My project 90 rebuild

Hi
Been looking at everybody's rebuild threads and thought it was time I posted up some pictures, I bought this 1985 90 back in the summer with a view of doing a Tdi conversion and various other jobs to it, this is how I bought it complete with original 2.25 petrol engine.

Hopefully pic will come out ok as using tapatalk on iPhone

Keep us updated ;-)

It needs bigger windows in the back!!

yep keep the pic's coming ho and get some paint lol

Yes plan is to do away with the back windows and to re spray it a different colour ( which is yet undecided which colour ) this is when I got it into the workshop and started stripping the body off

And taken the rear tub off

looks good already !

The rear part of the chassis wasn't too bad, had a new quarter chassis at some point in the past, just had to patch up a few bits including the rear tub supports

Next I gave the chassis a coat of paint and fitted rear relocation cones




I also ordered a set of QT radius and trailing arms as the previous owner had done a 2" lift on the original ones

Original drum brake back axle removed

View attachment 39806

And disco disc brake back axle fitted

View attachment 39807

View attachment 39808

Decided to overhaul the calipers whilst I had it all apart

Don't think my axle pics uploaded so hopefully here they are

Really like the look of this! Pleased for you that your chassis is in good nick (oohh-err matron!), it's a horridable feeling when alls you got left is a pile of rust! What paint you using on it?

Lucky with that chassis - keep the pics coming

I decided to use black smooth hammerite, done lots of research and decided that was the best for me. I wire brushed it all down first.

This is the original engine, a 5 main bearing 2.25l petrol


And this is the hole it left


Lifting out the 200tdi out of the donor discovery, it was easier than I thought

:nothingtoadd:

Looks good. I like the look of those new radius and trailing arms, and the chassis wasn't too bad either which is always a big help. Look forward to more pictures.

Have managed to win on eBay at a bargain price a box of various 2 1/4" stainless steel bends, custom side exit exhaust I think ?

I had to re drill and tap some stud holes so the lt77 gearbox mated up with the 200tdi


And here is the 200tdi all bolted up to the gearbox


Also took the turbo off and "clocked" it so the outlet pointed in a better direction

Had a bit of a trial fit up of the radiator and the intercooler

Nice thread, has it had any work done on the bulkhead as it looks mint for the year, I just spent 3 weekends rebuilding mine

If you have any of the exhaust bend left over and want to sell when your done
pm me

I think the bulkhead had some work done to it before I got it, it's certainly tidy enough for now, I'm planning on keeping this for a long time. Will certainly pm you when the exhaust is done to let you know what I have left, I am just about to order a stainless silencer and a short length of straight pipe so I can get cracking with it next week.

That's spot on cheers

Good luck with the work