Defender 90 200Tdi Rebuild

Here is my rebuild log for our farm Defender 200Tdi. It's a 93', but we've had it since 97'.

The 'original' plan was to just swap out the chassis for a galvanised one (simple I assumed). But I didn't quite take into account how hands on and time consuming it would be. Also seeing my wallet getting considerably lighter with each rusted piece I took off and inside knowing it would need replaced was heart breaking!!

Other than the new chassis, we ordered a 1.4 ration transfer box to replace the 1.6 ratio one installed a few years ago (only replacement at the time), it never ran right and always felt like I needed an extra gear about 45mph.

Thanks so far for the help must go to Clint, John and Mosside for providing lots of help on the more technical aspects of the build.

It's still a work in progress, but here is the progress so far...




Began with taking the IForWilliams canopy and bull bars off, it was at this point I knew I wouldn't have many free evening for some time to come:



Removed bonnet, front wings, windscreen and roof:


Removed doors, inner wings:



Seatbox, rear tub removed:

If you have any questions or tips, do feel free to let me know.

Removed Dash along with steering column (a lot of screws of different shapes and sizes, don't fancy putting it back together). The bulkhead was then subsequently freed from the rotting chassis and lifted away for further damage inspection.



The damage to bulkhead was worse than feared..









However; with much thanks to Mosside Land Rovers, the bulkhead was well looked after and got sand blasted, repaired and galvanised.
Prep work:




After being galvanised:

Bulkhead looks good!
Looking forward to following the progress
Rich

Out with the old... Final picture of old chassis, would advise keeping rear axle in place until engine is removed.



New Richards Chassis waiting to have things added to it (I did know it was upside down lol).


The front axles where grind'd down to bare metal to allow for a few red oxide coatings to hopefully stop rust reappearing in the near future.
Almost all of the mountings on the axles were too far gone, so I thought it best that these were replaced, all mounts for axles were purchased from YRM. Quick and easy to deal with, good rates on NI postage as well.




Similar story with the rear axles with the exception of a leaking diffpan, so purchased a one from Paddock Spares, could have spent time repairing old, but as they are so thin I thought it best to replace it entirely







A few top coates of black chassis paint to make them look like new. Radius arms, trailing arms, panhard rod, track rod etc where grinded down, primed with red oxide and then sprayed with a semi gloss black chassis paint.



Chassis was fitted onto some axle stands in order to get axles ready to fit.


Axles, new shocks + new shock mounts front and rear, galvanised turrets, new springs fitted to chassis. Decided to not pant the chassis. I will however be painting the rear crossmember for aesthetic purposes

This post brings everything up to date, the last 3 posts were accumulated photos from the work done over the last couple of months.
As mentioned in the first post, our original transfer box became knackered a few years ago. There was no 1.4 ratio box's available at the time so we opted for a secondhand 1.6 transfer box (potentially from a military 110) although can't be sure.
Because of the cruise speed on a 1.6 is annoyingly lower than that of the 1.4 making you wish there was a 6th gear above 50mph, we thought this would be a good oppurtunity to switch back to a 1.4 ratio box.
Ashcroft transmissions offer a good service which includes the ability to send back your retired transfer box.
There was a slight debate about whether to go with the 1.2 ratio, but as we intend to fit beefier tyres and because it will more than likely tow a few bits and pieces to and from the yard, the 1.4 was a happy medium between a road vehicle and a solid towing vehicle.


New 1.4 ratio transfer box fitted.

Whilst the engine was out in the open, and having forgotten when the timing belt was last changed. Now was as good a time as any.

New flexi brake pipes made up and installed.

Also new calipers as the previous had some serious corrosion.

Detachable crossmember and mounting brackets for gearbox/engine were primed and painted.


Fuel tank, waxoyl's and connected up to fuel pump

Giving it a test run to give me some motivation to build it back up lol

Looking good I know what you mean by wallet getting lighter everytime you remove a bit. I've got same problem I'm doing the chassis on my 200Tdi Defender as well.