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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

This week I've been painting yet another wheel in preparation for some wheel and tyre juggling to come:


Click image to enlarge

I also found a better box for my jack and associated paraphernalia - a 19 litre Really Useful Box that sits nicely on a wheel box:


Click image to enlarge

Then today I've made a start on kitting out the rear load bay. Firstly, I attacked it with a sharpened scraper and a sander to remove as much of the old glue as possible. Then, after much measuring, I drilled holes for the first of the individual rear seats and new seatbelts. I've found some nice reinforced mounts for the seat belts, allegedly FIA approved, and have made some rubber gaskets for them and the seats themselves to separate them from the aluminium wheel box:


Click image to enlarge

Redundant holes in the tub were sealed from underneath with some offcuts of aluminium and Sikaflex:


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Then I covered most of the tub floor and sides with Silentcoat. Still got the nearside wheelbox to prep and cover but I'm aiming to finish one side before moving to the other. The seat isn't yet fixed in place in this picture:


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Where the seat and belts are to be fixed to the tub, I've cut away the Silentcoat. I've also made some 6mm nylon spacers for the seat belt mounts to lift the anchor points up above the insulation and carpet:


Click image to enlarge

The wheelboxes and tub sides will be covered with 6mm closed cell foam before the whole lot, including the bulkhead, is carpeted. I hope to get some more of this done during the course of the week. 
Click image to enlarge

MY BUILD THREAD

Post #635199 2nd Jul 2017 9:28pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 4283

England 

The back is looking better already LRA Thumbs Up Really like the way you do things Wink Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up. Keeper.

Cheers
Clayton.

Post #635206 2nd Jul 2017 9:37pm
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Profyaffle



Member Since: 03 Oct 2016
Location: Leeds
Posts: 396

United Kingdom 1993 Defender 90 200 Tdi HT Arles Blue

Great progress LRA.. I imagine scraping that old glue off was a tedious job Rolling Eyes
It will be much quieter with the silent coat. 1993 200Tdi Defender 90

Post #635209 2nd Jul 2017 9:42pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

Heh, heh, thanks folks. Yes, removing the glue was a pain although I settled for just removing the loose and/or lumpy bits in the end. There was dust everywhere Rolling Eyes 
Click image to enlarge

MY BUILD THREAD

Post #635329 3rd Jul 2017 2:20pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

Progress has been oh so slow due to doing it in fits and starts in the evenings, but I've finally got one of my new seats in.

Having covered everything in Silentcoat, I put a layer of 6mm foam on the side of the tub and then covered with the first bit of carpet. Positioning the foam was tricky as the glue on it is as sticky as a really sticky thing but getting the carpet in the right place was a nightmare. The carpet I'd chosen is a stretchy stuff a bit like Veltrim and the instructions said to apply spray glue to both it and the surface it's to be stuck to. All very well but as soon as the glued carpet gets near the surface it wants to stick and not let go! Very difficult with anything but a very small piece. Anyway, I persevered and got there in the end:


Click image to enlarge

Next was the even bigger piece to cover the wheel box. I quickly abandoned the idea of foam here as it just had too much give in it, so the carpet was to be stuck straight to the Silentcoat. Where I'd cut that away for the seat to be mounted, I covered with masking tape so that the carpet wouldn't be permanently stuck. After much swearing, I eventually had a piece of carpet with a very complicated shape glued to the wheel box mostly as I'd intended. It was good enough, anyway! I then punched holes through the carpet where the bolts were to go and positioned the seat parts to cut around the mounting brackets, which was less difficult than I'd thought it would be. This left me with neat cut-outs like this:


Click image to enlarge

With the help of my son, the seat and seat belt were bolted into position using the rubber gaskets shown earlier, stainless nuts and bolts and nylon washers for isolation.


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With the exception of the seat belt mounts, I took care to install the bolts from beneath so that the exposed threads are inside. I've just ordered some black nut caps so will probably trim them down a little to finish them off.


Click image to enlarge

My son declared it a success and much better than the previous bench seats. Just got to do the other side now, before covering the bulkhead and finally the floor. 
Click image to enlarge

MY BUILD THREAD

Post #636771 10th Jul 2017 4:29pm
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trickster5000



Member Since: 12 Dec 2015
Location: Pocklington, East Yorkshire
Posts: 214

United Kingdom 1989 Defender 90 300 Tdi CSW Arles Blue

Fantastic job! Thumbs Up

Space to stash some goodies on the wheel arch now Smile not to mention more comfortable and safer! Matt.

1989 Ninety CSW - http://www.defender2.net/forum/topic46809.html

Post #636772 10th Jul 2017 4:38pm
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Procta



Member Since: 03 Dec 2016
Location: Sunderland
Posts: 1094

United Kingdom 1997 Defender 90 300 Tdi HT Baltic Blue

fantastic job that! was the carpet pre cut? Defender 300 TDi 90 ---/--- Peugeot 306 HDI hatch back

Post #636786 10th Jul 2017 5:45pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2238

2004 Defender 110 Td5 CSW Java Black

I can really recommend Mud Stuff's bulkhead removal bar, really transformed my 300Tdi.

...but if you are ever thinking about it, do it now before you fit any carpet as the swarf goes everywhere.

http://www.mudstuff.co.uk/products/mud-stu...l-bar.html

Post #636792 10th Jul 2017 6:15pm
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Rusty380



Member Since: 20 Jun 2017
Location: Nottingham
Posts: 81

United Kingdom 

Lovely bit of work there! How much silentcoat did you need To soundproof the whole rear?

Im going to be plying mine and that stuff looks as good as anything!

Post #636802 10th Jul 2017 6:36pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 4283

England 

Great and thorough job there as usual LRA Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up. Keeper.

Cheers
Clayton.

Post #636826 10th Jul 2017 7:55pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

Thanks Smile

trickster5000 wrote:
Fantastic job! Thumbs Up

Space to stash some goodies on the wheel arch now Smile not to mention more comfortable and safer!

Absolutely. See my picture of a Really Useful Box above. I'm also toying with the idea of fixing some cargo rail to the visible parts of the tub capping forward of the seats to provide some more convenient fixing points.

Procta wrote:
fantastic job that! was the carpet pre cut?

Nope, there was lots of measuring and scribbling on paper to work out the correct shape, made more difficult by my desire to do the wheel box in one piece rather than have a join.

Tiger wrote:
I can really recommend Mud Stuff's bulkhead removal bar, really transformed my 300Tdi.

I have considered one of those but in the end decided against it. I'm quite content with it the way it is.

Rusty380 wrote:
Lovely bit of work there! How much silentcoat did you need To soundproof the whole rear?

I started with a box of 20 sheets and have done the roof and drivers door as shown earlier in the thread and the rear tub as shown above. I've got 8 and a bit sheets left and I'm hoping that will be just enough to do the other wheel box. I'm probably going to need another couple of sheets to do the passenger door when I get to that part. 
Click image to enlarge

MY BUILD THREAD

Post #636838 10th Jul 2017 8:36pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

I recently noticed the dreaded radial oil streaks on the rear right hand wheel, indicating a leaking drive flange gasket, and also noticed a lot of rear axle noise at around 50mph, so this evening I sorted it out.

First off, I drained the axle oil, which looked ok although I think the level was a bit low. Next, removed the five bolts and whipped off the drive flange, which revealed a very tatty oil soaked gasket. A quick clean up of the faces with some fine wire wool, on with the new gasket and a drop of Loctite on the bolts and it was good to go:


Click image to enlarge


Before refilling the axle with 75w/90, I took the opportunity to fit a magnetic drain plug:

Click image to enlarge


A quick blast up the road revealed a much quieter axle and a nice clean wheel Cool 
Click image to enlarge

MY BUILD THREAD

Post #637392 13th Jul 2017 8:22pm
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 4709

United Kingdom 1992 Defender 90 200 Tdi SW Arles Blue

More progress on the interior this weekend! Spent a happy (not) couple of hours hack sawing off four bolts from the old seat belts on the NS wheel box and scraping off as much of the old carpet glue as possible Rolling Eyes Then plugged all of the redundant holes with some bits of ali strip Sikaflexed to the underside to end up with this:


Click image to enlarge

Then followed some careful measuring and drilling of new holes for the second new seat and belt:


Click image to enlarge

Next came more Silentcoat - I just had enough to finish this area and will need some more for the passenger door and seat box. Cut outs as before for where the seat and belt will sit:


Click image to enlarge


Finally for today, I cut myself a new rubber mat from a larger sheet. It's deliberately cut oversize for the time being until I've got all of the carpet in and can then trim it to suit:


Click image to enlarge

It's 3mm wide-ribbed rubber and is ideal for this purpose and only 30 for a 2.0 x 1.2m sheet. One of the offcuts has found a place on the wheel box forward of the first new seat:


Click image to enlarge

I hope to get the rest of the foam and carpet in during the course of this week Very Happy 
Click image to enlarge

MY BUILD THREAD


Last edited by LandRoverAnorak on 4th Aug 2017 12:05pm. Edited 1 time in total

Post #637884 16th Jul 2017 8:51pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 4283

England 

Good progress there LRA Thumbs Up nice bonus with the rubber mat under the box, nice protection for the carpet Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up. Keeper.

Cheers
Clayton.

Post #637893 16th Jul 2017 9:16pm
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Procta



Member Since: 03 Dec 2016
Location: Sunderland
Posts: 1094

United Kingdom 1997 Defender 90 300 Tdi HT Baltic Blue

getting there! rubber looks OEM! Thumbs Up Defender 300 TDi 90 ---/--- Peugeot 306 HDI hatch back

Post #637923 17th Jul 2017 5:06am
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