 | Home > My Defender > Introducing Buggsy my 110 TD5 |
 
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674   
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Okay very slow on the updates and not too much done but work is a little busy at the mo
I have started on the rebuild of the seatbox, fitting the sound proofing etc, both seats are back in and as my seatbelts didn’t look the best I thought it would be best to replace them. No pics yet 
Biggest development was this:  Click image to enlarge Click image to enlarge With the engine removed I have great access to the chassis rails and bulkhead foot wells so hopefully I will get time to give them a good clean and a good coating of dinitrol this week, the engine is due to arrive in a few days and I have a few bits to do on it before it goes in, so doubt it will be in until the weekend. Whilst I think of it does anyone know where I can get a parts cataloge for Buggsy, I am assuming the springs/ shocks will be upgraded so just want to make sure I have the correct numbers, also missing a few little bits that’s specific to my style of utility and didn’t know if it was easier to order new rather than fabricate them. Cheers in advance  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............ |
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30th Jan 2018 12:13am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Ok update time,
I started on the chassis legs cleaning off all the grime and oil, followed by rust converter on any rust showing on the frames welds: Click image to enlarge Whilst this cured I thought I would have a go at sealing the leak I have from the roof, it looks like the roof rack has at some point been overloaded causing the roof sections to seperate: Click image to enlarge Click image to enlarge I cleaned up the multi layers of added sealer and the original stuff and then applied some silicone, securing the roof with as much pressure as I could, not the best solution but hopefully it will do until I can remove the roof and do it all properly. Still waiting for the rust converter to cure I thought I would dig out the wire wheel and buzzweld to make a start on the rear crossmember, it looked a little crusty but didn’t appear too bad...... Click image to enlarge Guess it was 
New options; Repair (lasts a little while rot still there) Replace myself (not got a welder capable) Replace via a company (costs more but should be able to reduce the price if I prep, ie removal of tank etc) Leaning towards using a company, Devon 4x4 are just down the road so might be an option? With the front end solid (I’ve checked again) and the converter dry it was time to dinitrol: Click image to enlarge Only applied it to the tops of the chassis as I need to jet wash it thoroughly before I do the rest. Hopefully I can get the engine sorted and ready for fitting this weekend. 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............ |
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3rd Feb 2018 12:36am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Only a small problem, looking at it I can patch it for now and replace at a later date, obviously I will avoid any towing just incase.
Ok so that’s another weekend gone but I have managed a few more bits on Buggsy, Started to put the roof lining back together after adding some closed cell foam, I have only added a 3mm ccf at the moment but you definitely notice the difference; Click image to enlarge Click image to enlarge Once it was back together it was time to fit my now dried screen hinges, long story short the powder coating failed to apply correctly so I ended up spraying them, now anyone would think fitting these are easy, 3 bolts should be simple eh...... well no of course not as normal with landys they like to be awkward and this was it, all bolts thread easily and then the top bolt locks solid, hmmm ok try to undo it and no solid again, right out comes the impact gun and off with the bolt, threads stripped on the bolt and the thread insert full of bolt........... brilliant So out with the tap and die kit and a quick clean of the threads gives me a useable bracket once again 
Click image to enlarge that meant I could have this; Click image to enlarge I have also made a start on removing bits off the new engine and cleaning the oil/gunge from it, Few new parts to be fitted prior to instal so it’s taking me a little longer to drop it in but it will happen soon I promise. 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............ |
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5th Feb 2018 12:13am |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10513 
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Glad you got the hinge sorted out, nothing goes to plan when you want it to
 , but it looks good in place 1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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6th Feb 2018 10:00pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Land rovers being land rovers, do work on one and the others get jealous, not guna have an easy time on Jas or Maggie now I’ve given all this time to Buggsy
Plus note engine swapping of bits is going well, so work depending it might be ready to fit very soon 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............ |
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6th Feb 2018 11:52pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10513
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The girls will have to understand that a bit of male bonding needs to be done
Good news on the engine, going the right way 1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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7th Feb 2018 12:14am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Long overdue update;
With the two engines side by side I was able to do all the bits I needed, swapping parts and fitting new ones, I started with a new injector loom and rocker cover gasket: Click image to enlarge Click image to enlarge Whilst the engine was out I thought it was best to do the rear crank seal and as I had to drop the sump I might as well do the oil pump bolt too: Click image to enlarge Click image to enlarge With all this work it would be daft not to fit a new clutch whilst the engine is out so a quick clean of my freshly fitted flywheel (new bolts and torqued upto 110nm) I started on the clutch, now I don’t have a clutch aligning tool and refuse to pay for one when you can easily make one; Take one deep socket (14mm?) I think I’ve forgotten now insert it into the bronze bush, to check it’s a perfect fit, take so electrical tape and do a few wraps test the clutch friction plate and add/remove as needed to get a tight fit, now you have a perfect alignment tool:
Click image to enlarge Click image to enlarge Click image to enlarge Now time to fit, what a pain in the a**e it is to lift this engine straight, que some chains and non H&S and I was good, took a while but she fitted perfectly with the clutch lining up first time
Click image to enlarge Connecting up the engine I remembered the glow plug harness was u/s on Buggsy, all the insulation was missing, luckily the replacement engine came with the disco loom, some connections had been cut already so there was no resale value in it, this ment I could steal the loom for the glow plugs; Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Well it was then onto the refitting of pipes now they are all miss shaped after years of being routed wrong so it was a great pain to try and guess the correct route, I’m still not sure if they are correct. Engine in........... tick Electrics............ tick Fuel................. tick Coolant............. tick Pipes/exhaust.... tick Other stuff......... tick Engine runs first turn of the key........... TICK Whoop Buggsy now runs and drives again so happy I’m no longer punching her in and out of the workshop, now it’s onto the rear of the interior, mounting the radiator (missing the top brackets) anyone got any? And whatever else I find needs doing. 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............ |
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11th Feb 2018 10:41pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10513
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Great progress there Mash and even better that the engine started first time
 1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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11th Feb 2018 11:43pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Cheers Clayton, it is nice to hear the engine fire up (might currently be a straight through exhaust
 )
Well after a week of no work done on Buggsy and a pile of parcels to open and fit I moved her into the workshop, Parcel one: headlight switch, fitted and now have head lights
Parcel two: heavy duty drive flanges for the rear, after getting her running I was getting a horrendous cluncking from the rear, checked the prop, all good, ok must be play in the drive members ( didn’t check just ordered spares). Go to fit R/H/R, wheel off, hmmm every drive member bolt hand tight: Click image to enlarge Drive member off and cleaned up, excessive wear is easily seen: Click image to enlarge With the drive member off I could see that the hubs hadn’t been looked after very well, the grease was not healthy so one simple job turns into a more complex one, luckily I have 3 Defenders running near identical axles so I always keep a selection of seals/bolts etc in my box. So hub off and stripped: Click image to enlarge Bearings cleaned out and checked for damage, all ok so they were re-packed with grease, new rear hub seal fitted and it was good to go back together, torqued up and hub but staked: Click image to enlarge And finally get to fit my new drive members: Click image to enlarge Rear two done today and the front two shall be done tomorrow. Parcel three, take off lower dash (described as no rust) well it has some surface rust so a coating of rust converter prior to a paint has been done. Parcel four, new wiper arms and blades, the wiper arm is eventually removed, new arm doesn’t fit  guess it will be the old arms for now.
Parcel five, speakers........ 6.5” not the 5.25” I ordered, don’t think I can squeeze these into the dash so might now end up with a second pair fitted somewhere. Surprise parcel (wasn’t expecting this till next week) 5 new tyres just need to get these to a tyre shop to fit
So not too bad for post work on Friday, 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............ |
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17th Feb 2018 12:08am |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10513
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Nice bit of progress there Mash, and the new shiny drive members
1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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18th Feb 2018 10:45pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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Cheers Clayton
So on with the overhaul of Buggsys drive train, I started on the front end and it was evident that some work had been done at some point due to a thick covering in red sealant: Click image to enlarge Luckily both front hubs stripped down easily and everything was fine, I did notice both tracta seals leaking and after a rummage in the box of bits I found one set of seals (tracta and driveshaft) so I chose to do the R/H/F as it looked the worst: Click image to enlarge Started stripping it down on the bench and found this: Click image to enlarge Something tells me some of these fleet vehicles might not get the servicing people claim 
So a full strip and clean showed me that the challis was badly pitted and just replacing the seal wouldn’t do, so being the dedicated enthusiast to green oval (not hoarder swmbo would claim I am) it was off to the trailer where I knew I had the serviceable old units I replaced when building maggies axles. Finally able to rebuild the wheel station I’m now waiting for the bits to do the L/H/F. Sunday morning I made a start on bleeding the brakes to try and get rid of the spongey pedal, then it was onto the lift and Buggsy was up in the air so I could tackle a list of jobs, having her up in the air makes life a lot easier. Starting with a good grease on the props as they hadn’t been done in a while, I had to “modify” my grease gun a little by grinding down an edge to get on the front prop nipple, once this was done I got to do the really fun job of draining copious amounts of EP90 from the diffs, it was black! Now covered in the stuff I moved onto the T-box, cracked off the filler..... no oil, ok might be a little low, drain plug out and out drains 100ml ish of fluid, glad I haven’t driven more than in and out the Workshop, topped up the T-box and moved onto the gearbox.... so I always do any drain and fill procedure in the same way; Remove the filler plug Remove the drain plug Drain Refit drain plug Fill Fit filler plug So have a guess how far I got, yep removal of the filler, why would a t55 plug be round? Because some idiot was let loose on it, so after spending far too long trying to remove it I gave up, I will have another go next week. With Buggsy in the air I decided to swap the fuel filter bracket that had snapped, what a stupid place Land Rover, it fills with mud and cr@p there, one bolt sheared and one bolt came out, they could of used nut and bolt rather than captive but no they know best
So with all those problems I decided to move onto a clean job, re-assembly of the dash, I managed to get the lower section in place and the fuse box secure before calling it a night. Not as much achieved as I hoped but after the other problems thrown up it wasn’t a bad weekends work and I now have a good chunk of my to do list ticked off 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............ |
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18th Feb 2018 11:59pm |
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| Procta Member Since: 04 Dec 2016 Location: Sunderland Posts: 4940 
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I am not surprised about that, the stories I have heard about things "been serviced" makes you want to do it all your self.
You should have seen the laugh we had with the brakes on mine! Defender TD5 90 ---/--- Peugeot 306 HDI hatch back Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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19th Feb 2018 7:06am |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674
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I agree procta I think the standards of “mechanics” can vary massively, oh well guess it’s my job to set it right
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............ |
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19th Feb 2018 10:38am |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10513
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^^^ +1
1996 Golf Blue 300Tdi 110 Pick up. Keeper.
Clayton. |
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19th Feb 2018 9:46pm |
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