83 110 restored

[usadventureracing]

Got the truck out of storage and back home. Ready to start the rebuild with the new gal chassiss.

[jjstahl3]

where did you get your chassis from? mine might need one in the future - where are you getting parts from for the restoration?

I might be getting rid of my rear seats if you are looking for something let me know - or if you find some parts for early 110's let me know also

J

[usadventureracing]

Got the chassis from RN on sale. I think they are still on sale.

I will be getting parts from RN and other locations.

My plan is to;

get new shocks and springs
Fix all issues with bulkhead
new headliner
remove rust on all various parts
clean up engine and paint
fix any unknown issues (those found during the dismantling phase).

[jjstahl3]

I'll look at the frames there - I am going to have my headliner recovered locally they want 275 for all 3 pieces and installed - I think Im missing the vertical piece that fits above the rear door though

Ill be watching this restoration as my guess is we are in the same boat with a car of this age

[bjf]

where did you get your chassis from? mine might need one in the future - where are you getting parts from for the restoration?

I might be getting rid of my rear seats if you are looking for something let me know - or if you find some parts for early 110's let me know also

J

Jay

Looks good

What size tires?

[jjstahl3]

235/85 16 - I think they are basically brand new and the xzl tires on the wolf rims were from 1994 I switched them out and donated them to the classic

once I had the wheels off I saw how rusted the spring seats were so I ordered 2 from paddocks

[jjstahl3]

are you going to switch to lhd?

[usadventureracing]

Maybe, I have not decided yet. So far I like the rhd.

[usadventureracing]

Started the rebuild, took all 5 doors off - broke and scratched nothing - good start.

[jjstahl3]

what sort of trim do you have around the rear windows and above the rear door - I think Im missing something?

[usadventureracing]

There were three pieces for the back, covered with some type of material. Mine were pretty ratty so I removed them awhile back. Looks like you are also missing the headliner.

[One Ten]

Let me know if you decide to sell those side step bar/running boards.

[usadventureracing]

I have made a little more progress. Floors are out and only 2 more bolts to remove and the tub should be free. Then on to the front. My goal is to have the body minus bulkhead off next week.

[usadventureracing]

Let me know if you decide to sell those side step bar/running boards.

As of now I do not plan to sell the side step bars. My wife would kill me she needs to use then to get into the truck

[One Ten]

As of now I do not plan to sell the side step bars. My wife would kill me she needs to use then to get into the truck

LOL. That's what I need them for! :)

[usadventureracing]

Anyone know where to source a new middle row floor and new front driver and passenger floor. Also a battery tray.

[usadventureracing]

I am stuck..........how many bolts are on the front side of the rear tub? I cannot seem to get it off.

Thanks

[ArmyRover]

Brett if you need a hand wrenching let me know I live just down 31 in McHenry.

[usadventureracing]

Brett if you need a hand wrenching let me know I live just down 31 in McHenry.

Anytime, thanks for the offer. I am off all week. I will send you my number via PM.

[evilfij]

I am stuck..........how many bolts are on the front side of the rear tub? I cannot seem to get it off.

Thanks

There are two bolts through the floor, did you get those?

[mikeslandrover]

Have you got the bolts for the side frames & seat belt mounts on the sloping part of the front of the rear tub?

[usadventureracing]

Thanks guys, I figured it out. I just removed the T-post on one side but still have to do the other side.

Anyone know of a good source for T-posts?

[323jamie]

what motor is in yours trying to do a reinstall 300tdi to a lt77

[usadventureracing]

I have a v8 and will stay with that until I get more money and then swap out later on

[usadventureracing]

Body is off. Messy work over.

I am going to sell my old frame, not that bad of shape- will need new rear crossmember and right hand side bulkhead support if any one is interested- looking for 500 or obo, if no offer will take it to scrap yard.

[323jamie]

well I m replacing my engine and was admiring your steps of progress. Im considering going along the same path.

[usadventureracing]

Engine is out and now it is time to start cleaning parts and transferring them over.

[usadventureracing]

Engine

[usadventureracing]

Bulkhead issues need to figure out how to fix

[jjstahl3]

i think you need these

http://www.yrm-metal-solutions.co.uk/004-ns-defender-footwell-repair-panels-4-p.asp

just got turned onto this site myself

[KKilo23]

Rovers North carries replacement panels..

http://www.roversnorth.com/store/c-843-footwells.aspx

[130Tdi]

doesn't look bad @ all. Lots of NAS 90's and 110's look far worse and they are 10+ years newer.

Footwell repair panels are universally available.

[mikeslandrover]

Rovers North ones look closer to original.

[Skeena river rover]

Very nice rebuilt. But why not going LHD! You did the hard part already. LHD is easier to drive and better resale value!

Are you staying with the red colour or a different one?

[usadventureracing]

Thanks for info, how should I remove the floor panel on the bulkhead?

As for LHD what would I need and what would the cost be?

I an not painting the truck, going to leave it red as the paint is on good shape. I will be painting the inside and probably POR 15 the bulkhead in the engine bay.

Only items left on the old frame is the gas tank, muffler and a couple brackets.

I have moved the engine and drive train to the heated garage ( we just had are first snow of the season as it was 56 on wed and now it it 10, so i lucked out) as I will be starting to clean and assemble next week.

[jjstahl3]

thanks to doug here is what you need for a LHD conversion

http://www.dividingcreekimports.com/DefenderLHDConversionHowto.html

[jjstahl3]

this was good showing it actually happening a LHD conversion

http://www.expeditionportal.com/forum/threads/64553-improving-and-repairing-my-110-travel-vehicle

[jayz]

You must have a lot of time, and/or some good help! Looks great, can't wait to see how it turns out.

[usadventureracing]

No not that much time, just vacation it has slowed down now. Will start cleaning the drive train on Friday.

My goal is to have it finished by the 4 th but we will see.

[aka rover]

i think you need these

http://www.yrm-metal-solutions.co.uk/004-ns-defender-footwell-repair-panels-4-p.asp

just got turned onto this site myself

Nice build you have here keep the pics comming along.

Wow great site those axle brackets would make short work of a axle conversion.

Thanks Ed

[130Tdi]

don't know if he's changed his policy but the old guy who owns and operates yrm from his home wouldn't ship to the US last time I dealt with him.

[boswalt]

I just bought some repair panels from him a few months ago. No problem on shipping but communication was spotty.

[jjstahl3]

I just got some stuff from yrm metal and it was fast - the stuff got here in less then a week was shipped ups

now I need to see if i am going to restore my 110 or live with it

[usadventureracing]

Got some painting done. Time to assemble.

[usadventureracing]

Some progress

[Naplm00]

wow nice

[usadventureracing]

Engine in

[tomaco1]

If you still need the floor panels I have one from a td5 truck if that will work.
I think its the left hand side.

[usadventureracing]

I think I am good with the Flooe panels, but thank you.

[usadventureracing]

Does anyone have any advice/recommendation on cut the old footwells out? Should I cut them out?

[Naplm00]

I used a sawzall and a bimetal extra short blade. Was so effective I went through my clutch line as well...LOL

Used a 4 in grinder to straighten it up ad migged them in

[usadventureracing]

Thanks for the info, can I just rivet them in?

[Naplm00]

Personally I wouldn't. When they are in they give the bulkhead a lot of strength, welding would br besg I think

[usadventureracing]

Ok, thanks again for the info.

[usadventureracing]

I have ordered new t-posts that are primed black and my truck is re. Is there a company that can mix the paint for spray cans? I thought I saw a thread awhile back for this.

[grnrvrs]

You're going to dip those new t-posts, right? wink wink

[usadventureracing]

Was not planning on it as the original ones lasted this long. Does anyone know of a galvanizer in the Chicago, as I will get a price quote to see what the cost would be.

[grnrvrs]

Rumor has it that Chicagoland is liberal with the winter time salt. I would strongly suggest that you consider a galvy run with as many of the steel bits as you can muster. T-posts, bulkhead, cappings, door frames ... everything that is ever exposed to the elements. Not dipping them when they are already off the truck is false economy. There must be a few people in Chicagoland interested in getting stuff dipped.

[usadventureracing]

Yes the salt sucks here and that is why the truck will be stored during the salt season.

[Grover]

Engine in
Looks great! What kind of headers are you using? Did you have to modify them to clear for the steering?

Cheers...

[usadventureracing]

No modification to the headers as they are stock to me, as they came with the truck when I got it.

[usadventureracing]

Some pictures of my progress.

[usadventureracing]

What type of

Brake fluid
Transmission fluid (99 auto trans from a discovery)
Power steering fluid

Should I get?

Thank you!

[mikeslandrover]

What type of

Brake fluid
Transmission fluid (99 auto trans from a discovery)
Power steering fluid

Should I get?

Thank you!

Brake fluid - D.O.T 4 is what I use.

[nathanwind]

What type of

Brake fluid
Transmission fluid (99 auto trans from a discovery)
Power steering fluid

Should I get?

Thank you!

Brake fluid = Castrol GT LMA (prob only from AB, not available anywhere else I've found).
Power Steering = ATF (auto tranny fluid, type IV I believe).

[budzny]

Castrol brake fluid is also available at Autozone.

Sal

[nathanwind]

Castrol brake fluid is also available at Autozone.

Sal

Are you sure? I checked Advance & AutoZone recently with nothing.

[Naplm00]

I use generic brand Dot 4 for brake fluid, and cheap universal mercon IV for PS fluid

[cgalpin]

ATF type IV for the auto tranny as well as the power steering.

[budzny]

Bought a big bottle two months ago from Autozone. Also try Pepboys!

Sal

Are you sure? I checked Advance & AutoZone recently with nothing.

[MUDSUX]

Does anyone have any advice/recommendation on cut the old footwells out? Should I cut them out?

I was in your shoes not too long ago. Looks like you are making great progress. I ended up cutting out all the cancer in my bulkhead with a sawzall and made my own footwells. Back then YRM would not ship to the US and RN did not have replacement panels. I would just buy from RN and be done with it. It only cost me $50 to make mine but they are no where as nice as the ones you can get now.

http://www.d-90.com/forum/showpost.php?p=202687&postcount=74
http://www.d-90.com/forum/showpost.php?p=203167&postcount=83
http://www.d-90.com/forum/showpost.php?p=205200&postcount=113


To install the footwells I made mine overlap the original bulkhead and I just glued them in with panel glue I got from home depot, as suggested by some members here, and bolted all along the edges. It is a very strong bond and I am not concerned. Welding would be better though.

http://www.d-90.com/forum/showthread.php?t=22036

While you have the engine and tranny out, why not redo the clutch?

[usadventureracing]

Any recommendation on aligning the body? Meaning the t-posts, rear tub and bulkhead.

[mikeslandrover]

Any recommendation on aligning the body? Meaning the t-posts, rear tub and bulkhead.

When I did mine nothing lined up at all until the roof went on. Bolt everything together reasonably loosely and then it'll pull together when the roof goes on. Having a little slack means you can adjust alignments, door gaps etc.

[usadventureracing]

Thank you that is what I thought I was going to have to do. Going to install the front fenders on sat. Then start the wiring.

Does anyone know if I can buy a center cubby for an auto trans? If so do you have a recommendation.

Thanks

[MUDSUX]

Any recommendation on aligning the body? Meaning the t-posts, rear tub and bulkhead.

I used the "string method". I'll try and find a link for you.

[MUDSUX]

String method outlined by JimC for lining up the tub:

http://www.d-90.com/forum/showpost.php?p=225573&postcount=45

http://www.d-90.com/forum/showpost.php?p=229254&postcount=253

[usadventureracing]

So this ATF should work for the trans and power steering?

[cgalpin]

I've never used that but it should be fine.

[evilfij]

So this ATF should work for the trans and power steering?

I would NOT use synthetic fluid in a rover auto. It can clean out too much stuff and gum up the works. Get the cheap stuff.

[usadventureracing]

Does anyone know what this for looks like main power goes in and then stops

[usadventureracing]

I am getting no juice to the key

[mikeslandrover]

That's the numbering for a relay other than that I don't know.
It's obviously a LUCAS part so the smoke may well have already come out rendering it useless.

[usadventureracing]

Great day today....I got all rear lights working and the front turn signals done. The fuel pump is ready to be hooked up as soon as all lights are working, do not want the pump to run every time I turn the power on to check the lights.

Still need to get the headlights and small white lights in front hooked up. Also need to tuck all wiring neatly under the hood once I have everything worked out.

Question.... Do the small lights in front go on with the headlights or should I be able to turn those on by themselves?

[Jpayne]

I think they should come on with the tail lights, at the first position on the light switch

[usadventureracing]

Than you, that makes sense with the wiring configuration I have.

[usadventureracing]

Got her running and lights done. Bringing her home on a trailer on Saturday.

[usadventureracing]

Brought the truck he on saturday. Finished the rear wiring, it is tucked away neatly and installed the rear windows. Planning on installing the windshield and roof next weekend. Will them begin aligning the body.

[usadventureracing]

Any recommendations on fixing this issue with the door alignment. Thank you!!

[mikeslandrover]

Is the roof on? As I said in my PM that can sort a lot out, I spent days agonising over the door gaps only for it to sort itself out when the roof went on.
If pic 2 is of the front door to the B post try pulling the front bulkhead forward at the top ( slacken the bolts for the small brackets that mount to the footwell and main chassis rail or take one of he alli spacers out from between the footwell and bracket. Rear door - any scope for movement in the bolt holes? Support the bottom of the door with a jack.
Hope this helps. :)

[usadventureracing]

Yes the roof is on. I took the spacers out this morning and seems to make a difference. Now just need to tighten the brackets on the frame rails. Thanks again.

[dave_lucas]

Best advice I can give you is to leave everything somewhat loose till you have it all where you want it.

Start with the bulkhead and get it at 90 degrees from the frame and start adding other stuff from there using the string method. Go slow and try not to force anything it took me days of slightly moving little things around to get it right but it looks better that it did when it left the factory. FWIW having the fenders on might make it a little harder but not sure.

String method
http://www.d-90.com/forum/showthread.php?p=225573&highlight=string#post225573

[usadventureracing]

Any recommendation on where to get stainless bolts for the door hinges.

[grnrvrs]

Got mine at http://www.a2stainless.co.uk/
Shipping took a while, but they warned me that the royal post/USPS was taking a looong time (about a month or so). Very pleased overall.

[nathanwind]

A lot of folks like these guys (similar beveled head to the bolts as factory):
http://nakatanenga-tours.de/shop/category_Schrauben/Schrauben.html?sessid=gXYdQ8Yr4OmYmbHNK8ACeQkhWKhD l5AMqpWrn2QwPkxJRXqQMdEKu0pn3NhxoNRU&shop_param=cid%3D%26

But I went with Stig and like it:
http://www.a2stainless.co.uk/Defender-Series-3_B22EP.aspx

------ Follow up post added April 16th, 2012 09:13 PM ------

Ha that's funny....crossed posts with Paul, we both got them from Stig!

[usadventureracing]

Ordered a set from Stig today.

[usadventureracing]

Anyone know the size of the bolts that are needed for the top of the Front Radiator Panel to the wing. There are 2 bolts per side.

[Naplm00]

If you are talking about the part that the slam latch is on. Mine were just M6 bolts, I replaced them with SS and new well nuts

[usadventureracing]

it is actually the bolts that go through the front panel into the wings.......there is no nut as it looks threaded into the wings.

[evilfij]

Pretty sure they are normal metric bolts.

[usadventureracing]

I put the rear floor in and there are many areas that are not completely sealed. What have others used to seal to make it "water tight"?

[cgalpin]

Do you have a picture? If you want to be able to remove the floor, something like the black 3M sealer strips might be best (i forget the exact brand name), otherwise seam sealer is more permanent.

[evilfij]

I put the rear floor in and there are many areas that are not completely sealed. What have others used to seal to make it "water tight"?

Unpossible

Better to let it drain. Factory was thin foam tape on a NAS 110.

[usadventureracing]

Thanks guys that is what I used but still some gaps

Here is how she looks now

[usadventureracing]

My brake booster seems to be leaking around the edges will this stop after I bleed the brakes or does people think the seal has dried up because it was put of the truck so long ( abbott 4 months with no fluid in it? Can the seal be replaced?

[mikeslandrover]

My brake booster seems to be leaking around the edges will this stop after I bleed the brakes or does people think the seal has dried up because it was put of the truck so long ( abbott 4 months with no fluid in it? Can the seal be replaced?

Depends if the bore has corroded or it's just the seal that's gone, with brakes I'd always err on the side of caution and replace the master cylinder if at all suspect.

[usadventureracing]

Thank you for the info, I am going to purchase a new brake servo.

[evilfij]

Booster aka servo or master cylinder?

[usadventureracing]

This part in the picture, I believe it is the servo

[cgalpin]

The servo/booster itself doesn't have any fluid in it. So if something is leaking it's coming from the master/reservoir. Whee is the leak?

[usadventureracing]

Thanks for the info I cancelled my order. It looks to be leaking where the master goes into the servo.

[Naplm00]

most likely the brake master is letting go. It is a easy 15min job with a power bleeder.

Just make sure you have some flare nut wrenches

[usadventureracing]

most likely the brake master is letting go. It is a easy 15min job with a power bleeder.

Just make sure you have some flare nut wrenches


Are you talking about replacing the brake master is only 15 min. job?

Thanks

[evilfij]

Maybe a bit longer, but replacing the MC is not hard if the lines come out of it.

[usadventureracing]

Ok on to the next issue. For the life of me I cannot figure how to install the rear door bottom seal. There are two metal pieces and the seal, can anyone tell me how these all come together? Thanks!

[mikeslandrover]

Ok on to the next issue. For the life of me I cannot figure how to install the rear door bottom seal. There are two metal pieces and the seal, can anyone tell me how these all come together? Thanks!

Post a piccy of the bits!

[usadventureracing]

Here are pictures.

[mikeslandrover]

I'll snap a pic of mine this weekend.

[evilfij]

The metal sandwiches the rubber, but there are two versions so you might have the wrong seal if it is not lining up right.

[usadventureracing]

That is what I thought, I am thinking the wrong seal also.

------ Follow up post added May 4th, 2012 04:36 PM ------

Installed the drive shafts and brake master. Everything is wired , just need to correctly install battery with cutoff switch.

------ Follow up post added May 4th, 2012 04:38 PM ------

Bleeding brakes tonight. Only now have to clean up and install the seats and she will be drive able. A new interior will be a work I'm progress later this year.

[usadventureracing]

Tool her on her first trip around the block. Now on to the interior.

[mikeslandrover]

Good job, fast too:)

[draaronr]

nice job, looks awesome and man you are fast.

[Skeena river rover]

Man that was a quick built. How much hours do you think you have spend on this built?

[usadventureracing]

I am not completely done, need to finish the interior....this will be gradual, but atleast I can finally drive her this summer and fall. I worked on her almost everynight in April and May after work and from Friday - Sunday almost every weekend for about 20 hours. I learned so much and fixed tons of issues with the truck.....it was a great learning experience.

A few years from now I want to convert to a manual trans and diesel. Need to start saving now.