Defender 300 TDi Project!

Looking smart with those seats mate!

I've loved this thread. Congratulations on a cracking transformation!

Been a while since I updated as iv been doing lots of bits and pieces and taking pics as I go along.

Firstly I replaced the door seals, including the rear doors, new seals



Fitted





Old ones were split in various places





Tip: you can reuse the rear door seal for the bulkhead/bonnet seal if yours like mine doesn't have one



Next up was to recover the front headlining, removed



Stripped the old stuff off



Bought some black alacanara type stuff off ebay and covered it



also sprayed the visors black





I won a 3 piece headline set off ebay, as I didn't have a piece for the rear roof section



I will cover the rear piece when iv ordered some more material

I made some side panels out of plywood and covered with some plastic vinyl textured stuff and also sprayed the bare green metal with black texture paint

Just got the one side done so far



Covered and put in the rear lining piece



Should all come together nicely when I get the rear roof section covered and in

Another batch of updates

Sprayed the door frames from green to black





No more green on how when doors closed now



Coloured the door cards black too, this was using weird vinyl paint from Halfords that dyes the plastic rather than covers it like normal paint, first coat



Couple more coats and a before after pic



On the car





Then covered the rear section





Fitted pics, with the second courtesy rear light installed too







quite difficult taking pics of dark interiors clearly

Nice work. If I can do half of a good job as you on my headlining I'll be happy.

Looking good. Where did you get the retrim kits for that price?

Paddock spares

Ah I was looking at the price in Euro. The vinyl spray you used looks well could it be used on the dash?

Yep

Small update, tinted the two little windows alongside the main one

You've done a great job mate

So having not touched this for a while did some more work on it as mot is due soon etc

pulled off bottom rad hose



Not that much in there



However after I undid the engine block coolant drain plug



**** loads more came out

Now its empty and flushed with clean water

Also got the thermostat out

Housing



Removed



Old thermostat in the housing



Removed



So carried this on today, first up remove the viscous fan using the special spanner



Fan removed



And the cowl



Oil cooler pipes removed



Radiator and intercooler removed



Bit more room now





Rounded the bolt on the waterpump puller, had to remove my bolt extractors



Aux belt tensioner removed



Damper puller bolt



Pulling the damper off with the puller



Came off a piece of **** actually





Old belt



Then to set the timing and lock in place, line these marks up on the webbing



Woodruff key lines up with the mark above it



Injection pump should then be able to be locked with the pin



Notch on the flywheel should be in the middle of the breather hole



Lock that in place with the pin



Belt off



Tensioners off



Crankshaft pulley was seized solid, ended up getting an angle grinder to it and a chisel



Crankshaft oil seal removed



and replaced



New pulley and tensioners on



New belt on and tension set



Timing case bolts are all different sizes so made a quick template



Removed the timing case crankshaft oil seal



New one in



Timing case and new gasket back on



Old waterpump removed, loads of crappy gasket on the flange



old next to new



cleaned up the mating surface as best as possible



Greased the new bolts



Bolted on



Now of course a good job isnt right without something going wrong, and when I was doing the waterpump i noticed the power steering pump was loose and flapping around like a fanny in the breeze

The problem being part of the casting broke off, and one of the bolts sheered, no idea how or when that happened



It was also leaking fluid



So new pump ordered, cant do anymore til that comes, this is how it stands

So then, the swivel balls are leaking both sides, and as its due mot soon decided to get them and the seals changed.

Wheel off



Hib assembley/disc off



Half shaft extracted



Swivel ball housing



removed and cleaned up



The swivel ball





Bad pitting on the ball, which causes damage to the seal



Swivel ball off



with its seal and retainer





All the removed bits



So my teflon coated swivel ball kits turned up, bought bearmach and not the cheaper brit part ones



Loosely assembled all that in the housing etc



Fitted on the vehicle and set the preload with my spring balance. needed to add a shi, in the top bearing




Stub axle back on



Nice new swivel ball installed

SJW2511 said:

Click to expand...

A loverly fruit bowl!

That is one good write up with clear photos. Will come in very handy when i do mine.:clap2:

mick the builder said:

That is one good write up with clear photos. Will come in very handy when i do mine.:clap2:

Click to expand...

Could'nt agree with you more!!!

Bravo!! :clap2::clap2::clap2::clap2::clap2::clap2:

I've just sat and read this whole thread. All I can say is stunning! Your workmanship is fantastic. Mine has got a hell of a long way to go but it's certainly inspiring reading this.
Thanks for sharing it with is.

Looks stunning mate,
Just a tip paint the swivel seal covers as they rust like hell
Think it was a few weeks and i had to change mine as they were a mess

Cool cheers.

How do you change them without removing everything again..

SJW2511 said:

Cool cheers.

How do you change them without removing everything again..

Click to expand...

I had to remove everything, but it was not to bad as im doing a rebuild so its a rolling chassis as the moment and axles etc are yet to be filled with oil etc