Land Rover Defender 110 Rebuild

[KimB]

Sorry for the delay

It's been a really long day, just showered, only came in at 8.30pm, started at 9 :O
Got so much done
Finished the top windscreen corner around 3pm and spent the rest of the time sorting little brackets and other things out.
Just need to weld the brackets for the mats on tomorrow. They are already made I just forgot to do it :/
Then test fit and as long as it's straight (which it appears to be) then I can take it for zinc plating I thought this day would never come lol

Started by taking a few photos before work this morning

So I started with the top corner.
I thought that it was easier than the otherside, I was wrong :/. Ended up being worse in places. I decided quickly that I wasn't happy to bodge the door sill either, as you can see above its quite thing so I cut it all out in one peice to keep it for templates

Cut and folded the outer peice of the sill to start

Then cut some notches and carefully curbed it to the first correct angle

Then I used a technique from the other forum link posted and using a flat head hammer thing (technical term) I thinned it a little creating a nice curve to fit the old sill nicely

Trimmed and tacked it in

Then traced the other bit. Tacked that in.

Continued...

 

[KimB]

...Continued

Welded it all up and ground it all done to complete that

I was super pleased with myself at this stage. It came out very well, I think so anyway.

Same as yesterday I did the big filler peice in two sections to allow me to get the square hole in the correct place

Hard to see but I marked out the large filler. Cut it out with a jigsaw

Measured the bents from the datum point which was the too as it was the only square part. Like a moron I measured the wrong bend first and bend them all on the wrong place so has to unbend it and re do it, luckily its maluable

Here you can see my mistake :O I didn't notice the bent around the air vent.

Quickly corrected it

Ground it all down a couple photos of the finished article, I know I know, I'm showing off I'm so pleased though, I didn't think I could do anything like this

Continued...

 

[KimB]

...continued
Now the windscreen mount was done I moved onto the last couple patches
This being one. I've just remembered I've not drilled the hole so need to do that tomorrow as well

Had to cut out the centre section of the guttering and re assemble it :/ what a nightmare that was.

Then finally welded all the little brackets and mounts on. This is it basically finished

It's been such a hard week. And so stressful, wanted to give up and scrap it within the first hour but I persisted and actually did it and quite well I think
I just want to show everyone now because I'm so proud of myself

Oh to finish the day I ordered a brand new galvanised chassis I'll collect that in the next two weeks. I need to paint all the running gear and service axles before hand though. I think I'll paint the bulkhead as well. Then once the chassis is painted i can literally make it a rolling chassis and hopefully Get brakes bled, steering together
Can't wait!
Kim

 

[mr migwire]

that looks brilliant kim, are you sure you haven't had a landy before lol

 

[KimB]

that looks brilliant kim, are you sure you haven't had a landy before lol

Pinky swear! I even just got offered a job from a company that restores them, crickey! Must be doing something right.

 

[mr migwire]

Pinky swear! I even just got offered a job from a company that restores them, crickey! Must be doing something right.

I would be happy to pay you to do any work on my landy if A, I lived near you and B, I still owned one. unfortunately I have succumbed to lure of the soft roader in the form of a Toyota rav4.

 

[KimB]

I would be happy to pay you to do any work on my landy if A, I lived near you and B, I still owned one. unfortunately I have succumbed to lure of the soft roader in the form of a Toyota rav4.

Tut tut tut Mr! A rav 4 :O hehe sorry

 

[colnerov]

Congratulations on the job offer. Well done on the bulkhead.

Colin

 

[mr migwire]

Tut tut tut Mr! A rav 4 :O hehe sorry

in my defence its not the horrible Mk1 squashed frog looking one , its the slightly better looking Mk2 D4D but I do miss my landy

 

[KimB]

in my defence its not the horrible Mk1 squashed frog looking one , its the slightly better looking Mk2 D4D but I do miss my landy

I wouldn't know what that is
I'm never selling lou. It'll be like the American ans their first car although this is about my 7th lol

 

[The Devils Reject]

Oh to finish the day I ordered a brand new galvanised chassis I

Where did you order it from? And is it impolite to ask how much it cost?

 

[KimB]

Where did you order it from? And is it impolite to ask how much it cost?

Ordered from Marsland, quite simply because they had one on the shelf, was £1830, I've got to collect it however.

 

[The Devils Reject]

Ordered from Marsland, quite simply because they had one on the shelf, was £1830, I've got to collect it however.

Once I've saved up the pennies (probably 10 years from now) I'll be going galv under the 109 but it's going to have to be a custom job as I have an odd engine/gearbox combo so various engine mounts and crossmembers need to be moved so it's far from off the shelf.

 

[KimB]

Once I've saved up the pennies (probably 10 years from now) I'll be going galv under the 109 but it's going to have to be a custom job as I have an odd engine/gearbox combo so various engine mounts and crossmembers need to be moved so it's far from off the shelf.

Richards chassis may be better for you then. they make to order with about a 6week lead time.

 

[Robotstar5]

Ordered from Marsland, quite simply because they had one on the shelf, was £1830, I've got to collect it however.

They must have some strong shelves

 

[balmerchris]

I think you might need to put a guard on that grinder! Just incase. Don't want any missing digits. Nice work by the way.

 

[KimB]

I think you might need to put a guard on that grinder! Just incase. Don't want any missing digits. Nice work by the way.

I was waiting for a reply and wish I could but it broke. Rather extravagantly actually, it has a little tank for moving it somehow that broke while o was using it and I got hit on the tip of my finger with it lol. I'm cause carnage hehe
Anyway I normally just use it for wire wheel now and that was when it broke. Pointless then as it sticks out way to far.

 

[awemawson]

It's the Polystrip paint stripping disks I always seem to get cut by - vicious things! Guards are fine but they always seem to get in the way.

Kim that's a fine looking set of tool cabinets behind that bulkhead, it that your workshop or is that at college?

 

[KimB]

It's the Polystrip paint stripping disks I always seem to get cut by - vicious things! Guards are fine but they always seem to get in the way.

Kim that's a fine looking set of tool cabinets behind that bulkhead, it that your workshop or is that at college?

I use a guard whenever I can but like I say, it broke.

They are nice but they are my dads. Well we bought them because it was so messy in the garage. I say we, he bought them because I persuaded him that it would be a great idea

 

[KimB]

Another long day today. Got allot done. Pretty much other than fuel stuff and the wiring it's now a rolling chassis
Think I may have ordered the wrong chassis though I'll contact them tomorrow as I've got to collect it anyway
Here goes

So I started by finishing the bulkhead then I went to mount it but it was pinched by about 10mm at the bottom. Thankfully I used a tweaker to solve that with no issues.

Then fitted the windscreen, truck cab bit and roof

Although the door didn't line up around the screen I wasn't bothered as I didn't have the seal in place, the door was square from the rear tub and the bulkhead which was great

Lifted the rear body off with the help from my engine crane was so awkward though, I hooked it help me and I lifted a bit from the otherside which wasn't massively heavy but I tripped over everything before finally getting it completely off

Took the prop shafts off and began unbolting the gearbox.

Drained the oil from the gearbox and transfer box first. Is that normal for gearbox oil plug ? It was very rusty and doubt its been over for many years

Gearbox out after a huge struggle

Engine out after an even bigger struggle. It was so hard to move on soft ground

Pleased its all out now and just the rolling chassis left. It's so daunting the amount of work needed but I think once I get all the brackets for everything shot blasted and the chassis rolling it'll hopefully start coming together not to badly. Reality hit of how much I've spent so far, getting on 3000 in just parts. It's scary but I know it'll be like new when I'm done eventually!