finally got one but now the work starts

If you want a really heavy duty clutch then stick a 130 clutch in it. I know someone that tows a lot and a lot of weight and he did that.

couple more pics





driver & passenger floors are out, front doors are off and the new parts should be coming thursday so took a couple of days holiday to give me a long weekend on it

turns out it needs at least one new hinge for the 2nd row doors and think all bolts will be getting replaced with stainless but still quite happy so far

more bits ordered

polybush kit
door pillars

Clutch and gearbox are now back in

had a look at the bulkhead and took the door pillars off, it doesnt look too bad so rather than remove it i am going to repair it. caps have already arrived and may just fabricate some new tops and floor panels but spent yesterday taking off the old metal to be replaced along with the fuel tank and all rear crossmember bolts. So just need to cut out the old rear crossmember and bulkhead outrigger and I can start putting it all back together.

There are also a couple of bits that will be going up for sale and will add them to the for sales when ive finished but if your interested drop me a pm.

Tow bar backing plate with crossmember mounts, not sure where the tow ball is but if it turns up that can go too.
Full length galvanised roof rack with access ladder
Rear door, bit battered but seems ok got a replacement included in the sale

everything is near darlington, co durham and i wont be able to post so you would need to be able to collect or arrange a courier

use cheese instead of those polybush things

it's cheaper, Tesco sell it and you can use it to snack on when you get stranded

am sure there's one other reason why cheese is better but i can't remember it just now .....

cheers sean, nice to see your back and still happy as ever

considered using oe parts but searching on here (and google) and flo flex kits dont seem to have a bad rep so went with them, if they perish then i will go back to oe rubber

been a long week but starting to look like a land rover again

cut out the old floors and made new from 2mm plate and new os bulkhead outrigger now welded in. All sprayed up with schultz now and ready for winter.

gave it a quick service while the wings were off (easier to get to the filters ) and put the wings back on ready to reconnect the wiring.

just the crossmember to do, tank to refit and then off for mot.

didnt take many pics, just been trying to push through all the jobs to do but will post up what i have

a few pics

the old outrigger





what was left of the footwell before it got cut out



and the start of the bulkhead repair (didnt get the top repair panels in time so we fabricated our own from 1.6 plate)

Nice partially invisible outriggers!

Nice work you're doing Bobbler, keep it up mate

a few more pics

ns footwell



ns outrigger



patch to front of chassis



new os outrigger and floor



can anyone tell me what this plug is for? I have reconnected all the lights, washer etc but cant find where this should be

well after a couple of days away from it I went back to work last night and cut the rearcrossmember off. Turns out the new crossmember legs dont fit so will have to wait until the replacements arrive before we can go about refitting (sent 90 legs instead of 110).

While stood it seems to have developed a slight electrical problem, the main beam and dipped headlights have reversed on both sides (with main beam light lit on dash headlights are dipped and vice versa) and im sure it wasnt like this when we tested them after refitting the wings also the flash no longer works nothing has been done to affect this but the battery was almost dead so wondering if this could have something to do with it? Anyone have any ideas? I did think that I could have put the wires back the wrong way around but this doesnt explain the flasher no longer working.

Also, now that the rear xmember is off there is a tow bar with electrics and rear step up for grabs if anyone is interested

Changing a bulkhead isn't as easy as you might think. They're like jigsaws. People just say they're easy to change when they're trying to sell you a defender with a shot bulkhead. I would try and fix it for now but it will have to be done at some point so when you start, make sure you won't need you're landy for a while.

I got shunted up the backside 6 months ago, long story short, the insurance comp replaced the complete rear cross-member at a caffyns garage. The chief mechanic said it was one of the hardest jobs they have encountered. I know defender mechanics who will replace a cross-member in a day but these boys took 4 weeks!

khaos said:

Changing a bulkhead isn't as easy as you might think. They're like jigsaws. People just say they're easy to change when they're trying to sell you a defender with a shot bulkhead. I would try and fix it for now but it will have to be done at some point so when you start, make sure you won't need you're landy for a while.

Click to expand...

Not too bad to change but after a bit of fettling the inner wasnt too bad, only problem for me was my top cappings didnt arrive in time so had to fabricate new but made sure I put plenty of red oxide and waxoyl etc in there while we rebuilt it.

The plan is to change the bulkhead completely next summer when I have more holidays to use and weather is a bit warmer, lighter nights etc...

greenpaint said:

I got shunted up the backside 6 months ago, long story short, the insurance comp replaced the complete rear cross-member at a caffyns garage. The chief mechanic said it was one of the hardest jobs they have encountered. I know defender mechanics who will replace a cross-member in a day but these boys took 4 weeks!

Click to expand...

Not an easy job true but managed to get the old one off in less than an hour only to find we had the design for 90 legs and not 110 (completely different shape when put together). New parts should arrive today/tomorrow then hopefully just the wiring to sort and then off for mot monday

Well the time has come for mot, got to say a big thanks to Ian & Kev from richmond shotblasting (rock-sliders.co.uk) aswell for all the work and effort they have put in (late nights, weekends, coffee etc.). Didnt really take any more photos but will try to get some up of it finished.

X member was fitted yesterday, lights sorted, bushes replaced and did a couple of cosmetic jobs too but still needs undersealing for winter and a full paint job at some point.

MOT is booked in for tomorrow so fingers crossed I will be driving it tomorrow night.

she'll be fine

IT PASSED

couple of advisories,

surface rust on chassis but it is solid so plan is to get the wire brush out and undfersealing before the snow hits.

oil leak, coming from the sump so will get it off and replace gasket.

brakes a bit spongy, after being stood for best part of 2 years will see if they bed in but change pads asap.

Still a happy bunny though, just need to go and tax it now