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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue
My 90 having a full rebuild

Hello All new to this forum even though i have know about it for a while, I have owned my 90 for 5 years now and i used it mainly as a toy/back up truck when either my disco 1 (now sold) or 2 broke down.

About a year ago it came to MOT time and i knew it wouldnt pass due to some rather lovely work the tin worm had done to the chassis and the bulkhead, and the old girl was starting to look abit tired, I had 2 options at this point 1) get rid of it or 2) rebuild it. After a bit of peer pressure and beer from my brother and some mates it was option 2 that was chosen. Rebuild it.

Now i have never done anything like this before (complete amature), so it is and has been a massive learning curve for me and my mates and we all said how hard can it be (famous last words), and on one slightly sunny day we set about stripping the 90 and finding all kinds of bodge jobs and hidden problems over the years from previous owners.

Below are some of the photos of the 90 during the strip down




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I will keep adding photos to this post once i have sorted them all out Very Happy as there are hundreds of photos that i have taken hopefully helping me to put it all back together Laughing Laughing

Post #552115 29th Jul 2016 11:08am
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 9471

United Kingdom 

'reference photos' will help heaps, especially of the wiring!!

Post #552138 29th Jul 2016 12:45pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

i have so many photos of the wiring it is unreal, as me and wires dont get on well haha, half the wires i have come across already have been cut and not wired to anything on the truck so god knows what they were connected to Confused

also just been reading through your V8 rebuild and making me realise how much work i have got to do, but it has been inspirational and making me get motivated to crack on and finish mine now

Post #552143 29th Jul 2016 12:52pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

Been sorting out some more of the photos,

The chassis finally arrived and that got sprayed black, and then the preparation of all the panels, sanding them down and primer, then one night the bulkhead arrived all galvanized. Also refurbished the rear axle.

As you can probably tell from the photos, i am working out of three units, a container, garage and my works warehouse (on weekends) i gotta work with what i have haha, unfortunately i dont own a house and have my own garage and my mum refuses to have (as she puts it - a pile of scrap on her drive)



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Post #552160 29th Jul 2016 2:31pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 9471

United Kingdom 

Well mine would have been running months ago, if I didn't decide to put a new engine in... it's proving to be a major pain, the wiring I've not started on yet !!

But keep at it, at least you are not doing it in a single garage!!!

But photos were a saving grace. Also snap-chat, you can take pics, then add notes and save them..

Post #552163 29th Jul 2016 2:38pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

ahh luckily i havent decided to replace the engine the good old 300tdi only has 60,000miles on it so just got given a big service changing gaskets and belts etc, and i have actually got the engine and gearbox and bulkhead all in place now, just need to do the engine wiring harness, that will be a nice head ache haha. also got the brake lines fitted and most of the fuel lines fitted.

ye i have all the parts spread out across yorkshire in 3 units haha makes needing something a bit harder when you realise you have left half your tools in one unit and your working in another Evil or Very Mad Evil or Very Mad

ye there are notes and circles and arrows pointed on a number of the photos for the more fiddly looking bits haha

Post #552164 29th Jul 2016 2:47pm
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Mash



Member Since: 09 Feb 2015
Location: Guernsey
Posts: 1637

Guernsey 1998 Defender 90 300 Tdi HT Nato Green

Looking good so far bud Thumbs Up where did you get the galv bulkhead from? 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 #552181 29th Jul 2016 4:20pm
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custom90steve



Member Since: 21 Jan 2010
Location: South West England
Posts: 17818

United Kingdom 

Lots of work going in there. Thumbs Up

I'd seriously suggest with the wiring you consider getting new wiring or looms, especially for primary power etc and go from there.
That way you know it's safe and properly fused etc.

It would be awful to put all your efforts in and then have electrical issues or worse fire.

If you've got a new basic loom you can then go from there with other items you have.

If you do keel the current loom fully test it and check any surplus wiring present is fully insulated from shorting out anywhere.
Masking tape flags on wires can help too, using permanent pen. Thumbs Up Thumbs Up

Post #552183 29th Jul 2016 4:28pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

Mash wrote:
Looking good so far bud Thumbs Up where did you get the galv bulkhead from?


The galvanised bulkhead came from Ashtree Land Rovers in southampton, waited about 10weeks for it though. but they do personally come and deliver it so they can see the project it will be going on. Very nice people to deal with Smile Smile

Post #552189 29th Jul 2016 5:13pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

custom90steve wrote:
Lots of work going in there. Thumbs Up

I'd seriously suggest with the wiring you consider getting new wiring or looms, especially for primary power etc and go from there.
That way you know it's safe and properly fused etc.

It would be awful to put all your efforts in and then have electrical issues or worse fire.

If you've got a new basic loom you can then go from there with other items you have.

If you do keel the current loom fully test it and check any surplus wiring present is fully insulated from shorting out anywhere.
Masking tape flags on wires can help too, using permanent pen. Thumbs Up Thumbs Up


It has got all new wiring looms in place, i am just about to put the engine wiring loom on hopefully this week/next week some point, i did put little flags on the ends of the wires then like an idiot pulled them through the smallest hole possible and all the flags came off Big Cry that is what made me replace all the wiring haha

Post #552190 29th Jul 2016 5:16pm
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MetalMatt



Member Since: 29 Jul 2016
Location: West Yorkshire
Posts: 176

United Kingdom 1989 Defender 90 300 Tdi HT Baltic Blue

right pretty much up to date with the photos and finally sorting out the last of the decent photos to up load on here

so the under side of the tub got a coating of underseal to help protect it,


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then the most drastic of changes has happened so far. the colour chage Razz
first time spray painting, in not the best conditions an open container, me and my mate spent a full day practicing and then went for it all in the same day the whole car was painted. then it was left in the container whilst it was hot these last few days for it to set before it got the clear coat/lacquer


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Then the painted bulkhead went on read for the rest of the old 90 to be transferred over Very Happy Very Happy Very Happy


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Post #552195 29th Jul 2016 5:26pm
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Ade90



Member Since: 30 May 2014
Location: Birmingham
Posts: 130

United Kingdom 

Those pictures bring back all my memories of rebuilding Range Rovers and Series III's in my Dad's old factory......why? Because the BEST tool in the whole place was the fork lift truck, it saved so much time faffing about with jacks Rolling with laughter

Looks like a great job and I like the colour change. Fixing Land Rovers for over 25 years..........and making excuses to the wife for almost as long Smile

1984 110 V8 - Gone, but not forgotten....

Post #552245 29th Jul 2016 8:59pm
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Pickles



Member Since: 26 May 2013
Location: Melbourne
Posts: 3565

Australia 2013 Defender 90 Puma 2.2 CSW Keswick Green

Metalmatt,...GREAT thread mate, & well done for your efforts at "having a go", & doing things yourself.
Looking forward to more, Pickles.

Post #552286 29th Jul 2016 11:12pm
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Anderzander



Member Since: 08 Feb 2011
Location: Lancashire
Posts: 986

United Kingdom 

It is looking good - well done.

A couple of questions...

Did you blast the axles with them complete? If so what did you do to protect the swivels? And last one; what paint did you use?

I'll be doing the same with my series axles shortly Smile

Post #552305 30th Jul 2016 7:02am
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williamthedog



Member Since: 29 Dec 2012
Location: south wales
Posts: 3251

2011 Defender 90 Puma 2.4 PU Tamar Blue

That's going to be awesome when it's finished Thumbs Up

Post #552310 30th Jul 2016 7:44am
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