230623_185748889 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_185745230 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_190610444 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_190616744 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_190606916 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_193630248 by Tom Bayford, on Flickr Click image to enlargePXL_20230623_193636773 by Tom Bayford, on Flickr Click image to enlargePXL_20230624_102616103 by Tom Bayford, on Flickr Once it was all back together i reassembled the pulleys and replaced the tensioner and one of the idlers as they weren't in the best condition and also put a new belt on for good measure. As you can see the water pumps o rings had failed causing a slight leak but a quick trip through the parts washer and the block looking like new almost back together running a treat and not loosing water! Yippee. 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 8:44am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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Keen eyed readers will noticed i mentioned the Tub saga well it continues in this post!
After deciding that working 72 hours a week to afford land rovers mortgage life etc i decided it was time to sell my Discovery as i never quite fell in love with it after the one previous to it and also our Freelander 2 HSE as the cost of living was hitting us and just trying to be a grown up which sucks 
Another realisation was with the roller shutters in the rear tub it allows the side panels to flex alarmingly which made me realise that fitting a pop top to might not be the best and also trying to keep weather proof. i return to facebook marketplace which is the devils work to my wallet and find a 110 hard top rear tub sides and roof not a million miles away, Perfect! Click image to enlargePXL_20230810_170012523 by Tom Bayford, on Flickr Then i thought it would be easy ill just use the van tub and scrap the utility tub easy! Yeah right the van tub was considerably worn out and life expired so what do you do make more poor financial decisions or use yer noggin? Well noggin well and truly used i decided to keep the puma utility tub use the sides of the hardtop tub and use the hard top tub skin to make infil panels to replace the roller shutter frame in the tub so off i set with some sikaflex and rivets  I also managed to find some galvanised tub capping locally which i purchased and got the rear tub ready for action.
Click image to enlargePXL_20230904_134520478 by Tom Bayford, on Flickr Click image to enlargePXL_20230904_093659173 by Tom Bayford, on Flickr Click image to enlargePXL_20230904_093807401 by Tom Bayford, on Flickr Click image to enlargePXL_20230820_124808255 by Tom Bayford, on Flickr The only problem with this plan was the Puma tub though it had been undersealed the floor had a lot of big holes in that was covered in chequer plate so off to one of my favourite websites the YRM online shop for a new floor. Click image to enlargePXL_20230909_105427326 by Tom Bayford, on Flickr Its handy being mildly strong and having an overgrown wendy house in the garden. 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 9:01am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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With the job i do i work shifts which means if i book leave i get some nice time off which is great. As youd expect by now leave from work means leaving an easy job for a few weeks and working for a right tyrant. Me
With a plan in place it was time to strip the damaged utility tub over for what would be the start of the final instalment of the tub saga! Click image to enlargePXL_20230911_105026879 by Tom Bayford, on Flickr Click image to enlargePXL_20230911_114323312 by Tom Bayford, on Flickr Click image to enlargePXL_20230911_121454637 by Tom Bayford, on Flickr Click image to enlargePXL_20230912_125416813 by Tom Bayford, on Flickr Your only supposed to blow to Blo*** Doors Off! Click image to enlargePXL_20230912_125854192.MP by Tom Bayford, on Flickr Always a good time to remember to hoover your chassis out 
Found a rather weird part of corrosion aswell where the strengthening plates for the chassis had started to lift so a quick attack with the grinder and glued some new metal in Click image to enlargePXL_20230913_142232337 by Tom Bayford, on Flickr Click image to enlargePXL_20230913_155315189.MP by Tom Bayford, on Flickr Also while doing the windscreen to bulkhead seals we found a Deer tooth between the windscreen and the dash how bizarre Click image to enlargePXL_20230915_110510649 by Tom Bayford, on Flickr Then back on to refitting the tub Click image to enlargePXL_20230915_172338463 by Tom Bayford, on Flickr Click image to enlargePXL_20230916_115452320 by Tom Bayford, on Flickr Click image to enlargePXL_20230918_163858370.MP by Tom Bayford, on Flickr Managed to find some nice tinted rear quarter windows thanks to SP Panels So with the Defender back together and alot more watertight it was time for some more enjoyable work 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 9:52am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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With the tub saga over it was time to do some upgrades
 First off we have the ORE wheel carrier now as an Engineering Appreciator what a fantastic bit of kit it is very well designed and makes opening the door so much nicer.
Click image to enlargePXL_20230921_094116183 by Tom Bayford, on Flickr Then i fitted the Explore glazing rear half drop window the first real part of the camper conversion now happening
Click image to enlargePXL_20230921_110126374 by Tom Bayford, on Flickr I also changed out the rather worn out rear shocks Click image to enlargePXL_20230515_134516458 by Tom Bayford, on Flickr Then it was onto sorting out the insides scraping of loads of old sound deading and filling in holes to the arches ready to paint Click image to enlargePXL_20231014_160430181 by Tom Bayford, on Flickr Also cut out a fuel pump access hatch to make future Toms life easier Click image to enlargePXL_20231018_110438877.MP by Tom Bayford, on Flickr Click image to enlargePXL_20231031_111052272 by Tom Bayford, on Flickr i used Paintman paints coach enamel ontop of and Acid Etch primer so two coats primer two coats white undercoat two coats satin coach enamel i was very pleased with these results. Inbetween watching paint dry i also replaced the brake line flexis with those from Pioneer 4x4 and als added there fantastic calliper flexi lines to replace the horrid solid ones Click image to enlargePXL_20231005_123632636 by Tom Bayford, on Flickr Click image to enlargePXL_20231005_151234368 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 10:09am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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a Quick interim Visit to the land of ice and fire even hired the Real new Defender 90 and did 2500Km in it very impressed if not a little squashed
Click image to enlargePXL_20231109_153957225 by Tom Bayford, on Flickr Once back home it was onto a few little jobs a rear door gas strut and some new hinges in-between sound deadening and insulating the back Click image to enlargePXL_20231128_123021452 by Tom Bayford, on Flickr Click image to enlargePXL_20231130_201728929 by Tom Bayford, on Flickr Click image to enlargePXL_20231217_150512314 by Tom Bayford, on Flickr Click image to enlargePXL_20231217_150526646 by Tom Bayford, on Flickr Also while browsing the internet found a nice set of Boost alloys for sale with some decent tyres as the old Conti cross contacts have had a very hard life and where not the best Click image to enlargePXL_20231221_104528579 by Tom Bayford, on Flickr Click image to enlargePXL_20231221_122904122 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 10:20am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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Starting on with the camper build internals it was time to start insulating and sound deadening i used Dodo hex mat and Dodo thermal fleece 10mm which i am very impressed with makes quite the difference.
Click image to enlargePXL_20231124_120144031 by Tom Bayford, on Flickr Also fitted a Britpart load space mat in the rear as the idea behind this is anything spils or water ingress i can take it out to clean and dry the floor off and access the fuel tank when required. Fitted some new reverse lights aswell for fencepost avoiding while reversing in the dark around the farm Click image to enlargePXL_20231124_114350142 by Tom Bayford, on Flickr and another trip up the Plains with some freinds Click image to enlargePXL_20231230_143803227 by Tom Bayford, on Flickr 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 10:24am |
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| 34064 Member Since: 12 Dec 2023 Location: South Central Posts: 162
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Now to the fun part.
We had purchased a Overlandies pop top frame back in December 2022 while not without dramas we are now progressing onto getting that ready for this year 2024 for some big trips away hopefully First up lining the upper frame up with the roof Click image to enlargePXL_20240103_155236169 by Tom Bayford, on Flickr Then after the what seems thousands of stainless rivnuts it was time to mount the hing on the lower frame to start bringing it all together Click image to enlargePXL_20240118_140755680 by Tom Bayford, on Flickr Click image to enlargePop top defender build by Tom Bayford, on Flickr We have lift off all be it temporary Click image to enlargePop top defender build by Tom Bayford, on Flickr Its now progressing well and its all in top coat of paint i just need some dry weather and some time to be able to get the next steps done 110 Td5 Ex Utilities slowly converting into a pop top camper one day Build thread:https://www.defender2.net/forum/post1024784.html#1024784 |
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15th Feb 2024 10:29am |
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| SailingTom Member Since: 19 Nov 2013 Location: ESSEX Posts: 1717
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Good work
I follow this on instagram too and it’s looking great Defender puma dormobile camper |
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15th Feb 2024 2:30pm |
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