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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
I have a slightly odd plan, gonna heat them with a blow torch and then clamp some flat 40mm oak worktop offcuts really tight, hopefully this will work but who knows.... Rolling with laughter
Post #635838 5th Jul 2017 8:31pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Okay, so rear tub and I'm pleasantly surprised!!

Once I'd cleared 50 years of crud off it's actually in great shape, I suspect Land Rover in 1966 was pretty good at quality. Nearly 2 decades into production and before British Leyland. So much so I've decided 1966 was the best year for Land Rovers. (Also Wine & Football) Thumbs Up Thumbs Up

So in short it needs 1 new cross members and some galvanic corrosion neatening up.

50 years of crud


4 hours later (& a lot of wire brushing)


1 bad (steel) bit
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and lots of this


Last edited by Tiger on 9th Jul 2017 10:25pm. Edited 1 time in total
Post #636627 9th Jul 2017 8:45pm
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Mo Murphy



Member Since: 01 Jun 2008
Location: Letchworth Garden City, Herts
Posts: 2062

United Kingdom 1984 Defender 90 200 Tdi HT Pennine Grey
That's nice, good work
Mo The Land Rover 90 - Many are called, few are chosen.
Post #636669 9th Jul 2017 10:23pm
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zsd-puma



Member Since: 09 Aug 2016
Location: Kent
Posts: 2720

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black
Given the controversy it creates when someone describes a 'Series' Land Rover as a Defender. Why are we allowing this irrelevant post on the "Defender 2" Forum?! Shocked

Posted in Jest obviously! Laughing
Post #636679 9th Jul 2017 10:48pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Arrgh the thread started as something else.

I'll ask Martin to move it Thumbs Up
Post #636680 9th Jul 2017 10:51pm
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zsd-puma



Member Since: 09 Aug 2016
Location: Kent
Posts: 2720

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black
I was only joking, it's completely relevant to a Defender, the seat boxes and tubs are basically the same. The whole car is! I never understand why people get so upset when they see a leaf sprung vehicle described as a Defender, even though Land Rover themselves do it. The Series 1 was named in retrospect too.....
Post #636683 9th Jul 2017 10:59pm
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
The crossmembers on that tub look better than my 1999 station wagon Laughing
Post #636706 10th Jul 2017 8:00am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Rolling with laughter

Right a bit more progress. (its a bit of a hack but really didn't fancy new rear qtrs and the alloy bar and seen as it's mostly very solid I've cheated a bit.

So the galvanic edges of the rear qtrs I was just original going to trim a straight edge taking 5mm off the bottom the panel but instead I've decided to build it back up again using a bit of fibreglass.


..and from inside


jig off


bit of etch primer to show where i'll need a bit of knifing filler
Post #636713 10th Jul 2017 9:47am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Good 'tub' progress today.

One of the rear wings had a nasty crease in it and it wouldn't knock without with springing all in and out.

Anyway had an idea to clamp a bit of worktop to it and 'anneal it' with a blowtorch, the internet said 350c so armed with infrared thermometer and blowtorch and hammer i've been heating and gently persuading the rear wing to be straight(ish)

Very weird watching the ally bend and bow into it's own shapes under heat.

Clamped up


After heat (and few whacks)


Needs a bit of filler but really pleased Very Happy Very Happy Very Happy Very Happy
Post #636748 10th Jul 2017 1:39pm
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Pickles



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

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green
Great work Tiger,...looking forward to seeing more of this.
Pickles.
Post #636865 10th Jul 2017 9:55pm
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Okay so now the rear is tidy!

From crusty grizzly edges to nice and smooth Thumbs Up

Crusty and grizlly!


Flat & smooth!

Click image to enlarge


Next job is to replace the bad crossmember then paint!
Post #637133 12th Jul 2017 1:18pm
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Gareth



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 1038

England 2003 Defender 90 Td5 CSW Oslo Blue
Really interested in the detail of how you did the fibreglass edge on the rear quarters. Can you elaborate on your process? It looks very neat and my S2a is also suffering. 2021 Defender 110 X-Dynamic HSE D300 MHEV
1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2014 Jaaaag F Type 3.0 Supercharged.
Post #637437 14th Jul 2017 7:45am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Nothing too advanced, just wire brushed and flappy disc'ed the powdery edges to get to solid aluminium.

Then clamped 2 bits of wood up to make a rough shape with some extra.

Then built up using fibreglass filler, waited for it to dry, cut the edges 2mm to big with a junior hack saw then block sanded against a straight edge.

This post shows the highly technical jig...http://www.defender2.net/forum/post636713.html#636713
Post #637466 14th Jul 2017 10:17am
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Tiger



Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

2004 Defender 110 Td5 CSW Java Black
Right, more work on the tub..

The nearest tub cross member had had it so a new one was needed

Click image to enlarge


Patched the holes with my favourite stuff .... (flibreglass, used mating this time) as it was only 2 small holes in the tub floor.

Where the support beams had gone I slid 15mm Aluminium channel into the existing beams, this will reinforce the existing but also give me something to rivet the new crossmember to.

Anything steel was also primed

Click image to enlarge


New crossmember fixed into place and the whole underside of the tub was etched

Click image to enlarge


Then given a coat of Buzzwelds's CIO mainly because I had half a tin (horrible stuff!!) but neatens it all up and and extra layer in the battle against galvanic corrosion.


Anyway pretty please, just waiting for it to dry then turn it over never to be seen again. (apart from by an MOT man) Thumbs Up
Post #637468 14th Jul 2017 10:35am
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Gareth



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 1038

England 2003 Defender 90 Td5 CSW Oslo Blue
Tiger wrote:
Nothing too advanced, just wire brushed and flappy disc'ed the powdery edges to get to solid aluminium.

Then clamped 2 bits of wood up to make a rough shape with some extra.

Then built up using fibreglass filler, waited for it to dry, cut the edges 2mm to big with a junior hack saw then block sanded against a straight edge.

This post shows the highly technical jig...http://www.defender2.net/forum/post636713.html#636713


Thanks Thumbs Up 2021 Defender 110 X-Dynamic HSE D300 MHEV
1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2014 Jaaaag F Type 3.0 Supercharged.
Post #637501 14th Jul 2017 2:30pm
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