Land Rover Defender 110 Rebuild

[bash'it]

what a cracking job, it's looking really good, it is going to look brill when you have done

 

[TAITSIE]

Maybe a bit late but another good site for some part
http://www.yrmlandrover.com/epages/BT3575.sf/en_GB/?ObjectPath=/Shops/BT3575/Categories

 

[barracuda816]

Kim that looks fantastic. You have taken really well to spraying., What do you think of the jotun? I think its great stuff.

Out gassing the calipers would be a good idea but wont be necessary i don't think. The calipers shouldn't get hot enough to out-gas enough in use to cause any problems with the coating you are going to use. If it was a track car you may have an issue.

Good work, im really liking this thread.

 

[KimB]

Great work so far Kim.....being nosey was the bulkhead very expensive to get zinc plated?

Thanks
It was £100 plus shot blasting twice. First was rough which was £40 then they blasted again after when done to make sure it was stripped well, then zinc played. The second time was £60

what a cracking job, it's looking really good, it is going to look brill when you have done

Thanks and I hope so I've decided the amount of time I'm spending doing it there is no point cutting corners so every single black bracket I have I'll paint strip and re paint with the amazing paint I'm using it's incredible.

Kim that looks fantastic. You have taken really well to spraying., What do you think of the jotun? I think its great stuff.

Out gassing the calipers would be a good idea but wont be necessary i don't think. The calipers shouldn't get hot enough to out-gas enough in use to cause any problems with the coating you are going to use. If it was a track car you may have an issue.

Good work, im really liking this thread.

Thanks it's been a bit of a learning curve, was allot different to a spray can but really good non the less. The jotun is incredible. I'll do another post about midnight after I'm done for the day with some pictures.

So you think the paint will last on the callipers ? Could always get shot blasted again worse case scenerio if they don't adhere well.

Thanks everyone for all the compliments it's really nice and really uplifting, been such a long weekend, started at 10am today and I'm waiting for first coat of primer to dry so think I'll be going to near midnight :/ getting done slowly!

 

[darren.a.roberts]

Hi Kim,

That sounds like an absolute bargain! Keep up the good work.....

 

[KimB]

So it's a bit earlier than I said but I'm only primering now so won't see any changes for you all heres tonight's installment :P
Been a long day as I said earlier and seems like I've not got much done but it's taken horrifically long to do every job today.
Started by prepping the front axle for paint that took two hours alone , then mixed some jotun 87

Obviously painted it next
Did two nice coates. Then left it ready for top coat maybe tomorrow

Pulled the painted parts down and thought I'd get a photo of the first box of completed parts all ready to fit!!!

Then as much as I hate it I had a pile of parts to paint strip

After paint stripping there was two seized bolts or what's left of them stuck in two of the above parts so had to press them out, took my full weight on my press for them to budge but got them out as well as run a die over the threads on the tank mount above, luckily it was the nuts that stripped and not the threads
After that I began masking the parts up and came up with what I thought was a clever way to mask the holes of parts.
I first ripped of a little bit of tap then wrapped it round my finger and touched it together as you can see.

I then carefully put it in the cleaned hole and pressed one side down and wiggled my finger which released the other side and made it go nicely round the hole, then using a sharp knife I run it around the edge of the hole and left me with the result bellow

Hung all the parts as I said earlier and spent a while cleaning them all, wasn't very fun at all!

Then painted them this was after first coat which I admittetly went a bit thick to start so know for next batch not to go crazy on the first coat

Then after the second cost which I've just done I took a photo of fuel filter housing because I'm so pleased how it's come out

Off to do final coat of the night in a minute, really come along so well, I'm really pleased to finally see parts being completed. I'll top coat these parts tomorrow then get some more parts ready for painting Tuesday and I'll finish coat the axle Tuesday as I need to paint swivels tomorrow. Can't wait to not need to paint anymore but working hard this weekend has got allot done or ready for paint which is good, mainly loads of little brackets to paint now and the body lol
Anyway that's it today
Kim

 

[awemawson]

Excellent Kim

When do you pick the Chassis up?

 

[KimB]

Excellent Kim

When do you pick the Chassis up?

Mid week either wed or Thursday, it's a very long drive though, I'll leave about 6 and maybe when I get back I'll t wash it ready for painting the following day

 

[TAITSIE]

Mid week either wed or Thursday, it's a very long drive though, I'll leave about 6 and maybe when I get back I'll t wash it ready for painting the following day

When do you get time to sleep, eat etc

 

[KimB]

When do you get time to sleep, eat etc

Well I'm going to eat now lol then sleep, and go again tomorrow Although Ive got some work to catch up on first so that's main priority tomorrow and strip swivels and some other parts readyir paint

 

[Wedg1e]

After paint stripping there was two seized bolts or what's left of them stuck in two of the above parts so had to press them out, took my full weight on my press for them to budge but got them out as well as run a die over the threads on the tank mount above, luckily it was the nuts that stripped and not the threads
After that I began masking the parts up and came up with what I thought was a clever way to mask the holes of parts.
I first ripped of a little bit of tap then wrapped it round my finger and touched it together as you can see.
View attachment 60910

I then carefully put it in the cleaned hole and pressed one side down and wiggled my finger which released the other side and made it go nicely round the hole, then using a sharp knife I run it around the edge of the hole and left me with the result bellow
View attachment 60912

Kim

Good plan
Another technique I use for internal bores is to coat them in grease prior to painting. Once the paint is dry you just wipe it, and the grease away... it has the added benefit that the internal surfaces can't rust if the parts stay un-assembled for any time.

 

[KimB]

Good plan
Another technique I use for internal bores is to coat them in grease prior to painting. Once the paint is dry you just wipe it, and the grease away... it has the added benefit that the internal surfaces can't rust if the parts stay un-assembled for any time.

Good idea although I'm far to messy to be putting grease everywhere :O I'll end up ruining everything lol

 

[KimB]

Not been hugely productive today, got some stuff done. Had to wait for two deliveries this morning, then after that I did some work, got a load of parts pretty much all the bolts for the chassis and the swivel rebuild kits! I decided to call and order some more parts from Brit car, when I told the guy I wanted every brake pipe clip and every fuel pipe clip he went silent and laughed, he really wasn't amused haha, anyway ordered those clips and calliper rebuild kits, total was £140 and I asked for discount and got it trade so saved £20 the fuel pipe clips were £6.40 each :O and he wasn't sure on quantity so ordered 5 only but I'm sure I'll need another 5

Anyway, started by stripping the swivel housings. Puller the hub off..

Then removed the bearing stub axle thing, tried to remove the ball seal retainer but one bolt was too rotten.

Welded a bolt to it.

It was too small so snapped , then welded a bigger bolt to it

Then stripped the other swivel and washed the housing. Just need to de grease and paint them I'll do another batch of parts for spraying tomorrow which will hopefully be the last until I begin rebuilding it!!! Sick of it now

The parts look terrific though I really can't wait to be done painting! That's another lot done I guess though.

Coming along slowly, super pleased hopefully last lot tomorrow then I can begin the chassis when I get it! Not sure I'll be ready to assemble Monday though, it's taking a bit longer to paint everything than I hoped!
One question though, What would you all do with the hubs ? I don't want to replace all the wheel bearings because I don't think I need to. I'm worried about grit getting in and ruining them ? Half tempted to just leave then to be safe.

 

[The Devils Reject]

One question though, What would you all do with the hubs ? I don't want to replace all the wheel bearings because I don't think I need to. I'm worried about grit getting in and ruining them ? Half tempted to just leave then to be safe.

If it's in pieces on the bench now is the time to change the bearings - it's a lot easier to know you're starting from a point where everything is new/decent than having to pull apart all you good work 300 miles down the road.

 

[KimB]

If it's in pieces on the bench now is the time to change the bearings - it's a lot easier to know you're starting from a point where everything is new/decent than having to pull apart all you good work 300 miles down the road.

I thought about that but removing the hubs now on the defender can be done in no more than a few mins. Just seems daft to spend hundreds on things that dont need doing. ?

 

[The Devils Reject]

I thought about that but removing the hubs now on the defender can be done in no more than a few mins. Just seems daft to spend hundreds on things that dont need doing. ?

Fair point. Check the current bearings and give them a shot of grease and you'll be right Are the bearings on a TD5 gold plated? I'm used to the prices for Series III ones at about 8 quid each.

 

[KimB]

Fair point. Check the current bearings and give them a shot of grease and you'll be right Are the bearings on a TD5 gold plated? I'm used to the prices for Series III ones at about 8 quid each.

Not sure to be honest but if I'm doing bearings I'd replace all the stub axles too and wouldn't use cheap parts! It'll quickly get very expensive. Blowing my buget even further haha

 

[awemawson]

So what do you reckon the total job is going to have cost? Or is that too scary a figure to sit down and work out!

 

[KimB]

So what do you reckon the total job is going to have cost? Or is that too scary a figure to sit down and work out!

Currently I think I'm at £3000, I think there is at least another £1000 to be spent, I have got a stack of parts now however but every order I make adds an extra £100 at least to it

 

[waldershelf]

Not sure to be honest but if I'm doing bearings I'd replace all the stub axles too and wouldn't use cheap parts! It'll quickly get very expensive. Blowing my buget even further haha

If the stub axles are OK there is no need to change them, they don't wear out, unless you have a bearing fail. (Ask me how I know that one.) As you have discovered wheel bearings are dead easy to change on the Defender but the real problem they are guaranteed to fail when you are miles away from home or you need to go somewhere. For what they cost a new set of bearings and oil seals in the axles is worth doing. It's in bits now and you are doing such a good job on it, "spoiling the ship for a ha'poth of tar"?