Defender 300tdi Project

sea27n · Mar 30, 2020

Hi all
While I have a bit of time at home I thought I would do a few jobs on the 90 that I have been putting off. The passenger foot well is wetter than the river Avon and the clutch has been slipping for the last year, so here we go:

sea27n · Mar 30, 2020

First job was to strip the foot well out and find the rust!

sea27n · Mar 30, 2020

A previous owner from years age and used a lot of silicon!!

sea27n · Mar 30, 2020

I have cut out a lot of the rot, but the more you look the more you find.

Check the drivers foot well and that is solid but will remove the floor as the whole seat box will need to come out if I am going to do the clutch as well.

sea27n · Mar 30, 2020

Battery box has seen better days so that will need sorting now too.

Knappster · Mar 30, 2020

The battery box on mine looked the same until I had it welded.

sea27n · Mar 30, 2020

Knappster said:
The battery box on mine looked the same until I had it welded.

Did you have it plated out of interest or a whole battery box replacement?

Knappster · Mar 30, 2020

I had it plated. Longer term I’d like to replace it with a galvanised one.

sea27n · Apr 2, 2020

Got the seat box out and the rest of the floor - got the Bty box off ready to rivet the new box on.

sea27n · Apr 2, 2020

Next job was getting the front wing off to gain access to the foot well.

haza88 · Apr 3, 2020

Yrm do nice pre made bits I fitted one of ther battery boxes on my previous 90 well priced and great bit of kit

haza88 · Apr 3, 2020

They do the footwell panel your after too

resto_d1 · Apr 3, 2020

Good work mate! Nice little project this

sea27n · Apr 30, 2020

So here’s an update so far - new Battery box done, nice and light in alloy from YRM so many thanks to haza88 for that one.

sea27n · Apr 30, 2020

Next job was gearbox out and renew the clutch.

sea27n · Apr 30, 2020

Clutch all done and gearbox back in, no massive dramas so far, found another hole in the chassis so a bit more welding.

sea27n · Apr 30, 2020

So a big clean up of everything and a few other little jobs done, and then start putting everything back together.

sea27n · Apr 30, 2020

Forgot to post a pic of the new foot well, I admit my welding isn’t the prettiest here!

sea27n · Apr 30, 2020

As you can see above I had to fabricate the right hand side of the foot well, as I had to cut half of it away.

sea27n · Apr 30, 2020

From the outside, and this is why the wing has to come off.

Defender 300tdi Project

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