Hensey’s rebuild

I would do the wheels black too

Well where to start this update then

got hold of the 2.25 alternator bracket and spare it is now bolted to the engine but haven't got any pictures apparently


also took a grinder to the dash to fit my raptor dash


then it was time to start collecting new parts
brand new vented 110 calipers way overkill for what i need tbh but there the same price as the non vented calipers so i went with them


some procomp es3000s shocks for the front

and the discs and pads for the front

and new ujs for the front prop

that same weekend i got to getting everything fitted on the front axle





oh and for anyone planning on converting to coiler axles and using the series shocks on the front you'll have to use the rear sping/shock plate on the front otherwise the rear steering bar will hit the shock

and another pair of seats this come about when i had a customers defender in work that had a set of xs premium heated leathers in the front, i was originally looking for a pair of them after realising there waaaaay out of my price range i bagged myself a set of rx8 heated leathers from the jap breakers next door to work they look nice and ill have a toasty arse in the winter currently not fitted just placed in for now as i want to get under the seat base to mount the 90 fuel tank cant remember if i ever explained why i'm using a 90 tank but if i didn't its because he previous owner cut all the series tank mounts off the chassis. so once thats bolted back in and ive sorted out something with the filler neck ill mount the seats




so then Christmas rolled around mom and dad decided to get me a 52" led light bar so i ordered some lr challenge side mounts and get it fitted



it'd have been rude not to atleast post the one with the old man photo bombing me


then i had a little bit of a moment and ordered the wrong oil cooler kit ended up buying one with 8mm hoses instead of 12mm but jjc race and rally got me sorted in the end with the correct kit


also scored a 300tdi rad pack for £40 from the malven 4x4 spares day ended up going halfs with dad so it only cost me £20 as i only wanted to intercooler but i had a little surprise when i took it apart



so a nice little upgrade there and in alot better condition then the one i was going to use

so that leads us nicely on to me getting the intercooler and oil cooler mounted to the front panel




and after that was done i manged to get the the rad back in the upper rad hose on and had a look at the upper intercooler pipe using one of the left overs that originally came with the 200





not looked at the lower intercooler pipe due to me not knowing what turbo ill be using as i've still got the good unit off the 300tdi i brought but i cant remember if using it will interfere with the alternator now i'm using the 2.25 bracket i know someone will correct me and ill do a little bit more googling aswell before i make my mind up

and random video of me leak testing the oil cooler pipe work

and then come the fun stuff so if anyones read all the thead you'll know i got a detroit locker well i found out its actually a truetrac thats even better for me really with it needing to be somewhat road friendly as i intend to use it daily, well anyway it was time to finally get it fitted. was also genuinely surprised by the condition of the diff that came out that'll be getting saved for when i break he front diff as we know full well thats going to happen


heres a little video of it doing two wheel spinny things


soooo while i was in there i decided to check the rear brakes expecting the to be pretty mint with the condition of the rest of the axle welll errrr yeah ill let the pictures do the talking




so that was that really more parts ordered and some have now been fitted today like new brake master still need to swap the res over and a clutch master and slave kit including all the pipe work and cleaned the old drums up

You've been busy there.....
Looks good

I recognise those brakes, been there , done that,how did they ever work? good luck!

looking good, bet you can't wait for the day it is all done

suburban said:

looking good, bet you can't wait for the day it is all done

Click to expand...

i can't wait to get it done its been too long! its the most frustrating thing when i can't work on her because of the weather

This ones kinda short a sweet but you'll understand why i wanted to get this little update up asap

Well decided after talking to a few people that the route of going with the 300tdi turbo made the install that little bit nicer i decided i'd get into work on monday and get a inlet gasket ordered from ECP
then the following weekend i got the 200 inlet and turbo off and fit 300 turbo aswell as the inlet as it has its opening slightly over to one side unlike the 200 one but it made the upper intercooler pipe fit that much nicer


also on that note found out dads original 300tdi lower boost pipe to find out that now fits bang one



make sure theres no leaks and give it a few revs for good measure



decided to bleed the clutch then this happened!!


words honestly don't express how happy i am about this the first ever drive admittedly only off the drive and back on but it was well worth it i now really want to crack on and get her done

sunday was abit of a wash out manged to get the defender pedal fitted (disclaimer) i know the floor looks massively tatty here it was plated on the outside by the previous owner i do plan on getting it sorted in the near future


then decided as i'd like most of the pipe work to be done out of black silicone hose i'd order the cheapest 300tdi silicone hose set i could find(20quid) and that turned up today so decided just out of interest to see if the top house would fit and its close nice stainless joiner and it'll be perfect






also ordered a 200tdi throttle cable and some discovery +2 stainless steel brake flexies

whoo hoo, it moves

that must have been a good feeling

Another major update is needed but I’m not at the computer right now, so this ones going to be a little out of order with the major one, but now I have a fully road legal and insured series that is now on daily driver duties, so these are going to be a few snaps of days out ect ect

Well done! It looks really good, and that's comeing form someone who usually doesn't line modified Series, but the work that you've done really comes through.

Can't explain how nice that truck looks.....
Something about it just looks like it was always meant to be that way....

i did say there was going to be a big update, but after looking back at my pictures i didn't take that many at the time

so will carry on where i left off got both batts in and wired on a load sensitive relay just need to add a large solenoid to connect both batts together when winching ect another little hand me down from the old man now hes gone twin alts on his disco




also talking of hand me downs the old man also decided to retire his old qt shock mounts and 12" shock setup off the front off his disco i definitely don't need that much shock but there free so ill be using them


general idea of where i'm going with the shocks


also ordered some bits off raptor engineering

and brought a fancy head unit isn't wired in yet but makes a very good phone holder for the moment along with the cb that also isn't wired in


also changed the front plate i know people won't be a fan because of the size as it's abit naughty naughty i do plan to get a full size one in the same spot

Few teething problems with the old girl had to rebuild both swivels on the front and replaced the bearings while I was there, but other then that it’s been absolutely spot on getting me about,
Made a start on getting all the audio and gauges in and wired up ect ect




Also got around to fitting the shocks the 12” shocks didn’t actually worked out ended up being slightly to small hard to believe aye so we ending up using the 16” procomp shocks dads been saving for a rainy day just in case his started leaking ect




Also accidentally parked on the wall at work







Then took a trip out to caffeine&machine





Finally replaced the old rotten defender rear door for a series item I picked up at billing off-road show


Then Sunday finally picked up the last item I needed to complete the heater system from Peterborough lro show

like that early land cruiser next to you in one of the pix too

Right where to start alot of this update might be just a large photo dump as it stems over a few months

fitted an egt probe


replaced rear door to one that didn't have a big hole in



decided i needed another project and brought an NB mx5



Long story short the 5 got payed and supercharged (sneak peak at stuff to happen later in this little update)


fitted some rockslider



more daily driven pictures


fitted extended timing case and axle breathers



stuck some carpet on the roof

got given a roof rack



brought and fitted some rubber floor mats




dad brought a series


replaced a new 90 tank for a used one as i couldn't find the correct sender for the new tank, fuel gauge isnt 100%
but i now know if the fuel light i fitted comes on its got around a tenner left in the tank



swapped out the fixed back buckets for something a little nicer



modded the roof rack to make it a little slimmer and fitted my roof tent

picked up a maltesse cross grill for a decent price planning on finding a razor edge bonnet eventully



we decided to take a family day trip around elan valley so some prep beforehand was done in the way of an engine service, kitcar washer bottle and pump combo as i robbed the series pump for the mx5 when it got supercharged
and some much needed usbs





dad recently sold the series and brought a v8 p38 so we decided to take that with us on the day trip













the trip out made me realise i really really need pas, espcially now its my daily driver as the 5 is terrible on fuel after being supercharged so i started collecting everything i needed



i did buy a p38 steering box and other other bits i just didn't get any pictures at the time so this weekend the wing and front came off and fitting pass began decided im going to replace the tbelt while i'm at it also noticed the waterpump bearings are toast so that needs replacing also












also before i end the update heres a few from a local show i went to with my other half (r53 cooper s and our friend (mk2 golf)
these first few were took by a lad called :Jared Barnes Photography





and the only picture i took of us

Well the pas is done and it’s probably the best mod I’ve actually done to the drive ability, plus being able to use a 350mm steering wheels had made it vastly more comfortable to drive

Timing belt was also done at the same time and a few other small bits







Also replaced the old servo while I was in there and that vastly improved the breaking the brakes worked fine before just a little harder then normal I always put it down to “being a landrover” but how I was wrong the brakes are nice and light now and will put you through the windscreen if you stamp on them



The pipe work was a little bit of pain for the pas well the high pressure hose especially ended up converting the fittings from m14x1.5 on the box and m16x1.5 on the pump to 3/8 bsp, and that In turn meant I could use flowfits online pipe maker to have a high pressure people made up costing me all of £18 for next day delivery




And with it make on daily duties I decided to snap 4 teeth of the pinion on the way out of work


so looks like I’ll be leaving to swap the lsd center into another casing