90 rebuildrebuild

My 90 in progress! 1990 v8 swappee to 300 tdi
Origional; with a cracked chassis brought cat c

Big strip down

New chassis

Mounting everything, new brake and fuel pipes

Cheap bulkhead

So had to swap box to disco box to miss new dash
Bulkhead and body on


New tunnel

Doors new dash Bulkhead removal had to offset reservoir for puma bonnet

Current mare making td5 clocks for it

Looking good!
How were the body panels like seat box and front of the tub?

All new. Well newish haha

Ah, I now see you've replaced the centre bulkhead! I was typing while you were doing the last post.

Al2O3 said:

Ah, I now see you've replaced the centre bulkhead! I was typing while you were doing the last post.

Click to expand...

Yes, I wish I'd done the cut down when it was out too would have been alot easier! Was hard inside even with it empty dunno how they think you can do with seats in

Did you get your window stuff sorted?
Here's a couple of links
Window Channel this is very easy to cut and fit.
Plastic spacers and trim (Left hand the right one is there too)

Just need to figure out what to do with gear gaitors and sticks finish clocks and test then try mount in dash rear wiper to fit new window channels electric winders heated seat wiring central locking new handles new front prop if find one to fit. Make new seat rails weld the rest of exhaust mounts timing kit to fit. Figure out how to do some immobilisers/dead switches full oil changes batt swap 300 engine tweaking add final body bits then finally painting time! Then just soundproofing to figure out D: and internals
If there's no more problems haha

Al2O3 said:

Did you get your window stuff sorted?
Here's a couple of links
Window Channel this is very easy to cut and fit.
Plastic spacers and trim (Left hand the right one is there too)

Click to expand...

I finally found out it was called channel today haha I'd been searching seals with little success! They look better than the fleabay ones alot cheaper too thankyou

alexc2701 said:

Just need to figure out what to do with gear gaitors and sticks finish clocks and test then try mount in dash rear wiper to fit new window channels electric winders heated seat wiring central locking new handles new front prop if find one to fit. Make new seat rails weld the rest of exhaust mounts timing kit to fit. Figure out how to do some immobilisers/dead switches full oil changes batt swap 300 engine tweaking add final body bits then finally painting time! Then just soundproofing to figure out D: and internals
If there's no more problems haha

Click to expand...

Nearly there then

alexc2701 said:

I finally found out it was called channel today haha I'd been searching seals with little success! They look better than the fleabay ones alot cheaper too thankyou

Click to expand...

I used that channel on my rebuild. Glass fits nice and snug and slides well too. I re-used the old plastic trim, just spray painted it matt black.

I used a cheap Hawk Central Locking system. Easy to fit and has been working well since I installed it, about 8 months.

Al2O3 said:

Nearly there then


I used that channel on my rebuild. Glass fits nice and snug and slides well too. I re-used the old plastic trim, just spray painted it matt black.

I used a cheap Hawk Central Locking system. Easy to fit and has been working well since I installed it, about 8 months.

Click to expand...

It makes it easier when you say it fast right?
Does it seal up well or kinda drafty?
Yeah I've heard the aftermarket locking kits are good but defo go for the fender window motors? Or a nightmare so I've been told. Sounds good! I'm not sure whether to strip it all out or leave it till take to be painted rip out then replace after? Dunno if it will get in their way it's hard to judge how far to go with some bits. Need to find a decent painter got quoted 1200 by a garage round corner! Hope I can get cheaper than that. I need to get shift on cos I'll be 1 handed for 6 weeks after the 3rd!

alexc2701 said:

It makes it easier when you say it fast right?
Does it seal up well or kinda drafty?
Yeah I've heard the aftermarket locking kits are good but defo go for the fender window motors? Or a nightmare so I've been told. Sounds good! I'm not sure whether to strip it all out or leave it till take to be painted rip out then replace after? Dunno if it will get in their way it's hard to judge how far to go with some bits. Need to find a decent painter got quoted 1200 by a garage round corner! Hope I can get cheaper than that. I need to get shift on cos I'll be 1 handed for 6 weeks after the 3rd!

Click to expand...

Ha, ha, it's best not to think about everything left to do all at once. Just think of one or two things at a time. Long term plan jobs to get prep done, then forget about some of them in the short term. Otherwise, when things go wrong, it 's a bit over whelming.

That channel seals up really well. No drafts.

I've just done the central locking. No electric windows, that's a bit flash

I paid £1500 for my paint job, but that was with all of the panels separate and painted inside and out. That was a good deal I reckon and I am happy with the finish.

What's happened to your hand?

alexc2701 said:

When I've finished mine gana paint all the underneath in that and then waxoyl all the axles etc. Pity can't be galv like the chassis!

Click to expand...

You can galv axles.

This is Aaron Morris's gear. He galvs everything. Look his rebuild threads up - top work!

Al2O3 said:

Ha, ha, it's best not to think about everything left to do all at once. Just think of one or two things at a time. Long term plan jobs to get prep done, then forget about some of them in the short term. Otherwise, when things go wrong, it 's a bit over whelming.

That channel seals up really well. No drafts.

I've just done the central locking. No electric windows, that's a bit flash

I paid £1500 for my paint job, but that was with all of the panels separate and painted inside and out. That was a good deal I reckon and I am happy with the finish.

What's happened to your hand?


You can galv axles.
View attachment 121886
This is Aaron Morris's gear. He galvs everything. Look his rebuild threads up - top work!

Click to expand...

It's hard not to think about the other things though haha I think cos first one it plays on mind abit more. Bit diffirent to changing odd seal on my disco haha.
Already thinking I want to do a series or a newer d2 next
I'll go for them then! Do I need to buy the like drip line that goes to bottom of door separate?
Haha well I figure with the tdci bulkhead having the switches it'd be a shame not to use em!
Damn musta been sweating putting together trying not to scratch anything haha. I want in and out but not too fussed about inside skins of things that won't get seen. I mean they're all pretty new panels mostly sorta 2010+ and pretty decent paint so it's only really for colour change and to make em all match! Just doors and wings from the pickup haha. I wish I'd painted engine and everything when out rookie error saw gatsos and was green with envy it's one of those jobs where it really pays to know a painter save you tons
Pity I can hardly swap for my expertise haha
Broke it at work last year doc said sprain so never fixed and now it needs an op for ligament damage! Go GP's said isn't sprain feel grind she was like it's fine eeee.

And on Mr galv man that's impressive. He must work at a hot dip place that landy will last forever! Be cool if he Litterally galvanised the whole thing. Shiny.
Id've thought heat ruin an axle. Deform etc. I mean it's hit and miss with bulkheads apparently

alexc2701 said:

It's hard not to think about the other things though haha I think cos first one it plays on mind abit more. Bit diffirent to changing odd seal on my disco haha.
Already thinking I want to do a series or a newer d2 next
I'll go for them then! Do I need to buy the like drip line that goes to bottom of door separate?
Haha well I figure with the tdci bulkhead having the switches it'd be a shame not to use em!
Damn musta been sweating putting together trying not to scratch anything haha. I want in and out but not too fussed about inside skins of things that won't get seen. I mean they're all pretty new panels mostly sorta 2010+ and pretty decent paint so it's only really for colour change and to make em all match! Just doors and wings from the pickup haha. I wish I'd painted engine and everything when out rookie error saw gatsos and was green with envy it's one of those jobs where it really pays to know a painter save you tons
Pity I can hardly swap for my expertise haha
Broke it at work last year doc said sprain so never fixed and now it needs an op for ligament damage! Go GP's said isn't sprain feel grind she was like it's fine eeee.

Click to expand...

I'd do a Series way before a D2.
What do you mean by the drip line? Do you mean the thin metal packing plate that goes behind the channel?
Yeah, use the switches if you can get the gear, might as well.
Had to be real careful putting it all together, worth it though. Gatso does amazing stuff.
Bad news about the hand

Al2O3 said:

I'd do a Series way before a D2.
What do you mean by the drip line? Do you mean the thin metal packing plate that goes behind the channel?
Yeah, use the switches if you can get the gear, might as well.
Had to be real careful putting it all together, worth it though. Gatso does amazing stuff.
Bad news about the hand

Click to expand...

Yes the plates abit rotten on mine, I assumed it was to help any water that did get in find the drains as it goes all the way down to the bottom?
I kinda wish I'd done mine the same but they arnt in bad nick so maybe bit OTT
I was looking at his 90 build other day as he's done tdci bulkhead like mine, wanted to see his gear solutions. New tunnel custom gear levers? Nope he just remade the the whole top to fit like a standard tdci one

alexc2701 said:

Yes the plates abit rotten on mine, I assumed it was to help any water that did get in find the drains as it goes all the way down to the bottom?
I kinda wish I'd done mine the same but they arnt in bad nick so maybe bit OTT
I was looking at his 90 build other day as he's done tdci bulkhead like mine, wanted to see his gear solutions. New tunnel custom gear levers? Nope he just remade the the whole top to fit like a standard tdci one

Click to expand...

The water will get in and it won't need that plate to find it's way to the bottom! I read another thread, ages ago, where it was described as a packing strip. I didn't put mine back in. Make sure your doors are well protected inside and that the drain holes in the bottom are very clear.
Yeah, Gatso's work is top drawer. He seems extremely patient too, so gets stuff spot on. He did a Lightweight rebuild a few years back - stunning!

Haha true! I figured just be there to guide or stop drips. Shall I not bother putting it back in then? Did it make any diffirence haha
The paints surprisingly good. Makes me wonder if replacements. It's a diffirent colour on inside skin of door too so I'm assuming newer... there's pretty much none of the origional left
Ooh I didn't see that just his new one. Everything was perfect down to the smallest bit being painted that will never be seen! I'd love to do one to that level next time. Why I was thinking series so simple you'd have time haha. Be tempting to shove a tdi in it though ruin the history but waaaay better drive

alexc2701 said:

Haha true! I figured just be there to guide or stop drips. Shall I not bother putting it back in then? Did it make any diffirence haha
The paints surprisingly good. Makes me wonder if replacements. It's a diffirent colour on inside skin of door too so I'm assuming newer... there's pretty much none of the origional left
Ooh I didn't see that just his new one. Everything was perfect down to the smallest bit being painted that will never be seen! I'd love to do one to that level next time. Why I was thinking series so simple you'd have time haha. Be tempting to shove a tdi in it though ruin the history but waaaay better drive

Click to expand...

Either that or an older 90 and keep it old and simple with a raptor dash or something. None of this complicated new stuff hahah

alexc2701 said:

Haha true! I figured just be there to guide or stop drips. Shall I not bother putting it back in then? Did it make any diffirence haha
The paints surprisingly good. Makes me wonder if replacements. It's a diffirent colour on inside skin of door too so I'm assuming newer... there's pretty much none of the origional left
Ooh I didn't see that just his new one. Everything was perfect down to the smallest bit being painted that will never be seen! I'd love to do one to that level next time. Why I was thinking series so simple you'd have time haha. Be tempting to shove a tdi in it though ruin the history but waaaay better drive

Click to expand...

Well, I've never noticed a problem with my windows so I reckon ok without them.

don't understand what you mean about the paint being surprisingly good.........

Gatso's lightweight made Classic Land Rover magazine! Awesome, I'll try to find a link to some pictures.

Yeah, a series is not gong to be your daily commute to work vehicle.