Aaron's 90 rebuild (round 3)

Sooo.... those that followed my last thread will know I went out and bought another 90 last Sunday, so I guess it's that time again

Was kind of a last minute impulse buy, did I pay too much? Possibly, but let's see what we find when it's in bits completely first.
But seems pretty good overall, chassis seems solid but has been painted in old oil to protect it, which will make it lovely to work on
All doors seem solid, bulkhead looks reasonable, although I found a hole while viewing despite being advertised as solid, he said he's replaced the top corners, but it looks like it's been blathered with filler after (badly) so we'll see what it's like underneath.
The paint work is actually very good (better than any of my attempts) but the prep work lets it down.
Being an old 'un it's on 10 spline axles, I.E drum brake rear. So will try source a disc brake rear.
Genuine defender 200tdi engine which seems to be good, but needs a rear exhaust, gearbox/transfer box etc seem good so hopefully theirs not too many nasty's to be uncovered.
Oh and the chequer plate is bloody awful So it's got to go.

So what's the plan? Well a galvanised chassis is top of the list I think.
Then galv as much as I can, bulkhead, cappings etc.. It's what I wanted to do on the last build but didn't know where to start so gave up on the idea.
Just need to find a blasters locally, which is proving easier said than done.

This will be an extremely slow build as I'm rather busy at work at the mo and theirs no signs of it slowing down, if anything it's been getting worse.
But it's what I love doing so even if it's just one day a week I'll be happy

Anyway I'll shut up now and stick some pics up.













I forgot how small a 200tdi is



For those that haven't seen my other build, this is what is in that. (sort of)



Anyway, that's it for now folk.Will post more in the morning.
And hopefully this is of interest to some as I've done a couple of threads already.

Get in. It's like Game of Thrones starting again.

Glutton for punishment Bet the neighbours pulling his hair out Keep up the good work . Looking forward to the build.

Are you going to fix and galvanise the chassis or replace it?

Looking forward to another rebuild
The Defender Mender strikes again

Al2O3 said:

Get in. It's like Game of Thrones starting again.

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Cheers bud

robertcoby said:

Glutton for punishment Bet the neighbours pulling his hair out Keep up the good work . Looking forward to the build.

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Thanks Punishment for some, but I really looking forward to it, it's been a while since I've been able to do anything much.
As for the neighbours, well that goes without saying I thought long and hard about this and decided why should they stop me enjoying myself in the little free time I have, and well.... Here we are

cowasaki said:

Are you going to fix and galvanise the chassis or replace it?

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New chassis is the plan. I've never really been a fan of getting old chassis' done, as I don't think you could get all the crap out from inside, especially the double skinned bits. (possibly trapping it in once dipped)
But... When I started stripping it yesterday the chassis seems very solid, scraped some of the old oil off that's been sprayed on to protect it and it seems damn good, just surface rust.
If it's as good as it first seems it would be a shame not to do anything with it, but I've bought this to do it properly (I.E new) and not half heartedly if funds allow. Time will tell on this one.

greyhair said:

Looking forward to another rebuild
The Defender Mender strikes again

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You're not the only one It seems to have been a long time coming mate.
And Defender mender :lol:

aaronmorris said:

New chassis is the plan. I've never really been a fan of getting old chassis' done, as I don't think you could get all the crap out from inside, especially the double skinned bits. (possibly trapping it in once dipped)
But... When I started stripping it yesterday the chassis seems very solid, scraped some of the old oil off that's been sprayed on to protect it and it seems damn good, just surface rust.
If it's as good as it first seems it would be a shame not to do anything with it, but I've bought this to do it properly (I.E new) and not half heartedly if funds allow. Time will tell on this one.

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Have you seen "a 4x4 is born"? They strip, dip, weld and galvanise one on that and it seems like a top job.

Anyway, continuing....
I got home around 2:00 Sunday afternoon, sat down for an hour, had some dinner and decided not to waste any time and get cracking.
So we're off!
Roof off. Back door off.



Van sides off.



Doors, bonnet, windscreen off.
Thankfully most of the door to bulkhead bolts came out, as I had to drill 'em all out last time.



Interior, trans tunnel, floor pans etc out.



Now the bulkhead....
I've replaced the top corners he says
Shouldn't be too bad to repair anyway.





And that was it for last Sunday. Just enough to get it in the garage out of the way.

And onto yesterdays progress.
Well first thing was to take delivery of my new impact gun
Old snap on one I've got is on it's last legs and one of the batteries is dead, so decided to treat me' self.
First impressions are it's pretty good.



Carried on, seat box out.



Tub off. Electrics aren't really my thing so luckily the wiring wasn't too butchered when disconnecting.







Slam panel, grill and one wing off.
Again, the electrics where as good as I've ever seen on an old lr, no scotch blocks in sight
I just wished they all used the plug in td5 type plug on the wing as it makes life much simpler.



Tother wing off.



I was then waiting for a lift with the bulkhead so made a start removing the rad and a few other bits.



And.... the bulkhead off. Chuffin' heavy thing





Got the fuel tank and a few other brackets off and that was it for yesterday.
I'm hoping to get the rest in bits today so I best get cracking.

Good luck Aaron really looking forward to this she's about the same age as mine so interested to see wot you find hidden away

& I can't believe how bloody fast you work
Matt.....

It looks bloody tidy already!
My 110 is sat on the drive looking very sorry for itself as I don't know what to do with it!

progress is looking good already. out of interest, is the milwaukee 1/2 or 3/8?

Ah, here it is in stages. I saw the other post on 'What have you done . . .' and thought it must have come apart by magic. Seems like things have come undone fairly easily. That chassis certainly looks oily. Maybe that's kept some of the nuts and bolts moveable too.

cowasaki said:

Have you seen "a 4x4 is born"? They strip, dip, weld and galvanise one on that and it seems like a top job.

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Yep, but compared to a new chassis it can't be as good surely? But I think I will get some prices for shot blasting and galv to compare the costs.
Will give it a good going over myself first to make sure it's viable and if so it could be a goer.

Matt200tdi said:

Good luck Aaron really looking forward to this she's about the same age as mine so interested to see wot you find hidden away

& I can't believe how bloody fast you work
Matt.....

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Cheers Matt It's always interesting to see what you find (or sometimes worrying), or previous owners bodges
One things for certain, you always find more than you think, no mater how good the vehicle looks.
As for how fast I work. Taking it to bits is the easy part

JohnM70 said:

It looks bloody tidy already!
My 110 is sat on the drive looking very sorry for itself as I don't know what to do with it!

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Cheers, it probably looks tidier than it is, with a couple of underlying issues that have been covered up.
Don't know what to do with it in what way? Is it broken..

daddy2coull said:

progress is looking good already. out of interest, is the milwaukee 1/2 or 3/8?

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Thanks Milwaukee is 1/2" Seems pretty good from trying it out today on radius arm bolts etc..

Brown said:

Ah, here it is in stages. I saw the other post on 'What have you done . . .' and thought it must have come apart by magic. Seems like things have come undone fairly easily. That chassis certainly looks oily. Maybe that's kept some of the nuts and bolts moveable too.

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Yes not quite magic
Yes the chassis is very oily, but it seems to have done a good job of protecting it, some stuff came undone easy, some stuff was a complete **** but it's done now.

@aaronmorris it's not broken as such - just un-loved! Just picked up a set of alloys for not much money in an aim to try and gain the enthusiasm to do something.
It needs:
New drivers door in total
Lots of welding on the bulkhead
New dash in total
Electrics need looking at and sorting - fed up with having to wiggle stuff to get it to work
Rear wheel bearings
Interior sorting
Many other things I haven't found yet!

aaronmorris said:

Yep, but compared to a new chassis it can't be as good surely? But I think I will get some prices for shot blasting and galv to compare the costs.
Will give it a good going over myself first to make sure it's viable and if so it could be a goer.

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If I remember rightly it was shot blasted, dipped and then modified before being galvanised.

What are you looking at for a new chassis? How much for blasting, dipping and galvanising? Clearly would be less hassle for new galvanised one. Same with bulkhead. I'm looking at the cost of both myself at the moment although there is probably a good few years left in this one.

Well came in about half an hour ago (Bloody rain ) But it's now all in many many parts and it's now time for some dinner.

So first job. Pull the engine and box out.
Easy getting it out, but maneuvering it into the garage... that was the hard part on me own.





Rubber mounting on the transfer box has started separating, well their ain't a lot holding it on.



Steering box, and front axle off. Again not too bad on yer own, disconnect everything, lift chassis up and roll whole lot back on rear axle.





Then onto the rear axle, couldn't lift the chassis and roll it on my own so got a little helping hand, I could have got the engine crane out but it was ****ing it down by this point





And that's it, the bulk is now in bits, I now just have to strip each individual part, asses what I've got and come up with a plan.



Theirs some cracking rebuilds ongoing at the mo and I doubt it'll be up there, but that's the difference when you're on a budget so to speak, or the amount of money coming in over a certain amount of time, when you want it done before then.
We'll see, but for now I need to go and have a sortout, as the garage is a ****-tip and the garden has body panels scattered all over.
Not that theirs a lot I can do with the garage. Need to build a bigger one

I need to clear the garage before I even think of starting to do anything on mine!

You might want to change that fence post before you end up moving in with the fav. neighbors ;-)

aaronmorris said:

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Wahey! They're bloody brilliant aint they.