My 90 300tdi rebuild

Hi all, been on the forum a while now but not made many posts, after what seemed like a life time looking for a reasonably priced salvagable defender i found one on ebay, pics of how ive got on so far!














just got in today after getting seat box and rear tub off today, liberaly coated every nut and bolt in WD40 ready for next week when i have a couple of days to do a bit more!

Ooooh i do like a rebuild thread, good luck and keep the pics coming

Best bit so far was finding a block of wood holding the passenger window up! Worrying how rotten the bulkhead is, didn't look that bad all built up!

Oooh I love a good rebuild. What's the plan then repair what you've got or you going down the galv route?

Plan is to do as much as my budget will let me! A friend of mine valved his original chassis, going to see what mine looks like when it gets back from shot blaster! Going to get full respray and rebuild engine with ali sport huge intercooler one that will duck little bunny's up

marshy714 said:

Plan is to do as much as my budget will let me! A friend of mine valved his original chassis, going to see what mine looks like when it gets back from shot blaster! Going to get full respray and rebuild engine with ali sport huge intercooler one that will duck little bunny's up

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Ah fair enough, You doing the respray and engine rebuild your self?

Been in the accident repair industry ffor years so gonna prep body myself and a friend will paint it on the cheap engine will be a combination of me and my friend who works at rst land rover in Mersea Colchester

marshy714 said:

Been in the accident repair industry ffor years so gonna prep body myself and a friend will paint it on the cheap engine will be a combination of me and my friend who works at rst land rover in Mersea Colchester

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Cool, I taught my self to paint when I did a bit of a restoration on my brothers 90. and did my 90 when I rebuilt it. Got brothers 110 to paint at some point anorl
Only problem is that I have to do it on my front garden in a gazebo Not ideal but rather that than pay silly prices for it done.

got a bit more done today, rear axle moved out the way, had to invest in a 2 foot breaker bar and 30mm socket to get the trailing arm bush nut off! dam that thing was tight! need to invest in a high lift jack as getting the rear wheels under the rear crossmember to roll out the axle was difficult with a trolly jack! ended up taking the wheels off and dragging the axle out.

planning on getting the cover delivered tomorrow and getting bulk head off and a lot more of the front end stripped out. soon be ready for the sand blaster! see what the chassis is really like when i get it back!

Got the bulkhead off today just before the heavens decided to open! Be glad when this stormy weather is over! Going to set up a canopy next week wen the wind has died down!

got a bit more done, got the engine out and the front axle off, broke down the wings and front doors, dont know what some one done to the rear door but they welded some heavy duty plate on the back?! weighs a ton now so i have a spare of a series 109, only difference visually it has 2 hings not 3? will it fit my 90 hard top ok? heres somes piccys.




cant wait to get that horrible brushed on farmer green paint off! brought myself a tdci dash and heating unit to go on the tdci bulk head, 300tdi with some of the comforts of a tdci hopefully

nice, is the plate in the rear door to reinforce it for a spare or something?

thats all i can imagine, i stripped evertything that was on it like the glass and his make shift rear door card that was a sheet of wood and it still weighs alot more than the series door!

Yes the series door can be used, I used one on my brothers 90 and drilled the holes for the 3rd hinge.

Bloody hell, that dogs nearly as tall as the 90!! do like to see these sort of threads. Definitely worth doing most of the prep work yourself for paint, as I have learnt over the years, cuts down the price over half I reckon.

I have pretty much done a full on restoration on mine but I've done it whilst still using it as day to day transport (other than 2-3 weeks). I'd have loved to have had somewhere to take it apart and do a full on. Doing it in the garden takes a lot of nerve! Good luck and I also love these restoration threads. Maybe my next project will have one too (disco/defender/series hybrid )

well the chassis is with the sand blaster now! cant wait to get it back and start rebuilding rather than dismantling! starting to work on the axles now, decided to paint it firenze red with black roof and bonnet, not sure on black arches or red.


Good colour for the drain plug to look like? its from rear axle, front axle looked a little dirtier.

looks a little beat up! will it last? really didnt fancy welding a new one in :S

orange??

took 2 of us to undo the bearing nut! the other side was alot easier!

half shafts look ok to me? more experience opinion?

Nice job so far mate, how many hours has it taken to get it this far?

quite a while! i see now why people say they dont have the time! luckily i work 12 hour shifts 4 days a week so i get extra days off compared to other people, just had 6-7 days straight on it, ####ing rusty parts starting to slowly be less and less.