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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
80" project started at last!
Hi

After quite a few busy months on the 80" I thought I would give an update.

For those who remember it started with this.......
Dispatched on Jan 14th 1950, ex military, locked in a garage since 1985 until I took possession last June.
It's been on the back burner while I finished my 86".

But now it's full on project time again!

As found....



Click image to enlarge


Didn't look that bad until you start pulling them apart Big Cry



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On first inspection, the bulkhead looked OK?
But after spotting strange holes, and countersunk rivets under old filler, it turned out the front and back top sections,
Had been "re skinned" badly!



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So, the decision was made to refabricate the entire top front, and rear sections.
With fabricated door pillars.
A trip to my local sheet metal folders saw this...



Click image to enlarge



Click image to enlarge


Inbetween doing the bulkhead, the axles have been totally re built with new swivels, seals, bearings, brakes, diffs removed cleaned, checked etc, shot blasted and painted.


Click image to enlarge


Chassis needed repairing, not as bad as it could have been though!
Front dumb irons, and most of the underside where the mud sits!



Click image to enlarge


With the chassis all welded up over the last few weekends, today saw a trial fit of the bulkhead, new doors and new rear tub.
The tub was one of 12 that were made in Australia in the 90s by a well known restorer, an absolute work of art!
This is probably the only one that's never been used? Upto now, (Quite a rare find!)

Body work fits perfect, as does the tub. Very Happy



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That's about it for now, I will come back with another update in a few weeks all being well... Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.


Last edited by ian series 1 on 18th Mar 2018 4:16pm. Edited 1 time in total
Post #516078 19th Mar 2016 10:00pm
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Ellisboy



Member Since: 13 Oct 2013
Location: Deep South
Posts: 539

1998 Defender 90 300 Tdi CSW Epsom Green
Nice work mate Bow down it's looking good!

Stephen.
Post #516083 19th Mar 2016 10:10pm
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CY88



Member Since: 05 Jan 2016
Location: Offshore
Posts: 255

1986 Defender 90 V8 Petrol ST Keswick Green
Cracking stuff! Watching with interest!
Post #516088 19th Mar 2016 10:25pm
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Pickles



Member Since: 26 May 2013
Location: Melbourne
Posts: 3748

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green
Very good work. I'm intrigued by the "Aussie Tub"?.....Did you find it in Aussie or the UK?
Following with great interest.
Pickles.
Post #516108 20th Mar 2016 12:59am
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
Pickles, the tub has been in the uk for a while now.

A old chap in the series 1 club owned it, apparently he past away a few years ago,
I am not sure if he was the importer/ commissioner of the batch of 12?
But I think he had more than 1?

Apparently, No one can make them here, as the spot welder needs to be huge!
But it looks like someone down under has the tooling/ and skills!
The tub had changed hands a few times since then, until a good friend of mine brought it for his own 80" restoration.

He didn't use it either! I think people are scared to drill holes in it... Laughing

It's quite something to see close up, obviously the chap who made them knew what he was doing!
I will try and find out who it was.

Cheers guys😉



Click image to enlarge



Click image to enlarge
 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #516112 20th Mar 2016 6:03am
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milesr3



Member Since: 12 Feb 2013
Location: Suffolk
Posts: 873

2016 Defender 90 Puma 2.2 XS CSW Keswick Green
Fantastic project. Out of curiosity why does it need new doors and tub?
Post #516265 20th Mar 2016 9:17pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 19452

United Kingdom 
Looks good, you can see how much effort and detail has gone in.
It'll really show the attention to detail later on.

Good job. Thumbs Up
Post #516266 20th Mar 2016 9:22pm
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
milesr3 wrote:
Fantastic project. Out of curiosity why does it need new doors and tub?



I aim to go concourse with it, so it's got to be "bang on" plus 80" doors over the years go very weak, and crack around the inner frame.
Add all the "extra" holes drilled over the years and bodged repairs in to the picture, and your looking at a lot of work to put right.

My old tub will be repaired in time, and put Away for a rainy day.


Not every day you get a chance of a new 80" rear tub... Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #516270 20th Mar 2016 9:38pm
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Mash



Member Since: 09 Feb 2015
Location: Guernsey
Posts: 1674

Guernsey 1998 Defender 90 300 Tdi HT Nato Green
Looking great Thumbs Up now this reminds me how much I want a leafer Big Cry 90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html
110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html
52HG25 lightweight https://www.defender2.net/forum/topic72342.html
D3 Hse - Fiona
Capri 2l S - Anna

Think I might have a problem............
Post #516275 20th Mar 2016 9:56pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16809

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Oooh, major tub envy! Major workshop envy too!
Post #516280 20th Mar 2016 10:07pm
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
The end result should look like this....




I didn't fancy another green one! Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #516332 21st Mar 2016 7:15am
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Andy80



Member Since: 31 May 2013
Location: Essex
Posts: 484

England 2008 Defender 110 Puma 2.4 HT Cairns Blue
Hi Ian,

Did you find where KLX resides?


Andy Wink Working towards Carry on camping!
Post #516333 21st Mar 2016 7:55am
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
Hi Andy,

Couldn't find it anywhere?
Believe me I have tried, I Can't believe the AA, and most of the museums it visits simply don't know who has custody over it,
Or it's whereabouts?

If anyone on the forum knows where KLX resides I would be glad to hear from you! Wink
Cheers 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #516342 21st Mar 2016 8:30am
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22900013A



Member Since: 23 Dec 2010
Location: Oxfordshire
Posts: 3136

United Kingdom 2011 Defender 110 Puma 2.4 USW Keswick Green
KLX is in the motor museum at Coventry. 2011 110 USW
1973 Series III 1-Ton
1972 Series III 1-Ton Cherrypicker
1969 IIA 1-Ton
1966 IIA 88"
Post #516506 21st Mar 2016 6:34pm
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ian series 1



Member Since: 17 Nov 2014
Location: south
Posts: 3127

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
It wasn't when I enquired a few weeks ago?

I will give them a ring again tomorrow, thanks Thumbs Up 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #516510 21st Mar 2016 6:42pm
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