95 D90 SW "#2" rebuild

[dogbite]

So I bought a burned out SW (that just happened to be #2) last year about this time with plans of just putting a 300TDi in it and slowly fix or swap out all the damaged parts..... But after it arrived the burn damage was worse than I thought it was going to be so I decided to tare the whole thing apart and build it back up....

So I sold my Black ST to fund the build and started tearing it apart and buying parts...
found a center dash kit with a 300 wiring loom, a 300TDi 75k miles (new cluch and head gasket, Zues timing gear (does anyone have fitting instructions for this?)), rebuilt R380, 1.4 LT230, new (used)seats, new doors (all 3), and sent the body parts to the paint shop and roll cage parts to the powder coater....Frame got galvanized and all new suspension parts with a 3" lift, curry Johnny joined rear links and the 300 TDi motor mounts I made and welded them to the frame before galvanizing it. New SS brake lines, drilled and slotted rotors and new calipers, FOX shocks, Rovertym HD SS steering arm, HD pan hard rod, radius arms, springs, and shock mounts.

I have just recently received all the powder coated parts back and am starting to get body parts back from paint...so it's about time to kick it back into 3rd gear..

Was planning on posting this long ago but could never find the time....there are still parts I am looking for and I have a lot of stuff that’s not going back on this one so l will be posting it up some time soon.

[dogbite]

Well I finally blew off work and got some things done on the project...

Got the Zeus timing gear in as well as the new water pump, headgasket, and clutch.....removed the turbo and exhaust manifold to make room for the stage 4 VNT Allard turbo and goodies that are on the way.... put the engine in the frame and hooked the trans and gearbox to it as well.

then last night found some tim to put the bulkhead and sliders on..... dynomated front and back of the bulkhead and started fitteng the new TD5 center dash.

Meanwhile my new AC unit showed up from ECR so I'm gonna put that in sometime soon...

here are some pictures.... what ya think? O ya I got my new fan in the mail today and put it on.... thanks Jim.

[evilfij]

Looks great!

Are you going to run a custom exhaust? I noticed you still have the V8 crossmember. What did you do to the bulkhead to combat the surface rust from the fire?

Ron

[Shane@EVS]

I heard only bad things about the Zeus gears..........

[dogbite]

Looks great!

Are you going to run a custom exhaust? I noticed you still have the V8 crossmember. What did you do to the bulkhead to combat the surface rust from the fire?

Ron

Custom big bore, free flowing exhaust is what I’m thinking... as for the bulkhead surface rust, I soda blasted it myself as did my painter, followed by a chemical bath, self etching primer, and paint. From what I can tell it should be good as new.

------ Follow up post added July 17th, 2010 09:32 AM ------

I heard only bad things about the Zeus gears..........

Ya.....I was on the fence for awhile on the timing gear, until I found one for cheap (must be because people are uncertain of there performance and reliability) and after much debate and research I decided to give it a go. It fit nice and tight and the case is a great cast, and all of the components are very nicely made.
So I guess I’ll be putting it to the test with and big turbo, exhaust, intercooler, and big ole tires… so we shall see…..

[diesel_jim]

I heard only bad things about the Zeus gears..........



x2....

noisey etc. Personal preferance, rubber belt... BUT, if you got it cheap and all looks well made, you might be OK.

I'd tear it down every other service though and check all is still OK in the timing chest though.

keep us posted on the build though.... looks sweet!

[dogbite]

Got the SS brake lines, and clutch line in and blead for now. Also got the accel cable in, and the rear light loom....now trying to figure out the other 4 looms I have. Well one is the main....it's in now, and two others are the front lights....got them in...guess some of this must go to the trans/t-case?

E-brake hooked up....

damn wires are everywhere.......

[bjf]

Looks great. what did you do to the wheel wells to make them so black?

[JPBrown]

Did the burned 90 used to belong to Clarence? I used to live in Boulder and he had one the same color.

James
www.NoLimitX.com

[ssbartley1]

Looks great- I love to see the rebuild on these rigs. Keep up the good work-



Well I finally blew off work and got some things done on the project...

Got the Zeus timing gear in as well as the new water pump, headgasket, and clutch.....removed the turbo and exhaust manifold to make room for the stage 4 VNT Allard turbo and goodies that are on the way.... put the engine in the frame and hooked the trans and gearbox to it as well.

then last night found some tim to put the bulkhead and sliders on..... dynomated front and back of the bulkhead and started fitteng the new TD5 center dash.

Meanwhile my new AC unit showed up from ECR so I'm gonna put that in sometime soon...

here are some pictures.... what ya think? O ya I got my new fan in the mail today and put it on.... thanks Jim.

[ECR]

Just curious:
Why does your ID tag just say "2"????

In all the 95 NAS 90 Wagons that I have seen they all say "302/500" or "420/500", that sort of thing.

Its cool, just trying to figure it out.

[jaygoss]

Lookin' good Paul! Mine encountered a big hail storm- in a week or so when it's back together maybe I'll take a trip up to Boulder and check it out in person.

[dogbite]

Looks great. what did you do to the wheel wells to make them so black?


The wheel wheels got sand blasted, diped, and rubberized undercote.

------ Follow up post added July 20th, 2010 09:28 PM ------

Did the burned 90 used to belong to Clarence? I used to live in Boulder and he had one the same color.

James
www.NoLimitX.com (http://www.NoLimitX.com)

Nope...this one came from the East Coast just about a year ago.

------ Follow up post added July 20th, 2010 09:33 PM ------

Just curious:
Why does your ID tag just say "2"????

In all the 95 NAS 90 Wagons that I have seen they all say "302/500" or "420/500", that sort of thing.

Its cool, just trying to figure it out.

Thats what it's always said.....a least thats how it was when I got it. Any guesses? I have read that #'s 1-3 may have had blank plates from LR? But this plate looks to be authentic so not sure. I know I like owning number 2!

[bjf]

Cool, what were they dipped in and what type of rubberization

[ECR]

There is already some documentation on it here:

http://www.lrfaq.org/Defender/D90SW.db.1.html

Good old Rover... they never do things the same twice.:):):):)
Have fun with the build up!!

[ssbartley1]

So would it be this one?

SALDV3284SA974738'95SW 2/500Arles BlueOwner reported badge number is "2" not "4" as expected

[dogbite]

So would it be this one?

SALDV3284SA974738'95SW 2/500Arles BlueOwner reported badge number is "2" not "4" as expected

Yep that's her.

------ Follow up post added July 21st, 2010 08:48 AM ------

There is already some documentation on it here:

http://www.lrfaq.org/Defender/D90SW.db.1.html

Good old Rover... they never do things the same twice.:):):):)
Have fun with the build up!!

Ya thats where I read that "The numbering is a little screwy. When the owner of LRNA/04 first bought the Defender, it had a blank number plate. Then LRNA stamped \"LRNA/04\" on the blank plate. By #40 they were marked #40/500 and so on to #500. I don't know which D90 Station Wagon was the transition between LRNA/# and #/500. I also don't know if #1 through 3 still have blank plates or not."

http://www.lrfaq.org/Defender/FAQ.Def.NAS_Defender_95D90SW.html

[don]

Wow! IDK, that galvy chassis with the black powdered parts and the Fox shocks is perfect. Must be hard to put a body on it and cover that all up.

Need to add about how nice the components are and how good the fab work looks like the johny joints rear links.

[dogbite]

Lookin' good Paul! Mine encountered a big hail storm- in a week or so when it's back together maybe I'll take a trip up to Boulder and check it out in person.

anytime Jay just let me know. You still have my email?

[dogbite]

Well I got the TD5 center dash mostly installed (still need so random hardware) with my new Elite A/C unit....

[bjf]

looks good

[jaygoss]

anytime Jay just let me know. You still have my email?

Actually I don't! I switched over to a new phone and lost a lot of old contact info. Can you pm it to me as well as your cell? Thanks!

[dogbite]

Well I got some more done over the weekend... windshields in...both wings are in....doors are back together...rear tub is mocked in and SW sides and windows installed...still waiting on the new turbo..

then I got bored and put the safari guard bumper on to see how that was gonna look....can't deside if I wanna keep it or get something else?

[bjf]

what wheels are going on the truck?

[dave_lucas]

then I got bored and put the safari guard bumper on to see how that was gonna look....can't deside if I wanna keep it or get something else?

If you decide not to use it I can pick it up when I come over to get the hood frame :)

[aosias]

If you decide not to use it I can pick it up when I come over to get the hood frame :)

Or I can take care of getting it out of your way when I bring the condensor back :)

[Gren_T]

Looking good, I like the early 4 spoke wheel and td5 dash.
nice to see a quality touches coming together, having to choke down some serious garage envy though.


regards

Gren

[James Pierce]

Looks Great!

Were did you source your dash? I'm considering doing the TD5 upgrade.

Thanks in advance!

[dogbite]

what wheels are going on the truck?

Not sure yet...keep changing my mind so for now it's just gonna be the black steelies and some bfg's

------ Follow up post added August 9th, 2010 08:39 PM ------

If you decide not to use it I can pick it up when I come over to get the hood frame :)

Sounds good to me....and if you don't take then Alex can have it......turns out the Warn 9.5 XP winch won't fit unless i modify the mounting plate so it's out....unless it goes on my new parts truck :)

------ Follow up post added August 9th, 2010 08:40 PM ------

Looking good, I like the early 4 spoke wheel and td5 dash.
nice to see a quality touches coming together, having to choke down some serious garage envy though.


regards

Gren

Thanks...I love the 4spoke wheel just can't seem to find one in great shape....any one got one out there?

------ Follow up post added August 9th, 2010 08:46 PM ------

Looks Great!

Were did you source your dash? I'm considering doing the TD5 upgrade.

Thanks in advance!

Got the dash from a friend in Canada....think I can get 1 more but there not cheap.....it came with complete 300 TDI wiring looms, fusebox, heater and lots of misc. part....no hardware and missing a couple components to make it complete but was I was able to find them....and now that the parts truck is here it shouldent be to hard to finish "finding" what I need...

------ Follow up post added August 9th, 2010 09:14 PM ------

So I have a crazy story about the parts truck I just picked up.... bought it a couple weeks ago and it was scheduled to arrive shortly thereafter but didn’t end up getting here till last Friday, at 5:30 am....and that Friday just happen to be my GF birthday.... so after a cup of coffee, off we went to check her out... Everything seemed to be in order and when I drove it off the truck everything seemed fine. Engine was real strong and pulled pretty well. So I decided to go for a cruise. After about a mile and a half down the road my GF says to me “is that smell coming from this thing” so I slowed down a little and puff. The cab filled with smoke, I slammed on the brakes, shut her down and pulled over. GF jumped out and I tried to pop the hood and snap. The hood release cable broke…. So I jumped out and gave a quick look underneath and oil was everywhere….. muffler smoking like hell…You guessed it…Oil cooler line burst and was spraying oil all over the exhaust manifold and pipe. Luckily the smoke died down then stopped so we hitched home to get my truck to tow her back. Washed her off with the Hotsy and in the garage she went. Crazy hun? Soooooo glad she didn’t go up in flames, that would have sucked losing all the parts I’m after in only a couple miles of getting to know her.

[MUDSUX]

Dude, seriously? You are one lucky guy! I think you owe your girlfriend a day at the spa for her incredible sense of smell. That could have ended up on ECR's Car-B-Que page. Maybe it was a blessing in disguise the cable broke. I read anecdotal stories about how you are not suppose to open the hood in case of an engine fire-it just creates a draft and adds oxygen to the fire and make it worse. Glad everything is OK.

[dave_lucas]

Thanks...I love the 4spoke wheel just can't seem to find one in great shape....any one got one out there?


You might watch john craddock in the UK on ebay, they have posted a few new ones in the last year or so.

Sending you a PM about Barrys hood and the bumper :)

[dave_lucas]

Had a chance to check out Paul’s 90 today and it looks great :pimp

Sorry for drooling on it

[bjf]

will the 4 spoke work on a NAS column?

[dave_lucas]

Yes sir

[bjf]

are they any cheaper?

[dogbite]

harder to find 4 spokes in great shape....

The wait is over for my new turbo!!!! this things sick......I'll post some pics when I have a chance to start the install

[bjf]

can you get the four spoke new?

[jaygoss]

Paul- what's the latest?

[dogbite]

Well I finnaly found some time to work on #2 again after a great trip to Alaska fishing... I got the rear door and mantec tire carrier on, as well as the ECR LED tail lights. The turbo still needs to get ceramic coated, and I need to figure out how to install the oversized intercooler, but im waiting till my new rad shows up (anyone have any ideas on this?) I have been looking at a lot of other installs but still not sure what i'm going to do.... take a look.....

I also got my parts truck (the stepchild) running and driving so that has quenched my urge to get #2 back together for now, but I still need to find time to work on it.

[KKilo23]

Looking good. The plan is to get it out to you tomorrow!

[bjf]

Is that a trailer plug you installed on the body?

[KKilo23]

Looking good. The plan is to get these other parts out to you tomorrow! :cool: