90 Chassis Change - jobs only a garage should do!

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Floyd

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  • Name: Graham Dallas
Re: 90 Chassis Change - Day 21 the rebuild
« Reply #60 on: April 15, 2012, 08:00:28 PM »
Facinating thread Dave, I think we all take our hats off to you, can't wait to see the finished product :)
Graham

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'95 Defender 110 300 Tdi

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Pilot Custard

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  • Name: Ian Stuart
Re: 90 Chassis Change - Day 21 the end is in sight
« Reply #61 on: April 16, 2012, 02:43:54 PM »
Quote
And finally ........... Get it muddy, I'm sure the to do list will grow but the end is near!
Would an organised "Treasure Hunt" at Drumclog suit?

Everything set out with a [moderately] standard Disco  :D

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Dave T

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Re: 90 Chassis Change - Day 21 the end is in sight
« Reply #62 on: April 16, 2012, 08:08:58 PM »
Absolutely
1994 Defender 90
2016 D4 Graphite

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Pilot Custard

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  • Name: Ian Stuart
Re: 90 Chassis Change - Day 21 the end is in sight
« Reply #63 on: April 16, 2012, 09:09:19 PM »
That's the plan for the driving day at the end of May ;-)

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Dave T

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Re: 90 Chassis Change - Day 21 the rebuild
« Reply #64 on: April 17, 2012, 07:06:25 AM »
can't wait to see the finished product :)

Just don't expect the bodywork to look A1, I know what I'm going to do with it so am not wasting money replacing/repairing dented panels just now, just spraying sections that are corroding, but it will be good mechaincally.  ;D ;D
1994 Defender 90
2016 D4 Graphite

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Dave T

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Re: 90 Chassis Change - Day 21 the end is in sight
« Reply #65 on: April 18, 2012, 06:42:12 PM »
 New water pump, thermostat and belt arrived today, all fitted and working just fine. It took longer to warm it up to get the thermostat to open than refit everything!

Horns also came today, just need to make up a bracket to fit them, they are certainly louder than the toot, toot of the old one ;D ;D
1994 Defender 90
2016 D4 Graphite

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Dave T

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Re: 90 Chassis Change - Day 22 the end is in sight
« Reply #66 on: April 20, 2012, 06:22:36 PM »
Quite a good afternoon today, managed to get all the brake lines secured, used the small plastic clips for the axles that are held on by tie wraps, very neat and tidy. Winch is now back in place and cables run and secured although not connected. Also secured all the breather pipes whilst in a tie wrapping mood  ;D ;D.
Next was the washer bottle, nice and straight forwards to replace and pump worked as well, bonus!  ;) ;) Also made up a bracket for new horn, and a wee cable loom for it and fitted grill, so almost looking complete from outside.
Perhaps the longest job was putting the NATO hitch on the back. As its a TD5 rear cross member it only has holes in the rear wall with captive nuts. I really didn't like the thought of being recoverd, or recovering, using just a single skin, so I drilled through from the back with a small enough drill so as to leave the bolts intact, then drilled out to 12mm from the front of it and then used long bolts right the way through the cross member so it is tight on the captive nuts and then a plate over the bolts on the inside of the cross member secured with nuts ....... god that sounds complicated, but really straight forward as I'm sure you can imagine.

Straight into the electrics tomorrow morning, hopefully straight forwards ............... fingers crossed.  ;) ;)
1994 Defender 90
2016 D4 Graphite

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Dave T

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Re: 90 Chassis Change - Day 23 the end is in sight
« Reply #67 on: April 21, 2012, 12:24:26 PM »
A very good morning, just in for lunch and qualifying. I'd been putting the electrics off a bit, just a problem with the indicators but frustrating. Started off checking switch wiring, that was ok.  Tried checking the voltages at each corner and the plugs were ok, but had very corroded connections into the lamp holders on two corners. Then a strange thing, phoned Taggarts to try and get new bulb holders, getting OEM bits from land rover, the front ones only come as a complete unit whilst the back as two parts, holder and lens. Went to get some, and they are identical bits but as I say, different ways of buying, can anyone explain that? Not too bad a pice either, less than 3 quib for the holder, so electrics all sorted now, just to finish off the dash now and that's virtually it!

So finished off the day refitting floor and tunnel. Tomorrow just need to find some screws for the dash then I may even be ready for a test drive!!!!!!!

Still loads of small bits to do but I think that is virtually back to being roadworthy again  ;D
« Last Edit: April 21, 2012, 05:38:54 PM by Dave T »
1994 Defender 90
2016 D4 Graphite

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Dave T

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Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #68 on: April 22, 2012, 05:41:58 PM »
Lots of securing lots of wee bits today, then changed the wheels and rear brake pads followed by the first venture out of the drive, wheels turned, nothing fell off, that was a bonus, brakes worked and steering ok from lock to lock.

After a spot of lunch it was a check round to make sure it all looked tight and complete (ish) then a trip to the garage and a chance to get it fully warmed up a bit of a run, all seems good.

Still loads of wee bits to do like door cards and fittings, headlining and stuff like that but its looking good for the GRR next weekend but without all the normal defender luxuries  ;D ;D ;D ;D
1994 Defender 90
2016 D4 Graphite

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allyipod

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  • Name: Ally Conlon
Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #69 on: April 22, 2012, 05:51:17 PM »
Great job Dave in under a month. Fantastic!!
mm0pod

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genem

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  • Name: Gene Maxwell
Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #70 on: April 22, 2012, 06:50:25 PM »
Ver well done ! Superb effort Dave. Looking forward top seeing it "in the Flesh".
If its not broken you are not trying hard enough....

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Buffalo Bill

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  • Name: Bill Conner
Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #71 on: April 22, 2012, 07:30:09 PM »
well done mate i take it nothing fell off lol ;)

cheers Bill
1989 110
1990 90
1988 90
1972 V8 WOOP WOOP

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Dave T

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Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #72 on: April 22, 2012, 07:39:29 PM »
Not yet....... and the back end felt connected  :o :o don't get me wrong, there is loads left to do but it is working again and can be done slow time now. It certainly helped ticking off jobs before starting the change, like replacing the bushes, discs, wheel bearings etc.
1994 Defender 90
2016 D4 Graphite

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mel

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  • Name: Patrick McInally
Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #73 on: April 22, 2012, 09:55:52 PM »
Great, well done you ve inspired many of us to try it ourselfs, been a great post to fallow,thanks for sharring.NOW your neibour can have their drive back.

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bairnr

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  • Name: David Russell
Re: 90 Chassis Change - Day 24 test drive complete, nearly there
« Reply #74 on: April 23, 2012, 12:56:35 PM »
well done in getting it back on road as quick the small jops can be done as you go along
2000 discovery td5
1989 LR Defender 90