Ian's 90 300tdi rebuild

Hi all , started my new project the other week , she's already stripped so thought I'd put some pics up of the work to do have already had the chassis and bulkhead blasted which highlighted a fair bit of work on the chassis but bulkhead okay just the driver's side footwell but have decided to replace both with hd ones from classic bulkheads while its off ,as passenger side is rusty and it looks like it goes under the re-inforcing then they're both off to work to be galved.

Well there's plenty to be going on with will put more pics up with progress as I go .
cheers Ian

Your pile of parts looks similar to mine! Good progress so far, and looking forward to seeing more photos. What sort of spec are you going for? Are you uprating anything?

Have you considered replacing the chassis altogether?

Yes you always start with a pile of parts don't you, then you have to start remembering were they go . The chassis is down to cost plus I'm a fabricator/welder and I have a descent welder at home, so I'm confident I can sort it plus I already had the plate, and I can get it galved at work so it was money I don't need to spend at the moment although it would have been nice so will do that at a later date. As for spec I'm doing it as a road only landy as I've just done a 200tdi 110 which was for going fishing and laning in. I'm turning it into an auto and I'm thinking Keswick green and black wheels and such , I will proberbly upgrade the turbo , intercooler and tweek the pump and I have a few other mods in mind but they're still in the thought stage and I can't make my mind up whether to lower it or leave it at standard height.

Progress some of the holes have gone

just need to find were the front arb mounts go know so I can weld them on .
cheers Ian

Hi all , all welding done on the chassis except the rear , I'm fitting a 1/4 chassis so waiting for that to come

missed the front end the dumb irons are done will get a photo of them tomorrow and nobody panic I took the photo of the front arb's before I welded them .

Last few photo's of the chassis

so while waiting for the rear 1/4 chassis to come thought I'd start on the bulkhead new footwells

and on to the PITA job of drilling all the spot welds out

can't make my mind up whether to replace the footwell side panel or weld a bit in ?

cheers Ian

So a bit behind here took the foot well out last week

decided a new side panel was needed so made one of those

then did a test fit of the side panel

all good so yesterday tacked the foot well and side panel in for a test fit

and made sure the gearbox tunnel part fitted properly upto the bulkhead

well pleased then after a few small jobs on the 110 this morning went in the shed and welded her in


got a few more strengthening plates and a few other plates that hold wiring plugs and such to weld on then its on to the passenger side , its being galved at work so will apply the seam sealant when she comes back.
cheers Ian

I wish I had your welding skills! Looking good!

Thank you , i did cheat a little I'm a fabricator/welder by trade .

Lovely job fabbing up all the plate & sheet parts. Hat's off to you.
Everyone will be dead jealous of your galvanising it too!

Cheers Dan, only made the side panel myself the footwells were brought from a company.

Hi all , haven't been on here for a while and totally forgot about this thread , so I have been carry on with the rebuild have got a lot done so I'll update this over the next week or so , so here goes .
So got the bulkhead finished but decided not to galv it as the place you want to treat most is the inside and if there's paint in there the acid bath won't remove it so in my opinion a waste of time .



the rear quarter chassis came and got fitted along with some new other bits .





and got galved at work

I then decided to move the fuel tank to the TD5 position .








so with all the fab work done chassis and bulkhead got primered .




I'll leave it there for now , and I'll upload some more tomorrow got the tub rebuild , axles and lots of other pics to upload .
cheers Ian

Epic build so far, looks like it was proper rotten.

Will be interesting to see what you do with it beyond getting it back together.

Thank you , yes there was plenty of work to do . There’s was plenty of fab work that I did on the tub also , I’ll put the pics up of that over the next few days . I’m fitting an auto to this one so I’ll use it as a daily driver and my 110 will be used for green laning , Land Rover shows , camping and fishing .

Ian Maycock said:

Thank you , yes there was plenty of work to do . There’s was plenty of fab work that I did on the tub also , I’ll put the pics up of that over the next few days . I’m fitting an auto to this one so I’ll use it as a daily driver and my 110 will be used for green laning , Land Rover shows , camping and fishing .

Click to expand...

What power train and drive line are you going to be using?

I have seen some amazing builds using various engines and transmissions, one of the best I have seen so far was the 110 with an M57 BMW 3.0TD engine and 5 speed auto box mated to a divorced LT230 transfer box, it was amazing, two more cylinders and a heap more torque and usable power.

Nice
Good job mate il be keeping an eye on this one

Cheers kevstar , I'm sticking with the 300tdi and mating it to a Disco 1 auto the pump will be tweaked and a uprated chra in the turbo also possibly a uprated intercooler . I do fancy a BMW m57 but was thinking of putting it in the 110 when this is done .
So next up was the axles and suspension arms to get some paint . they all got sand blasted then a coat of tractol then buzzweld gloss extreme.









The brake calipers got painted then rebuilt with stainless steel pistons and new seals .

Then the chassis got etched primered as above then a few coats of chassis CIO .




Next up was the tub that had some major work , I made some new panels myself as you couldn't buy them and also the seat box was rebuilt .
Will try and upload that Wednesday night as it's Land Rover club meeting tomorrow night .
cheers Ian

Gold calipers

No there copper coloured actually wanted something a bit different from the usual all black, they’ll be covered in muck soon enough so won’t be seen anyway hahaha.

Great job buddy.