Another 90 Rebuild

Keep it up mate its looking good.

Good luck with the wiring, let me know if there are any bits you want me to check. At least you labelled yours, I just took pics and regretted it later...

I found one connector on the bulkhead connected in 2 possible places, but it only started when it was connected to one of them!

Another frustrating day. Started with the big squeeze getting the engine bay parts of the harness through the central hole.

The largest connector block has to go through first!
Ok, so far but....

Then I discovered holes were missing that I needed to bolt things to. The green box lying in the drivers footwell should bolt in to two threaded holes just to the right of the steering column hole. There are several holes missing on the engine bay side and no holes for the door light switches
Went in to panic mode for quite a while, cos I thought I might have the wrong bulkhead. Why can't things just go a little more smoothly?
In my panic I put another post on LZ about galv bulkhead experiences. I can't get an answer from Ashtree which is where I bought it.
Anyway, when I calmed down I started to think logically again. I've sat the windscreen frame on and the bracket holes line up, the pitch of the hinge holes match the doors, the gearbox tunnel flange fits spot on. The steering column hole is offset from the power steering box, but I reckon it's supposed to be like that. My dismantling pictures don't show it clearly, but the steering column shaft has a dog leg in it.

Better day today and no rain!
Spoke to Ashtree this morning. Looks like they've sent me a 200Tdi bulkhead instead of the 300TDi I ordered. They were very apologetic and said they would swap it, but its beautifully painted so it's too late for that. They assured me everything would fit, so I bashed on.
Glued some M6 nuts on to take the green box of electricary that mounts alongside steering column.

Feels quite sturdy.

Made a sturdier bracket for the EGR controller. Aluminium plate with squares cut out to glue two M6 square nuts in to it.
Then stuck it to the bulkhead where the holes should have been.




Then I took the plunge and got to work connecting up the clocks.

Then got the dash frame in and got the binnacle connected to it.

Next was the steering column.


Got the indicator and light stalks and steering lock on and all the connector blocks in matched up. There are five terminals and only four connectors to go on the end of the ignition barrel/steering lock and my dismantling picture doesn't clearly show where the white one goes. I'll have to find a wiring diagram to be sure unless someone knows
Doesn't look like a great amount done, but I am very happy with today's progress.

Too much rain today to get a lot done
Spent a lot of time cutting gaskets to seal pedals to the bulkhead in an effort to keep water out!

Got the clutch, brake and accelerator pedals fitted, between the showers.

Took the air filter box retaining rings of as they needed a clean up and three of the four rubber mounts had come apart.
Rain forced me indoors, so I started to rub down the rear window frames.

Put the refurbed front calipers on today.

Took the driving members off and cleaned the old gaskets and sealer off and replaced new gaskets while I was on.
Cleaned the rear wiring loom with good cloth and hot soapy water. The electrical tape was worn through in places, but the wires inside were fine. I re-taped the lot and it looks brand new. Hard to tell in the picture though.

I threaded some garden wire through the chassis from front to back and pulled the wiring loom through the chassis rail. Bit fiddly getting the three electrical connectors through the hole in the chassis, but didn't take long. I taped them down to the loom so they slid out more easily.
It's slowly coming together.

Al2O3 said:

Put the refurbed front calipers on today.

Took the driving members off and cleaned the old gaskets and sealer off and replaced new gaskets while I was on.
Cleaned the rear wiring loom with good cloth and hot soapy water. The electrical tape was worn through in places, but the wires inside were fine. I re-taped the lot and it looks brand new. Hard to tell in the picture though.

I threaded some garden wire through the chassis from front to back and pulled the wiring loom through the chassis rail. Bit fiddly getting the three electrical connectors through the hole in the chassis, but didn't take long. I taped them down to the loom so they slid out more easily.
It's slowly coming together.

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Great work mate. Keep it going. I must get on with mine

james6546 said:

Good luck with the wiring, let me know if there are any bits you want me to check. At least you labelled yours, I just took pics and regretted it later...

I found one connector on the bulkhead connected in 2 possible places, but it only started when it was connected to one of them!

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Thanks James. Most of the electrical connectors are sorted (I think) in the engine bay. Got the light clusters to sort once the wings and the tub are on. When I try it all I'll no doubt have things not working - you might get a shout then!

defenderdog said:

Great work mate. Keep it going. I must get on with mine

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Cheers, defenderdog. Things are coming along, though never as fast as I hope. After a long time it's dawning on me that I'm not fast at doing this. Too much of a worrier I reckon.

Well today, as forecast, it's rained not stop. Spent hours tidying the garage out/up, which has created a lot more working space. It also got me re-familiar with where all the remaining bits are in the boxes.

Also finished off one of the rear windows. I'd rubbed one down the other day, etch primed it and then painted it satin black.

I then started fitting the felt strips I bought of ebay. They have adhesive on the back and turned out to be a perfect fit. I cut a wedge of wood to use as a tool to push it in, but it actually went in very easily.

The fixed window was a tight fit to get in. Don't know how you are meant to do it, but I fitted the rubber to the glass first, lubricated it with a smear of vaseline and fitted it like that.
I just used new Britpart sliders because the originals were brittle and broken. It looks great and the window slides well, but it's tight.

Time will tell how the felt performs and how much water the window lets in.

I think the lugs that are on the middle chassis cross member that the seat belt brackets bolt to are in the wrong place. The brackets have got slotted holes in them, but they didn't give enough adjustment. The tub was held 10mm away from the rear cross member lugs. Had to cut the slots longer, which is a shame cos they are galvanised. Anyway, got the tub bolted on.

The underside and wheel arches etc have been painted with black stone chip and then the wheel arches painted the body colour red. However, I decided to Dinitrol the tube sections of the floor and the top and inner wing face. Did this before I put the tub on!

Unfortunately, rain stopped play after that.

Looks brill ur trappin on now done by August me thinks

'Trappin on', is that another Oldham term?
Yeah, you've mentioned August before. Got a couple weeks holiday camping coming up though, so that will push it back a bit. Hope to get sides, windscreen frame and roof on tomorrow. That way I will be able to wrap it in the new tarp I've got ready for me going away. The current one had developed holes with rubbing on exposed sharp corners when it's been moving in the wind. Amazingly, even the gear stick wore through!

Its looking really good
well worth all the effort

Am I jealous at how red and shiny it all looks? Me? Never!

Another quick update.
Spent a lot of yesterday helping a friend move house. But, got some big bits on. Last play on Wednesday saw me trying the passenger side rear window frame on. The seal was going to need a trim and I got the bolt situation sorted. I think

So, got the side panels on.


Got the windscreen seal on and the windscreen frame bolted on.

I bought a new seal for the top of the windscreen to roof, but thought my original side panel to roof seals were ok. However, when I got them out of the bag I had them stored in I found a couple of small bits were slightly perished. So, I put the roof on temporarily.


Putting the roof on enables me to slide a tarp over the top easily. It also gave me a morale boost to see it coming together.
The new window sliders eventually arrived from SP Landrovers, so today will be refurbishing the inner doors and mechanisms.

Really is a cracking job you're doing!

Looking forward to seeing you rebuild the doors
As that's the bit that I'm not looking forward to

Red was defo the right colour to go with again it looks great

Bennehboy said:

Really is a cracking job you're doing!

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Thanks, mate. Appreciate the comments

greyhair said:

Looking forward to seeing you rebuild the doors
As that's the bit that I'm not looking forward to

Red was defo the right colour to go with again it looks great

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Spent a bit of time on one of them today. Haven't taken any pictures yet, didn't feel 100% and so heart wasn't in it. I'd already taken all the fittings and furniture off the old doors. The 'plastic filler' trim from around the windows was very faded, so today I rubbed them down, etch primed them and painted them satin black. They came out looking like new. I didn't want to screw them back in to the frame as I didn't want to drill though the plastic coating, so I have glued them in. I've cut the new window channels ready to go in, but I've stopped there. I'm thinking about using heavy duty polythene to guide any water that comes in from the window down to the bottom of the door and out through the drain holes at the bottom. Thinking of putting a plastic tray in the bottom of the door with tubes from there, through the holes that are already in the bottom frame, to outside in an attempt to keep water out of the frame. Going camping for a few weeks, so I'll contemplate it while away.

@Al203 Where did you get your calipers done and did you get the other parts - anti-roll bars etc done the same method?

The front calipers I had done at a plastic coaters near Wallsend on the Tyne. They shot blasted them first. That's a long way from you
The rear ones are new and I painted them myself.
The anti roll bars, etc I did myself with a needlegun and compressor, drill with wire wheels and abrasive pads. I then treated them with rust inhibitor, primed and painted them. To be honest, I wish I had got them shot blast as they are starting to break through in places already and it hasn't even been on the road.

Looking great. It's wonderful when it starts to resemble a Land Rover again.