Another 90 Rebuild

Still waiting for the bulkhead to arrive.

Got the door frames and calipers back on Friday though







I've spent ages scraping the original adhesive off the door skins.



I've since primed them with etch primer. I'll then paint them and properly seal them back to the plastic coated frames with sikaflex. The plan then is to coat the inside of the frames with Dinitrol. I'll need to research this as I have never used it before. I know there are different types and so I am thinking a one that is initially fairly fluid. I could then put ducktape over the holes, pour a load in and rotate the door to get an all over coating inside.

The calipers were such a mess, so I am pleased with the way they have turned out.

Nice, Calipers look good dude

Yeah, really pleased with them. I couldn't get one piston out of one of the rear ones and so I just got the front ones done. Going to get stainless pistons for the front and I'll buy new ones for the back.

Spent more time rubbing the window sections down today.


and putting some coats of Aquasteel on the steel corner pieces.


Having etch primed the inside of the door skins I started painting them matt black.


Then I started on the seat box. Going to replace the battery box as it is too rotten to save. Contemplating an ali one from YRM. Does anyone know of any better alternatives?


A closer look at the rot.


Rubbed the side panels down and got them primed.

wow great job and good thread ,,i got my r.o.w chassis from Marslands ,order to delivery 3 days ,,well chuffed and comes with compliance cert ,happy days will start a rebuild thread like you once i get off ma arse and into the garage ,,ol

Good luck with your rebuild. Hopefully nothing unexpected turns up. If it does, and it will, treat it as another exciting opportunity to conquer adversity
What's a compliance certificate?
I presume another opportunity to conquer adversity

Those calipers look a great job, what paint did you use? I did mine with engine enamel and it never dried. I wondered about baking them in the oven...

I had them shot blasted and powder coated. Was going to cost £40 for the set, but I couldn't get one piston out of a rear caliper

The bulkhead arrived today.
Loosely bolted it on just to make sure it lined up. Fitted perfectly.







Got new neighbours a few months ago. Defender owners (see first pic) Great people, obviously! Fella has offered to help when I need an extra pair of hands and said I can use his truck to check stuff out if needed.

Al2O3 said:

The bulkhead arrived today.
Loosely bolted it on just to make sure it lined up. Fitted perfectly.

Got new neighbours a few months ago. Defender owners (see first pic) Great people, obviously! Fella has offered to help when I need an extra pair of hands and said I can use his truck to check stuff out if needed.

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Looks really good mate
where did you get it from

Ashtree Landrover International Ashtree Landrover International | Homepage

Not cheap tho

Primed the window sections today.
Washed down the seat box, panel wiped it, the used the detail sander to rub down the ali corrosion. Not to bad really. Will get primer on it tomorrow.

Filled the plastic coated door frames with Dinitrol. Pumped loads in and kept rotating them to stand on each side for a few minutes to let it run in all the gaps. The 600mm tube that comes with it is very handy.





Going to clean the faces up tomorrow and bond the skins on with Sikaflex.

Then, if there's time, the tub will get more cleaning and hopefully the rub down will begin.

Got some primer on the seat box and it's starting to look a lot better. poor picture though.



The Dinitrol took some cleaning off the face of the door frames, which is obviously great news
Put a bead of Sikaflex along all edges so that it sealed the skin from the elements getting in behind it. Even so the back of the skin is painted now instead of bare ali and the frames are plastic coated.



The doors now feel really solid and are much better bonded on than they were originally.



Not as good as galvanised, but hopefully they should last a hell of a long time. And with that lovely solid feel, they might sound like a golf when they shut

"not a golf but like a golf" ,,,great work on the doors ,,great idea powder coating frames before skins go back ,,,may nick that idea off u ,lol

"not a golf but like a golf" ,,,great work on the doors ,,great idea powder coating frames before skins go back ,,,may nick that idea off u ,lol

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It was a lot easier to do that I expected. The original bonding of the skin to the frames was quite poor, so they came off easily.

It's plastic coating not powder coating. It's supposed to be very durable, more than powder coating. Cost £40 per door to get them shot blast clean and plastic coated.

Busy weekend family wise, so not a great deal done.
Rubbed down a lot of steel bits and started getting coats of rust inhibitor on.

Booked the tub in to get shotblasted on Thursday.

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When I got there the guy was concerned that their metal particles would be too harsh so had to bring it home

T washed the bulkhead today tho and got the first coat of primer on

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Got the tub back from the blasters today. Not that impressed with the job, but most of it has worked out well.



Where the seat belts bolted through and the tubular tub supports from the chassis bolted on it was badly corroded.

I cut some aluminium patches and sikaflexed them on.





I think they'll be solid with the sikaflex, but there'll be bolts going through them too.

I've got the galv YRM repair sections for below the bulkhead where the body bolts on to the chassis.



I've got some 3mm aluminium plate and so I thought I would put some patches in where the triangular shaped holes were corroded through, even though they will be covered by the YRM bits. I cut the holes square first.



I sikaflexed them in and bonded a larger panel over the back of them.



very pleased with the results.

Some shiny bits have arrived
Thanks to greyhair for the stainless piston advice and to james6546 for the brake pipe kit advice. Very much appreciated.



Quite sunny here today, so I'm going to spray the new rear tub panels. Keep the caliper assembly for a rainy day