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Starting to refurbish my 1997 defender 300 TDI

Discussion in 'Defender 90 / 110 / 130' started by marksman, Mar 10, 2018.

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  1. marksman

    marksman Member

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    As the title, I'm about to start my refurb. and would like recommendations regarding what best to carry out based of other members experiences so far on my list are

    1, Galvanised chassis
    2, Bulkhead repair / galvanising
    3, New brakes all round
    4, New STD suspension all round
    5, Buzz weld cavity wax and chassis in one
    6, Full fluids change
    7, Timing belt change
    8, Full re spray
    9, New clutch &master cyl, check rear crank seal

    Budget is not limitless

    Anything else I should consider
     
    Last edited: Mar 10, 2018
  2. Kwakerman

    Kwakerman Well-Known Member

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    Chuck a clutch in while the engine/gearbox is out unless it is very new. Will be a lot easier doing it now than when its installed
     
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  3. marksman

    marksman Member

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    Thanks I now I have this on my list, new clutch, cyl. & flywheel, check rear crank seal at same time
     
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  4. marksman

    marksman Member

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    Wheel bearings renewed at the same time
     
  5. landy-lee

    landy-lee Active Member

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    lots of photos please!!!!
     
  6. Flossie

    Flossie Well-Known Member

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    New brake pipes.
     
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  7. zeaphod

    zeaphod Well-Known Member

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    I'd add fitting led sidelights and indicators, maybe a boomslang headlight harness. If you fit a galvanised chassis you won't have to worry about injecting wax , in my opinion. Don't forget to budget for new fasteners all round.
     
  8. Kev12

    Kev12 Active Member

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    Bushes & bolts, A-frame ball joint, exhaust rubbers, steering ball joints. All cheap parts and much easier to change while you have it in bits. Possibly swivel rebuilds unless they have been done recently.
     
  9. neilly

    neilly Well-Known Member

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    Wiring in for extras, Lights , fuse box with extra outlets, , etc etc. so you are not adding to it later.

    Making the wiring harness "big" enough to avoid the normal LR issues and have excess earth cables.

    Cheers
     
  10. Al2O3

    Al2O3 Well-Known Member

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    You'll probably need to do a fair few body panel repairs. Particularly the front of the tub and where it bolts to chassis. YRM do a very solid, galvanised repair section. If you are going that far then get galvanised cappings for the tub. You can also get galvanised rear floor struts. Check out their site for ideas YRM They could well be close to you, depending on where you are in Durham.

    EDIT
    As you strip it down you will see what you need to add to your list ;) :)
     
  11. mick the builder

    mick the builder Well-Known Member

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    Have a couple of grand in a slush fund.
     
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  12. zeaphod

    zeaphod Well-Known Member

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    And then be prepared to spend more as you go along and find "issues"
     
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  13. Jan the man

    Jan the man New Member

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    Not sure if you bought a galv chassis, but you can try Shielder. I got one for £1400 delivered and it includes a gearbox Xmbr. From there on, it's safe to go mad and buy everything new. Yep, the pit gets deeper! 2005-02-05 20.34.57.jpg
     
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  14. Mo younesi

    Mo younesi Member

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    Hay Mark, good luck mate. Sounds like that you are going to be very busy for somtimes. Given the extent of refurbishment you are planning, I would say brand new wiring loom could save you a lot electric type hassels in future.
    Cheers.
     
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  15. Foxyred

    Foxyred Well-Known Member

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    Loads of little bits and bobs soon mount up in price, While you list the big items the bolts/washers pipes and clips cost little money they all add up and you will find issues you wont know about until you strip and rebuild.
    Good luck its a long road ahead
     
  16. Sting Ray

    Sting Ray Active Member

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  17. marksman

    marksman Member

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    Thanks,
    I'm adding suggestions (clean ones) as I get them, I'll keep the thread updated as I proceed
     
  18. Jimsky Korsokov

    Jimsky Korsokov Member

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    I'd include a slick-shift in there - put one in mine and it makes the whole driving experience better. The cheapest mod for the most reward! Great video from the guys at Tirsbaek TV

     
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  19. marksman

    marksman Member

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    Had one fitted to my Impretza, does it make that much difference on a Defender ?
     
  20. Jimsky Korsokov

    Jimsky Korsokov Member

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    Mine was a bit like stirring a bowl of porridge - the slick-shift made it tight and driveable by the whole family - almost like a proper car (how do you go from an Impretza to a Defender?)
     
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