90 300tdi Rebuild. Hints and Tips Please

Hi all,

In the Summer i plan on rebuilding my 90, i want to do a few things to help it last. I will be purchasing the parts and tools etc between now and then so its not one big expense.
Im planning on around a £4k budget.

- Galv Chassis
- Galv Bulkhead
- Waxoyl Both
- New +2" Springs + Shocks
- +2" correction parts (props, Castors etc.)
- Re-Paint All body parts

I have a whole load of questions, but so not to bore everyone.
I will ask only a few to get me going.

- Is there a "Guide to Defender Chassis Swap" lerking around anywhere?
(i did search around but couldnt find anything)
- What bushes etc should i replace?
- How long should i give myself to do the whole job?
- Any other hints, tips or possible hurdles to be aware of?


Cheers Sam

I can't answer your questions Sam, but a whole heap of work ahead of you.

Would be great if you could keep and post a photo guide (a le Buster) for those that follow in your footsteps

Station House said:

I can't answer your questions Sam, but a whole heap of work ahead of you.

Would be great if you could keep and post a photo guide (a le Buster) for those that follow in your footsteps

Click to expand...

No Worries.

Yeh i realise its not an afternoons work!

I intend to set a time Lapse Camera up in the work shop, and take Pics/Vids of any cruical steps.

A chassis swap can be done over a weekend, But thats lifting off the body, Takes longer since your replacing the bulkhead as it all has to be stripped down, New spring/dampers, copper brake pipes and loads of new bolts and nuts required.

Why the 2 inch lift ? are you fitting bigger tyres ? If not i would stick to standard height springs, HAve you driven a defender in the wind with +2 springs ??? its very interesting


I use britpart poly bushes but loads of people dont like britpart,
Super pro bushes get a great reputation. Change the A frame ball joint while your there.

andy mcd said:

A chassis swap can be done over a weekend, But thats lifting off the body, Takes longer since your replacing the bulkhead as it all has to be stripped down, New spring/dampers, copper brake pipes and loads of new bolts and nuts required.

Why the 2 inch lift ? are you fitting bigger tyres ? If not i would stick to standard height springs, HAve you driven a defender in the wind with +2 springs ??? its very interesting


I use britpart poly bushes but loads of people dont like britpart,
Super pro bushes get a great reputation. Change the A frame ball joint while your there.

Click to expand...

Yeh i heard it can be done in a weekend by lifting the entire body off, but seeing as im repaint and replacing bulkhead i will do it a panel at a time,
Im planning on doing it in a month, with only evenings and weekends.

Yeh i have im currently,
Running 35/12.50 R15 with +2" SuperGaz Springs n Shocks.
Going to upgrade to Terrafirma.

Ive heard bad things about Britpart so prbably use FloFlex.

Sam

my brother rebuilt his it took him about 6 months that was weekends an after work with help from me a aswell, but he didn't do the bulkhead as his was mint so there was no point ,as soon as he finished it he said he wouldn't do it again but after a few months had past he said he would lol when you get ****ed off just remind yourself its worth it in the end an good luck , take deep breaths