Rebuild Advice - What do I need?

I'm going to be doing a full rebuild of my K-reg Defender 90 over the next year or so.

Does anyone who's been through this before have any recommendations about what stuff I will need to get before I start. From the smallest, e.g. little bags for bolts, to the largest, like engine stands/tools etc.

I'm sure things will crop up along the way but anything that you found essential or just really handy would be good to know in advance.

Cheers,

Tim

When you say a full rebuild do you mean of the whole car or just the engine? Gearboxes too or not?

Alpinejim said:

When you say a full rebuild do you mean of the whole car or just the engine? Gearboxes too or not?

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I mean a chassis-up rebuild and repaint. Hopefully not too much work on the engine. It was running alright before I abandoned it ten years ago, but I'm sure it'll need a bit of an overhaul.
If there's any issue with the gearbox I'm not sure I'd attempt that myself. Again, that was fine when I left it!

I tackled my rebuild in sections, and as a result prepped for each section. It's a lot to think about in one hit. Also once you have finished using a specialist bit of kit you can flog it to buy something else you may need.

I’m still rebuilding my K reg defender. My tip is don’t purchase all the expensive items up front as there will be times you’ll just need to order a cheap item (gasket, bolt etc…) and its crazy spending £5 on postage when the item is only 20p. Cheaper in the long-run to add an expensive item from your list to the order to qualify for free delivery.

Other tip would be a good set of tools/equipment:
Engine Crane, Impact Wrench, Torque Wrench, Angle Grinder, Wheel Dollys, Brake pipes and flaring kit, Nut remover kit

Also as previously mentioned, tackle jobs in sections and finish a section before moving on. Take lots of pictures as well.

A dismantled defender takes up a lot of space!!

Get the number for the Samaritans in big wheelie bin size and put it on the garage door, oh and the local scrap man too for when you are finally sick to the back teeth of looking at it costing you money, skinning your knuckles and showering you in grinder sparks and welding spatter.

Failing that, start with new galv chassis, 6 axle stands, engine hoist, 240V rattle gun, get some cheap tupperware boxes of various sizes for yo fastners, few stacky boxes with lids and labels to put various parts as you take them off, if they are suspect as you remove them then make a not of the part and bin it immediately as you end up hoarding junk that takes up space and gets in the way, don't order anything parts wise until you know what you need and only order parts to do specific jobs as and when you are coming up to them as they inevitably get lost/broken.

Oh and leave the steering wheel nut on a few turn when you try to remove it or you'll be needing new front teeth.

Are you doing this in a garage?I
If it is big enough, then build shelves and devote them for different parts of the job so you dont get them mixed up.
And save the old parts until you are sure the new parts you have bought are the same.
Have fun.

Space (preferably inside)
Time
Understanding family
Deep pockets
Sense of humour this is my drive circa Christmas 2017, as stated previously a 90 can take up a lot of room when it's in bits.

Take plenty of photos as you dismantle stuff.
Label things, either with proper labels or masking tape so you have a fighting chance of knowing where that bit went when you put it all back together.

A digital camera, decent socket set, impact wrench and sockets and a multipack of plasters will see you through almost all of it.

Pfft all these peeps that lecture me on how "expensive" my P38 is to maintain should wander over to the 90/110 and Defender sections LOL

As for what you need.

Simple.......






One of everything

Thanks everyone. I just need to stop planning and actually make a start now.

manchestershire said:

Space (preferably inside)
Time
Understanding family
Deep pockets
Sense of humourView attachment 188904this is my drive circa Christmas 2017, as stated previously a 90 can take up a lot of room when it's in bits.

Click to expand...

The family are understanding, even encouraging, at the moment. Not sure that's going to last though!