110 CrewCab restore project ...

[Retrofit]

Ok, here goes:

Started off with an imported 1984 Defender 110 that had already been somewhat restored with a galvanized chassi and a 60k 200tdi engine. Even though the work had been done in the UK I was unsatisfied with alot of it.

1 - The bulkhead was starting to rust but not rot yet. It was also from a diffrent vehicle and was of a diffrent collor.

2 - The electrical was a disaster waiting to hapen. When they (the previous tech that woked on it) took the bulkhead from the donor Rover they just cut all the wires at the bulkhead and spliced them back to the other harness in a fashion that would make your spaghetti bowl look pretty neet and orderly.

3 - The whole thing was put together crooked. The doors where closing with a large gap that could not be filled by the door seal. Even when closed, you could see daylight between the seals and the front doors.

4 - The damn thing was missing so many bolts that it was starting to worry me.

5 - The engine needed some work to make it nice. Turbo needed an overhaul, timing belt, water pump, steering box.

6 - And finaly needed to instal a Webasto Blueheat.

So with all that I figured might as well start from the bottom up.

To see the truck as it was when imported you can check my web site here : www.quebecroverimports.com

So I took a full day to strip the whole truck and take it down to the bare rolling chassi, engine and trany.

Follow-up Post:

After the whole thing was taken appart I elected to have the bulkhead, door post assembly and radiator brackets mediablasted and then galvanized. I had some experience in metal treatment but never something of that nature and that fragile.

So I did some seaching and found a place that would professionaly do the blasting and one that have large enough facilities to acomodate the bulkhead for hot zinc coating.

I picked up the parts a week ago and here is what it looks like :

[JimC]

Mmmn, lovin' it. Cant wait to see more.

[TDI Guy]

Gooks cool. I guess you are keeping it RHD huh...

[Retrofit]

Originally Posted by TDI Guy

Gooks cool. I guess you are keeping it RHD huh...

Yep, I'm actualy fond of the right hand drive, and so is the wife.

[Cirbo]

Looks like care was taken by the galvanizer. Nice results!

[TDI Guy]

I would be into a pole driving RHD. I drove one once and got all freaked out. lol

[Retrofit]

Originally Posted by Cirbo

Looks like care was taken by the galvanizer. Nice results!

Yep ! I was very satisfied by the medial blasting peoples and the galvanizer. Very professional and did an outstanding job.

Now up to the painters, they are supposed to be very good with these types of jobs. I am taking all the parts for them to be painted individualy. Then I will start going the other way ! Building back the truck.

Pat

[mikeslandrover]

Looks good, I've just got my bulk head back from the galvanisers too.

[TDI Guy]

See you guys were all afraid to dip your bulkhead.... I told you it would come out nice and BLING.....

[Retrofit]

Just took delevery of the Webaso heater friday and finaly took a look at it today and I have to admit this thing is very well built and packaged.

The instal kit I got is very complete and looks almost childish to install. Can't wait to try this baby.

Having the truck apart makes it so much easyer to install such items. Ordered 4 wiring harnesses for fog lights and also 2 for the winch (front and back) that will be seemlessly integrated to the trucks main wiring harness.

Tomorow I will be ordering all the VDO gauges and probes:

Mecanical Temp
Mecanical Oil
2 Volt meters
1 Amps meter
1 Tach

And also an Omega i32 EGT gauge and thermocouple.

I will also be putting in an IronGoat center console. Any one with recomendations on this unit ? I think it looks OEM and is not too bling.

Let me know what you all think, and suggestions are always welcome !

Pat

Follow-up Post:

Originally Posted by mikeslandrover

Looks good, I've just got my bulk head back from the galvanisers too.

Did you do the sills and piler as well ? How about the tub cross bars ?

From my experience with the galvaniser I have to admit that even as minor as it was there was a light warp in the metal in some (mostly invisible once put together) part of the bulkhead from the very high heat of the zinc baths.

Pat

[mikeslandrover]

Originally Posted by Retrofit

Did you do the sills and piler as well ? How about the tub cross bars ?

From my experience with the galvaniser I have to admit that even as minor as it was there was a light warp in the metal in some (mostly invisible once put together) part of the bulkhead from the very high heat of the zinc baths.

Pat

Yes, and I'll be getting the body cappings and under floor stiffeners done too, maybe the font shock turrets as well, but I might just fabricate some new ones.
See
http://www.d-90.com/forum/showthread.php?p=86431
for the ongoing rebuild story with my 110.

Follow-up Post:

Crew cabs are very cool, especially the Tomb Raider ones.
I did consider rebuilding mine as a crew cab

[brn24whl]

Don't forget to Galvy all the body to frame mounts and the front bumper while your at it :-) I picked my Galvy up last week and all came out well very very little warping where the heater mounts and thats it.

Eric

[Retrofit]

Originally Posted by mikeslandrover

Yes, and I'll be getting the body cappings and under floor stiffeners done too

I did not get the stiffeners done yet cause I am making a rceiver for the winch that will allow me to mount it up front or slide it out of the front bumper and slide it in the back close to the bumper with the swinging gate open and to use it in the rear as well. Once you are done with the winch you can just slide it all the way to the front against the cab and lock it there.

So I will probably end up modding those alot to make the floor realy solid.

Pat

Follow-up Post:

Originally Posted by brn24whl

Don't forget to Galvy all the body to frame mounts and the front bumper while your at it :-) I picked my Galvy up last week and all came out well very very little warping where the heater mounts and thats it.

Eric

Same warping here.

Pat

[Retrofit]

... with the pre paint body work. Even though the body was in very good condition it requiers a large amount of time to prepare for a color change. Taking all the doors apart and taking out all the windows ... finaly it is almost done.

My next step will be to address the electrical system. Being in the aviation industry I was able to get my hands on aviation type breakers. So I decided to do away with all the fuses all together. I will be putting a circuit breaker panel similar to the ones found in aircraft. Included in the panel will be all the breakers for aux lights, winch, Webasto, CB, radio, and so on ...

I understant this might take few extra hours in making a panel for this even if I am starting with a Painless 18 circuit wiring harness. But I believe this should look quite professional and be very practical to have in the long run. This panel will not have a cover and will be apparent.

Here are a few exaples of what I mean.

Let me know what you all think !

Pat

[mikeslandrover]

Looks good to me
My only thought is dust/water proofing

[Retrofit]

Originally Posted by mikeslandrover

Looks good to me
My only thought is dust/water proofing

Good call Mike, I will work on a nice stainless steel container like housing. Should give it a nice look.

Thanks I did not think about that.

Pat

[mikeslandrover]

Aeroplanes tend to keep a good deal cleaner than the inside of a LandRover. well if mine's anything to go on. It was previously owned by a farmer, I found straw in every corner on disassembly. & spent cartridges in the 110-it's ex-military

[Retrofit]

Mine was not so much of a mess but you did get me thinking, and I thank you for that.

I will be putting the breaker panel in a enclosed box, probably a Pelican case or something of that line, made of hight quality plastic and waterproofed.

Again, always glad to have your input.

Pat

[kevb]

looking good Pat, make sure you disable those thrust reversers! i am watching with interest as i just got a 110 for a wee project. i am thinking of using the body for a 100" TDi auto but if I do then I have to shelve the 11a for a while and get the lightweight finished and sold.

[Retrofit]

Well after a little baby girl and a change in primary employment, I finally got some of the parts back from the paint shop.

Here goes.