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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue
My Series 2a restoration thread.

Following the purchase of this lovely old S2a in THIS I thought it would be good to put an on going restoration thread in place.

So far I have just stripped the wings off, bonnet off, and generally had a good old poke around. I got a set of correct wheels and tyres from a member of the Series 2 forum, which has been a very useful place to be.

I stripped the brakes off it to allow me to move it easier, it will need new brakes as they were seized.

The diesel engine fitted turns over ok, although I have not tried to start it yet. Mechanically it seems pretty good. I connected electrics and the oil light came on when I put the ignition on!! Nothing else worked though.

The chassis is actually pretty solid, except rear crossmember a couple of out riggers, and front dumb iron. Having said that, it has had some repairs in the past so will more than likely get renewed with a Richards Chassis period replica.

The big problem seems to be the bulkhead. There are a few companies advertising either new or reconditioned bulkheads off the shelf, but I have not been overly impressed by either their enthusiasm to get business, or there ability to return phone calls or emails. I'll keep looking, but I may well end up renovating the bulkhead myself. I have welding and fabrication skills, from 30 years ago! I just need to acquire some decent sheet metalworking tools.

So next job is to strip the interior, seats, seat box, roof, sides and rear tub. Should have that done by end of next week, and I can have a proper look at things.

Yes I do intend to keep the patina as much as possible.

Here's a timelapse of the first part of the stripdown.

[/img] 1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #728985 14th Sep 2018 7:17pm
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Clemmo



Member Since: 03 Aug 2012
Location: Mile Oak
Posts: 746

England 

Great 👍
Will be following with Interest as have been working on a 2A over last 3 years. Now in use but always something to do 😉
Clemmo


Click image to enlarge
 Make today a little better than yesterday but not so good as tomorrow ....everyday will be a good one
Series 2A 1963......Bronze Green
BMW 5 Series estate................Blue
VW Beetle Convertible..Met Blue
Ford Kuga................White

Post #728989 14th Sep 2018 7:37pm
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HK07



Member Since: 15 Dec 2016
Location: Hampshire
Posts: 415

England 2007 Defender 90 Puma 2.4 HT Cairns Blue

Good start- well done!!! Thumbs Up 2007 90 Puma - Love it - Best car I have ever owned.

1989 Ninety 200tdi - In re-build - http://www.defender2.net/forum/topic56156.html

Post #728995 14th Sep 2018 7:56pm
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g-mack



Member Since: 07 Jan 2014
Location: northumberland
Posts: 1952

United Kingdom 

following Thumbs Up ive had mine 8 month and hardly touched it Very Happy My 109 thread

my youtube channel

Post #729026 14th Sep 2018 10:24pm
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PumaPhil



Member Since: 26 Oct 2014
Location: Swansea
Posts: 158

Wales 2015 Defender 90 Puma 2.2 HT Aintree Green

Looks good! Is that an electric winch you are using to pull it in and out?

Post #729084 15th Sep 2018 1:26pm
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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue

No, I have another 2a, with a Mayflower PTO winch. I used that with the plasma rope around a pulley block attached to the back wall of my garage. Useful because the drive slopes and I can't push it on my own. 1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #729122 15th Sep 2018 7:21pm
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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue

Done a bit more today. Took out the the floors, and steam cleaned the engine bay and bodywork, and underneath. It looks much better now. I noticed that the chassis has had extensive repairs, but they seem to be done really well. It needs 1 outrigger, and a rear cross member. I'm still debating whether to get a Richards chassis for it.

I think the bulkhead is toast. I was having thoughts about refurbishing myself, but I think it would need a lot of additional patching, as the bottom of the dash has rotted on the left side, also the vent panels are not in the best of condition. I have decided to try and purchase a new pattern bulkhead from Owen Engineering, as talked about on the S2 forum. Pricey, but I think my time would be better spent on other jobs on the rebuild. It looks like a long lead time so will have to be patient.

Next job will be to try and get the engine to run, so I can judge its condition, and decide if I keep it diesel or find a petrol 2.25 to fit.


Click image to enlarge



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Click image to enlarge
 1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #729126 15th Sep 2018 7:41pm
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PumaPhil



Member Since: 26 Oct 2014
Location: Swansea
Posts: 158

Wales 2015 Defender 90 Puma 2.2 HT Aintree Green

GarethR wrote:
No, I have another 2a, with a Mayflower PTO winch. I used that with the plasma rope around a pulley block attached to the back wall of my garage. Useful because the drive slopes and I can't push it on my own.


Nicely done Thumbs Up

Post #729164 15th Sep 2018 10:16pm
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22900013A



Member Since: 23 Dec 2010
Location: Oxfordshire
Posts: 2436

United Kingdom 2011 Defender 110 Puma 2.4 USW Keswick Green

Loving that signwriting! My 88" has some in the dash area, dating from its use with Southern Electric in 1966. Its having a new bulkhead but I have asked to keep the original dash and paint just to keep the signage.

With yours, a bumper and some proper wheels and tyres and it will look perfect as it is! Don't forget the wheels would have been green to match the body at this age. 2011 110 USW
1973 Series III 1-Ton
1972 Series III 1-Ton Cherrypicker
1969 IIA 1-Ton
1966 IIA 88"

Post #729198 16th Sep 2018 8:24am
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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue

Yes got some wheels to paint. Need to know how to paint stuff to have a 50 year old patina look? 1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #729230 16th Sep 2018 11:49am
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22900013A



Member Since: 23 Dec 2010
Location: Oxfordshire
Posts: 2436

United Kingdom 2011 Defender 110 Puma 2.4 USW Keswick Green

Not really possible, but being steel wheels they will wear in pretty quickly. 2011 110 USW
1973 Series III 1-Ton
1972 Series III 1-Ton Cherrypicker
1969 IIA 1-Ton
1966 IIA 88"

Post #729283 16th Sep 2018 4:36pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 5955

England 1996 Defender 110 300 Tdi PU Coniston Green

Great to see this happening Very Happy 1996 Golf Blue 300Tdi 110 Pick up. Keeper.

Cheers
Clayton.

Post #729651 17th Sep 2018 8:59pm
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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue

Got another set of hands tomorrow, so hope to get the rest of the bodywork off, at least down to the rear tub. 1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #729664 17th Sep 2018 9:48pm
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GarethR



Member Since: 12 Dec 2011
Location: Bramhall
Posts: 528

England 2003 Defender 90 Td5 CSW Oslo Blue

Latest work done yesterday and today. The storm Ali prevented much outside work, so had to squeeze into the the garage. I managed to get the seats, seat-box, roof and sides removed. The seats were an absolute £*&%!! to remove, they were fastened with rusty nuts and bolts and the drivers seat over the tank was really tough. Ended up drilling some bolts out because I couldn't get on the back to hold the nut. Note to self - fit captives!!

The roof and sides were easy.

Also, I managed to speak to Robert Owen, and discussed the bulkhead. I now have a replica bulkhead on order, what a knowledgeable guy, and a pleasure to speak to. Approx 15 weeks until delivery, so plenty of time to refurbish or find/replace the many parts I have or need. There is going to be a lot of cleaning, blasting, painting, oiling, dismantling, rebuilding and I'm sure so much more over the winter!

I am still undecided what to do with the chassis. Its not that bad, and I'm sure some on here would repair it. It needs left dumb iron, left bulkhead out rigger, rear cross member. Right hand bulkhead and fuel tank front out riggers have been replaced previously, as has the right dumb iron. Unfortunately that means the chassis number is not stamped on it. I have not yet lifted the rear tub off yet, which may well expose more rust. As I am putting a new bulkhead on, whats the opinions on me trying to save the existing chassis? or might I be bettor off complementing the new BH with a new Richards chassis? Does my existing chassis have any value? I am not sure of the legalities of selling an old chassis, does the the log book go with it? Any advice received is welcome!! Seems a can of worms.

The car was originally registered as a petrol engine, and has been fitted with a diesel. I think from the engine number (90633675c) its about 1963? I am not that knowledgeable about the starting/stopping procedure of the diesel. It has a coil thing on the bulkhead, below and left of the clutch cylinder, this is connected to the glow plugs. It has a knob on the right bottom of the dash panel labelled Cold Start. The ignition key has an ON and Start position, no separate starter button. My questions are:

1. Are the glow plugs automatic?
2. Do I use the Cold Start knob like a choke on a petrol?
3. How does the Cold Start light in the bottom of the speedo work?
4. How do I stop the engine?

Sorry for the basic question, but on my Disco 4 I just press a button and it goes, press it again and it stops!!

Really getting into this now, and with me not working for now, I have plenty of time to throw at it. Anyway sorry for the long post but here's some pictures. Sorry but I tried another timelapse, but the battery on my Gopro failed.


Click image to enlarge



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Is this plug from a Lucas Alternator? The car still has its voltage regulator on the bulkhead, but I suspect its been converted to an alternator.


Click image to enlarge



  1966 S2a 109 aka Betsy
1968 S2a 88 aka Bob
2002 TD5 90 CSW
2013 D4 HSE Lux
2014 Jaaaag F Type 3.0 Supercharged.

Post #730030 19th Sep 2018 9:42pm
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JOW240725



Member Since: 04 May 2015
Location: Suffolk
Posts: 4742

United Kingdom 2012 Defender 110 Puma 2.2 XS CSW Orkney Grey

Great to see another one being saved! Well done you Thumbs Up Bow down James

MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html
MY1990 110 200TDi SW beautifully faded Portofino Red

Post #730053 20th Sep 2018 7:12am
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