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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Installing Puma Seats in a TD5
Right so I've being doing this a while but here goes:

Here are my old Td5 seats, Techno cloth, yuk!!! Shocked




And since I have kids seats in the back I wanted better seats in the 110.



So I got a set of Puma seats, cubby & fixings Thumbs Up






Fronts are a straight swap so dead easy, the green string is a centre line running from the ash tray in the middle of the dash to the rear door handle to get a centre for the rear seats for fixing.



Once I'd got a centre I could offer the floor plate up and drill the six bolt holes



The floor plate bolts through the floor plan to large brackets that sit on the chassis rail (bought from Duckworths Thumbs Up )



These sit on top of the chassis rail and are bolted to the chassis via 3 bolts so you need to drill and tap a thread into the chassis.
The problem being that with tub in place you can't get these on top and over the rail Big Cry



So I had to cut the front off the bracket and, bolt it via 2 of the fixings and going to have to get it welded to the chassis for total safety. This makes the Puma seats a lot more secure, the TD5 seats and seatbelt anchors have no chassis fixings!! Shocked



Puma tubs are shallower to allow for the bigger seats this means in a TD5 you need to cut holes to make room for the seats to out came the jigsaw



Then in a true Heath Robinson fashion I made some high tech composite bodywork lowering device.
(Chinese takeaway box cut to size to make a mould and fibreglassed Rolling with laughter )




Paint to disguise




Getting there!




Next I needed to make some strengthening brackets for the seat fixings, they are too heavy to bolt straight to the Ali floor.

I bought some builders brackets from Wickes as I couldn't get the LR part.



Cut them down and drilled them



Test fit




Just another 3 to make now




Each one was bolted to the 1st to ensure they were the same



Painted



Next job is to re-trim the seats in Leather and fit them Thumbs Up


Post #302475 26th Jan 2014 11:59pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769
England 2004 Defender 110 Td5 CSW Bonatti Grey
Great write up Thumbs Up I'm thinking I might do this instead of exmoor high backs. Could you tell me the part numbers of the brackets you got from duckworths please and rough idea on cost?

Cheers
Ray
Post #302481 27th Jan 2014 12:23am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Part number is AQR710290

25 each
Post #302482 27th Jan 2014 12:31am
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769
England 2004 Defender 110 Td5 CSW Bonatti Grey
Thumbs Up excellent cheers
Post #302485 27th Jan 2014 12:58am
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 19611
United Kingdom 
Is that re trim completely leather? Diesel$ Live$ Matter. ⛽️🛢️👨‍🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧
Post #302492 27th Jan 2014 1:58am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Nope, just normal XS stuff
Post #302502 27th Jan 2014 8:23am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Started the retrim.

Puma seats are well made Shocked Took some doing in the end to do one seat Rolling Eyes





The base and back are held in with Hogrings which are a bitch to get to to bend open



Start fitting XS half leather.



1 seat done

Much better than the Grey Vinyl

Post #302771 28th Jan 2014 9:35am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Updated List:

Done List

Install additional CAT2 Immobiliser - Done
Secret Squirrel Security Upgrade 1 - Done
Defender Windscreen Sticker - Done
Swap Alloys - Done
Leather Gear Gator - Done
Secret Squirrel Security Upgrade 2 - Done
New Chrome Caps for Wheel Nuts - Done
Mud Tray - Done
LED Interior Lights - Done
Upgrade Headlamp bulbs - Done
Clear Front & Side Indicators - Done
LED Side Lights - Done
Add BBUS Sounder - Done
Alloy Gear & Transfer Knobs - Done
Secret Squirrel Security Upgrade 3 - Done
X-Defend Steering Column - Done
Roof tag - Done
Modify key to one piece - Done
Fit Leather XS Steering wheel - Done
Fit better aerial - Done
Paint & Fit Roof rack - Done
Paint & Fit Ladder
Fit Air intake Cowl - Done
Fit Crystal Wipac Headlights - Done
Fit LED number plate light - Done
Fit LED reverse light - Done
Fit Headlamp Guards - Done
Fit Puma Interior Seats - Done
Fit Rear Speaker panels & Wire - Done
Fit new Front Bumper - Done
Paint Wing top Checker Plate - Done
Fit Mantec Swing away wheel carrier - Done
Fit Discovery Bike rack - Done

Immediate To Do (parts sat waiting)

Fit Tints to rear
Fit Lightbar
Fit LED Worklamp
Upgrade headlight loom
Fit SS Bolts
Fit side window demisters
Fix flappy door cards (&strip locks to stop bounce)
Fit MUD 12v Points in Front & Rear
Fit MUD curry hooks
Fit XS Leather Seats - 1 Seat done
Fit Heated Seats
Fit 'classic' LR SW Badge - Was done, fell off, need to rivet this time
Fit Soft 'A' bar
Fit Heated Screen
Fit Heated Mirrors
Finish Stereo upgrade (inc Amp, Sub and Speakers)
Fit Rock sliders

Future 'To Do' (don't have parts)

Window Guards
Dog Guard
Soundproofing
New Carpets
4 x X-Trouser
Rear step or NAS Rear Bumper
Repair rear heated screen - Done
Post #302777 28th Jan 2014 10:10am
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william8



Member Since: 03 Apr 2013
Location: Motherwell
Posts: 259
Scotland 2008 Defender 90 Puma 2.4 XS CSW Zambezi Silver
Looks great!

Great to see a list like any Defender should have. Constantly evolving and getting better with age and mods. Try and do that with a new vogue Cool

Keep it up Tiger (this line sounds bad) William
Post #302779 28th Jan 2014 10:36am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
It's just a case of finding the time to tinker.

Kids, work, life all need time aswell.
Post #302793 28th Jan 2014 12:06pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Did a bit more work on the Install of the Puma Rear seats

The Chassis brackets are now fixed.

First job was to drill 8mm holes in the chassis rail in line with the seat retainer brackets fixing holes


Click image to enlarge

The the holes then had to have a thread tapped so the brackets could be bolted with M8 high tensile bolts


Click image to enlarge

Not easy to see from the photos but the bracket (new black metal bit) is now bolted (shiney silver bolt in view) directly to the chassis rail.

This means the Puma seats and therefore the seat belts are anchored to the Chassis rather than just through the thin ali floorpan like on the TD5 seats.

Took some doing but glad I'm trying to replicate the Puma rather than going the easy rout and just securing through the floor.
Post #305294 5th Feb 2014 2:53pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Last night I started to retrim the 60 Rear Seat



Tools needed



Ideally you could do with some hog ring pliers but I used needle nose and filed a small notch in the backs

Step 1 - Remove the plastic Trims (3 screws each side and one bolt. Biggest screw in the middle). The reclining handle pulls off and the trim takes some jaunty angle to remove it past the metal handle and mechanism.





You need to remove the bump stop (6mm allen)


Click image to enlarge

Then the Fir Tree trip clips ( Every Defender owner should own a trim clip tool, they are ace and dead cheap)



Nice re-useable un-mangled Fir Trees



The Plastic / hardboard base will now slide off



You can now see all of the clips that hold the seat cover to the fusion and frame. Carefully undo these








Click image to enlarge

Once all the clips are undone the cushion and cover will come away from the frame


Click image to enlarge

The middle seat belt goes through the trim and needs to be undone first (Torx T50)





Base now fully removed



Right now the awkward bit, price open the hog rings at the rear corners.



Once undone you can peel the cover back from the edges to reveal the hog rings that hold the centre of the seat to a metal wire in the fusion foam.



Carefully prise open the 20 hog rings to release the cover from the fusion





I then straightened them as I didn't know the size prior to taking the cover off, the job would be easier with new rings as you could then just cut the old ones.



Here's the size for future reference




Click image to enlarge

You can now start the re-trim

Place the cover over the fusion with the edges turned inwards



Working from the centre out re-fit the hog rings





Re-fit is the same in reverse, don't forget the centre seat belt Thumbs Up


Click image to enlarge

Easy to do and a neat job


Click image to enlarge

For those wondering why an Amp has appeared, I wanted to fit the amp somewhere discreet and the underside of the seat was perfect. Also while the seat was in pieces it gave me the chance to attach it to the frame of the seat not just the thin base.

Position



Mark & Drill



Rivnut into seat frame



Screw through base into 4 rivnuts using 4 SS Torx pan heads



Might do the back tonight if I get time Thumbs Up

Last edited by Tiger on 12th Feb 2014 12:29pm. Edited 1 time in total
Post #307385 12th Feb 2014 10:35am
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Martin
Site Admin


Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6485
United Kingdom 2015 Defender 90 Puma 2.2 XS CSW Montalcino Red
What a superb write up, keep it coming Bow down Bow down  1988 90 Td5 NAS soft top
2015 D90 XS SW
Post #307415 12th Feb 2014 12:22pm
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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018
United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green
Really informative - thanks for taking the time to photograph each stage and write it up Thumbs Up
Post #307446 12th Feb 2014 2:35pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265
2004 Defender 110 Td5 CSW Java Black
Cheers Thumbs Up

I figured now that the 1st Pumas are coming up to 7 years old then a few might be doing this soon
Post #307482 12th Feb 2014 4:02pm
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