complete rebuild need help

good evening I need some one who knows defenders well what I want to do is buy a galv chassis and use the v5 off my off roader and build a new one with a td5 engine in it so what im asking is should I get the chassis td5 spec or get the chassis for the year of my 90 and get td5 mounts with it basically what im asking is what's the best way of achieving what I want to do and where would people go to purchase the parts I need ebay is expensive many thanks .tom

Just buy a chassis suitable for a td5. And if by best, you mean cheapest, forget it - there ain't a cheap way. I'm guessing your "off roader" is probably all worn out, in which case, you may be better off starting with something else. Regarding parts, you mean New parts? Ebay is overpriced - I've had almost everything from lr direct.

It might be worth finding another donor but if not don't worry as there is plenty of advice on here! I'll probably do the same as you in a couple of years when I fit a galv chassis and bulkhead to mine. I've found a company that does everything for a defender galvanised except the chassis then get a decent galv chassis. I have a 300tdi and another 300tdi disco so I'm buying new +2" suspension and will build a complete rolling chassis rebuilding the engine, both boxes, both axles, steering box and even props first so I can lift off the body and drop it on. It's worth doing something similar with the rolling chassis on yours.

make sure you get pics of your old chassis and it cut up so you can verify where you got the vin for the new chassis from at a later date if needed . TD5 chassis will allow the build without chassis mod which saves a lot of headaches with DVSA . If you are doing engine swap notify DVLA one item at a time , it confuses them and causes problems if you change few things at same time HTSH

I do mean cheapest but but also want to know the best way of going about it basicly I thought about buying a disco 2 for the engine and box and running gear and convert the gear box to defender spec then buying and then find a 90 that's being broken and buy the shell to put on it but so much to think about like will the rad and inter cooler fit what way would others go about doing this project many thanks