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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
110 tdci Utility wagon build
Picked up this 2.4 110 Tdci with unrecorded front end damage and the plan is to build it into a galv chassis 110 USW. Lots of bits robbed of it or missing but most of it was lying in the back. Going to take the head of and see if the engine needs a rebuild on the the lump. Transfer box is missing, but its had a new gearbox fitted not long before this mis-hap.


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Pulled the wing straight as its much easier to do when it's attached


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not too bad


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Get the lump onto the stand next


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stripping begins...


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Last edited by NickMc on 24th Nov 2018 12:36am. Edited 4 times in total
Post #446525 16th Aug 2015 3:44pm
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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
Due a bit of an update here! Been getting bits and pieces done between other jobs and the stuff that pays the bills Yawn


Gearbox whipped out of the donor car.


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Engine on the stand to be stripped and rebuilt


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Thats looking like its got a bit warm Laughing


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Spun the conrod bearing


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All Stripped, good bores etc


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Some of the Body parts arrived genuine tdci tub and USW sides Cool


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Hardtop body off


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Strip the body down to what i need


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USW Tub fitted


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USW Sides fitted


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Roof fitted


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Bit of the body work started, thats easier to do when its together, little damage to the rear quarter hammered and pulled out


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Axles and chassis stripped


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It's now off for paint Keswick green and white roof I've settled on. Now waiting on the galvanised chassis etc being returned.
I'll check over all the mechanicals and change all the bushes, a-frame balljoint, springs, shocks etc. and the assembly is a walk in the park sure Whistle Rolling Eyes


Last edited by NickMc on 24th Nov 2018 12:37am. Edited 1 time in total
Post #516320 21st Mar 2016 1:33am
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Brewstop



Member Since: 28 Oct 2012
Location: South Oxfordshire
Posts: 311

United Kingdom 2002 Defender 110 Td5 CSW Zambezi Silver
Great project!

Are you going to sound proof it? Sandy
Post #516328 21st Mar 2016 6:51am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16812

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
I don't know what year the donor vehicle is, but seeing the photos of the bottom end reminds me that the early 2.4s had the potential problem with the piston cooling jets. I imagine that you're replaceing them anyway during the engine rebuild but it would, I suggest, certainly be worth doing.

Intersting thread, please keep the updates coming, especially the engine rebuild photos!
Post #516348 21st Mar 2016 9:44am
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JOW240725



Member Since: 04 May 2015
Location: Suffolk
Posts: 7866

United Kingdom 2012 Defender 110 Puma 2.2 XS CSW Orkney Grey
I'm so impressed with builds like this! Thumbs Up
Post #516367 21st Mar 2016 10:35am
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AJC



Member Since: 30 Nov 2015
Location: Lancashire
Posts: 1327

United Kingdom 
Awesome!!!
Post #516381 21st Mar 2016 11:50am
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shaggydog



Member Since: 12 Aug 2012
Location: Kent
Posts: 3346

United Kingdom 1991 Defender 110 200 Tdi USW Arles Blue
Now thats a hell of a rebuild! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter Very Happy
Post #516403 21st Mar 2016 1:06pm
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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
Thanks I'd love to get a bit more time spent at it.

It's a 2010, but the good engine was pinched and put into an 08 which that one has come out of,so there's a good chance the piston jets are the fault.

Sound proofing, I'll apply spray on sound deadening under the panels that's over paintable and bed liner that's on the inside that's colour matched, I've done this before and it looks excellent and last well.
Post #518217 27th Mar 2016 3:12pm
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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
Haven't got much done, but I did get the paint ordered and mixed up.

Still amazes me how different it can look in the tin and different lights.


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Good match Thumbs Up


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Paint for the Roof and Wheels.


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Post #519434 30th Mar 2016 11:59pm
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g-mack



Member Since: 07 Jan 2014
Location: northumberland
Posts: 1967

United Kingdom 
great thread Thumbs Up not often we see puma rebuilds, i guess we will see more and more over next few years though!!
what sound deadening spray do you use for underneath? My 109 thread

my youtube channel
Post #519514 31st Mar 2016 9:46am
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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
Well feeling very guilty about building so many and letting my own sit there in limbo, but that’s always the way! I’ve tried to make a bit of a start onto this again.

Stripped the car down, started into body work, got a ton of shot blasting done, got my machining done for the engine, new piston rings, big end and main bearings, timing chain kit, gasket sets, piston cooling jets, oil pump, set of seat re-trims for the seats, cleaned up the wiring, removed the hideous chequer plate from the bonnet and gathered a stack of parts.

Quality parts for the engine rebuild, Victor Reinz gasket and bolts, Yenmak rings, king bearings, BGA timing kit and new gears too. Another crank as ive two of these 2.4s to build Rolling Eyes


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Honed cylinder wall porn.


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Block all honed and washed for assembly


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Galvanised Bulkhead from Mosside Land Rover

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Bulkhead stripped pictures in reverse order for some reason?

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Chequer plate off bonnet, TIG up the holes.


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Shot blasting back for galvanising- think I’ve got everything? Laughing


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Chassis is mint quick wipe off the dust off it, think it was two years in service.


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Before strip down


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Happy and now it’s all in bits again, off to paint and I’ve started building up the components to put it together


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Post #705711 7th May 2018 12:28am
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NickMc



Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1546

Northern Ireland 2006 Defender 90 Td5 HT Bonatti Grey
g-mack wrote:
great thread Thumbs Up not often we see puma rebuilds, i guess we will see more and more over next few years though!!
what sound deadening spray do you use for underneath?


Sorry didn’t see this comment, I use 3M products or Evercoat, expensive, but they last long term which is the aim for me. Big difference in quality between bodyshop products like anything automotive.
Post #705713 7th May 2018 1:03am
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Nidge



Member Since: 27 Jan 2008
Location: Kildare Ireland
Posts: 809

Ireland 2009 Defender 110 Puma 2.4 HCPU Cairns Blue
Nice work there Nick....look forward to seen it finished Thumbs Up
Post #705727 7th May 2018 7:30am
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10355

United Kingdom 
Watching this with interest.
Post #705790 7th May 2018 3:36pm
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Oldyellar



Member Since: 04 Sep 2015
Location: Central
Posts: 337

Scotland 2015 Defender 90 Puma 2.2 XS CSW Corris Grey
Nice work m8 keep it up
Post #705842 7th May 2018 6:48pm
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