1991 200tdi Defender Rebuild

Ian1991 · Jan 7, 2016

I bought my long awaited landy in Feb last year, what should have been a few patches to the chassis and a new outrigger turned out to be a rotten botched repaired mess. I had planned on a chassis replacement in a few years after having a bit of fun first but that snowballed lol, so a new chassis was required!

Ian1991 · Jan 7, 2016

Ian1991 · Jan 7, 2016

Ian1991 · Jan 7, 2016

Ian1991 · Jan 7, 2016

Ian1991 · Jan 10, 2016

Griff097 · Jan 10, 2016

You have got a bit ahead of you then, nice chassis.

Ian1991 · Jan 10, 2016

Yeah just a bit lol

Ian1991 · Jan 15, 2016

Thought i would put some pics up of the rot and mess i found when started hoking at outriggers ect. I spent around three months on and off patching holes and replacing outriggers, worked my way around from passenger wheel to driver rear wheel and a fellow landy guy suggested lifting the tub off to check rear cross member. He had found all sorts of trouble when doing his, so I lifted it off and what i found scared the crap out of me lol. Three months wasted and a few hundred quid down the drain. I guess experience comes at a price.

flat · Jan 16, 2016

Ian1991 said:
View attachment 95137 View attachment 95138 View attachment 95139 View attachment 95140 View attachment 95137 Thought i would put some pics up of the rot and mess i found when started hoking at outriggers ect. I spent around three months on and off patching holes and replacing outriggers, worked my way around from passenger wheel to driver rear wheel and a fellow landy guy suggested lifting the tub off to check rear cross member. He had found all sorts of trouble when doing his, so I lifted it off and what i found scared the crap out of me lol. Three months wasted and a few hundred quid down the drain. I guess experience comes at a price.

Jeez. That was badly ****ed.

Nice repairs on the bulkhead though

Ian1991 · Jan 16, 2016

flat said:
Jeez. That was badly ****ed.

Nice repairs on the bulkhead though

The chassis was a total mess when I power washed all the old underseal off, I guess the upside was I had a few months welding, cutting ,grinding and fabrication practice. Nearly there with the bulkhead, its been a long slog as I don't get much time at it. Cheers for the comment I welcome any even if pointing out if its not done right.

Dan_Trials · Jan 16, 2016

Love the panel work on the bulkhead, good work, keep it up!

Ian1991 · Jan 16, 2016

Dan_Trials said:
Love the panel work on the bulkhead, good work, keep it up!

Thanks Dan, I've really enjoyed it so far.

Ian1991 · Feb 8, 2016

Finally got the bulkhead welded and all welds ground and primed, what a pain in the ass of job it turned out to be! Just the finish coat to go on and get the bloody thing back on and move on to something else.

Ian1991 · Feb 8, 2016

Ian1991 said:
I bought my long awaited landy in Feb last year, what should have been a few patches to the chassis and a new outrigger turned out to be a rotten botched repaired mess. I had planned on a chassis replacement in a few years after having a bit of fun first but that snowballed lol, so a new chassis was required!View attachment 94832

Any of the experts out there could advise how to find paint code or know what this grey is???

Needalandy · Feb 8, 2016

Great job. You must have the patience of a saint? The guy I use to MOT my 90 has pointed out a fair amount of corrosion in the driver footwell above the pedals which would fail next MOT. Was wondering whether these replacement foot wells you can get on eBay for about £60 are any good ? Where did you get yours?

Ian1991 · Feb 8, 2016

Needalandy said:
Great job. You must have the patience of a saint? The guy I use to MOT my 90 has pointed out a fair amount of corrosion in the driver footwell above the pedals which would fail next MOT. Was wondering whether these replacement foot wells you can get on eBay for about £60 are any good ? Where did you get yours?

Its testing my patience at present but I can see the end soon, I was going to go the route of replacing the footwells but they look flimsy so I made a a jig to fold my own and made them out of 3mm steel. It was a lot of work but enjoyable also and I'm pretty happy with the end result.

Retroanaconda · Feb 9, 2016

From your photo, the colour is probably Pembroke Grey/Pennine Grey. Code is LRC.476 or LUS.

Same as mine (one year younger) as well as this one I found on the net:

Ian1991 · Feb 9, 2016

Retroanaconda said:
From your photo, the colour is probably Pembroke Grey/Pennine Grey. Code is LRC.476 or LUS.

Same as mine (one year younger) as well as this one I found on the net:

Cheers and thanks for the help

Ian1991 · Feb 21, 2016

I didn't get a lot done this weekend with having to do the timing belt on my car on Saturday and then working until lunchtime today, all I got done was put the bulkhead on which to much relief fitted a treat.

1991 200tdi Defender Rebuild

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