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My new project Land Rover 90 (its not a defender)
tomgregory2000 - 11/10/11 at 07:33 PM

Well after selling the insane 321bhp viento ive decieded to take a much much much slower pace of life with my new project.

And here it is


well this is what it used to look like


tomgregory2000 - 11/10/11 at 07:41 PM

A few more pics before i start

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You can see the tell tell signs of rust on the bulkhead
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Oh look some more rust
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Seats are a bit nackered
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Wheels244 - 11/10/11 at 07:45 PM

I've got one a bit like that - was virtually standard until I got my hands on it

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tomgregory2000 - 11/10/11 at 07:47 PM

Oh well time to remove some of the big bits

Got to start somewhere and find out what is lurking under the bodywork

Might as well start with an easy bit
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And then a bigger bit (it only took 2 hours to remove)
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This is the point when i decieded that i would be converting to soft top
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And then to get the back door off
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tomgregory2000 - 11/10/11 at 07:49 PM

It does look alot better without the roof
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tomgregory2000 - 11/10/11 at 07:52 PM

quote:
Originally posted by Wheels244
I've got one a bit like that - was virtually standard until I got my hands on it

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Now that is a good set of tyres and looks very tidy


Stott - 11/10/11 at 07:56 PM

quote:
Originally posted by Wheels244
I've got one a bit like that - was virtually standard until I got my hands on it

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YES!!! That's epic!!!


Tom, good luck with it, always fancied one myself


Wheels244 - 11/10/11 at 07:58 PM

quote:
Originally posted by tomgregory2000
quote:
Originally posted by Wheels244
I've got one a bit like that - was virtually standard until I got my hands on it

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Now that is a good set of tyres and looks very tidy


I've just fitted wider arches to cover them ( 35x12.5x15 )
Just about to fit hard top sides with windows similar to yours - I've just tinted the side windows ( pimp my ride )

What's the plans for yours ?
Looks like a good base for a project.


tomgregory2000 - 11/10/11 at 08:04 PM

Now its time to get the doors off
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Then off with the bonnet
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And then to look at removing the front wings
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And the other side (much easier when you have done one before)
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Look no wings (it aint no RED BULL)
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HowardB - 11/10/11 at 08:10 PM

I did that with a series II, it started as a "let's have a look under the wing" and ended up as a chassis up rebuild,....

great fun, still got it!


richardh - 11/10/11 at 08:13 PM

ditto, done a series 3 full rebuild and a range rover classic and am now on my 2nd rangey classic.
she's stripped right down to just half a floor pan and some seats and on wheels right now


tomgregory2000 - 11/10/11 at 08:17 PM

quote:
Originally posted by Wheels244
quote:
Originally posted by tomgregory2000
quote:
Originally posted by Wheels244
I've got one a bit like that - was virtually standard until I got my hands on it

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Now that is a good set of tyres and looks very tidy


I've just fitted wider arches to cover them ( 35x12.5x15 )
Just about to fit hard top sides with windows similar to yours - I've just tinted the side windows ( pimp my ride )

What's the plans for yours ?
Looks like a good base for a project.



Im keeping it simple

Its getting a 300tdi (yes it has one in allready) hooked up to a auto gearbox and positioned in the correct place for the 300 so i can fit standard land rover parts.

I have a hydraulic winch for the front

New suspension

New soft top roof

Its going to be nice but not too nice so i dont mind driving along over grown greenlanes

Well EVERY bit of steel is being galvanised and i mean EVERY bit i hate rust and it has no place on this world

I was thinking of fitting 35" tyres on my 18" pro comp extreme but i might just fit 285/70/18 bfg at's (come in at just over 33" as i have my set of 305/70/16 grizzly claws sat in the garage


richardh - 11/10/11 at 08:49 PM

no, go 37's and don't look back


NigeEss - 11/10/11 at 10:24 PM

quote:
Originally posted by tomgregory2000
Its getting a 300tdi (yes it has one in allready) hooked up to a auto gearbox and positioned in the correct place for the 300 so i can fit standard land rover parts.




Coming along nicely

I've got a 300tdi with autobox in a Disco I'm scrapping.
It's got the edc pump which can be made to work in a 90 or stick a manual one on.

Open to sensible offers.


T66 - 12/10/11 at 12:11 AM

Keep posting up your progress, I did a 1965 S2 a few years ago - body off, chassis repairs etc, bulkhead rotten ..


Loved it



Next 4x4 weapon is going to be a Discovery TD5 -


Irony - 12/10/11 at 07:27 AM

Looks like its going to be epic mate. There is just something about Land Rovers that are awesome. The more dents and scratches on a Landy means only more character.


02GF74 - 12/10/11 at 09:34 AM

It would be rude not to post a photo of mine.

must get it MOTd and rive it somewhere ....


blakep82 - 12/10/11 at 09:40 AM

wow this is going to be awesome when did you start stripping it?
i really really want to do one sometime soon...


tomgregory2000 - 12/10/11 at 10:12 AM

02GF74 that look tidy and it looks like salisbury plain to me?


tomgregory2000 - 12/10/11 at 10:14 AM

quote:
Originally posted by T66
body off, chassis repairs etc, bulkhead rotten ..





That sounds like mine


tomgregory2000 - 12/10/11 at 10:18 AM

quote:
Originally posted by blakep82
wow this is going to be awesome when did you start stripping it?
i really really want to do one sometime soon...


I started about 2 months ago and only just got around to getting the pics off the camera. Will be putting up some more pics soon.
They are great (and simple) to work on but you do need space, about 3 times the space of a land rover is best and with the bodywork being aluminum its nice and light, just big


tomgregory2000 - 12/10/11 at 10:21 AM

quote:
Originally posted by NigeEss
quote:
Originally posted by tomgregory2000
Its getting a 300tdi (yes it has one in allready) hooked up to a auto gearbox and positioned in the correct place for the 300 so i can fit standard land rover parts.




Coming along nicely

I've got a 300tdi with autobox in a Disco I'm scrapping.
It's got the edc pump which can be made to work in a 90 or stick a manual one on.

Open to sensible offers.


Ive got myself a 1995 disco as my donor that came with 12 months mot and 6 months tax so am running that as my everyday car till i need the bits from it, so its a no from me


tomgregory2000 - 12/10/11 at 05:07 PM

Well here are a few more pics

Start on the interior (well if you can call it an interior)
Passenger side
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and then the drivers side
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and then onto the luxury seats
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seat base out
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and then with the back and frame
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and the other side
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and out with seat box
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which had very little rust on the battery box and the rest is alloy


tomgregory2000 - 12/10/11 at 05:11 PM

Now its time to look at the rear tub
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and just like that its off
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not looking too bad 'yet'
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a 'little' bit of rust, but i knew about that
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tomgregory2000 - 12/10/11 at 05:23 PM

im going to leave the back end for now and look at the bulkhead and windscreen
i was impressed that the windscreen hinges still worked
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and off with the screen
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What do we have here?
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rust, rust, rust and air and fibreglass and mastic
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and the door pillar
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start to remove the dash
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off it comes
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oh look more rust
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NigeEss - 12/10/11 at 09:29 PM

quote:
Originally posted by tomgregory2000
quote:
Originally posted by NigeEss

I've got a 300tdi with autobox in a Disco I'm scrapping.
It's got the edc pump which can be made to work in a 90 or stick a manual one on.

Open to sensible offers.


Ive got myself a 1995 disco as my donor that came with 12 months mot and 6 months tax so am running that as my everyday car till i need the bits from it, so its a no from me


Can't blame me for asking



Is yours the EDC pump ? I've a fair bit of info for making that work.

Do your tyres scrub the chassis on lock and articulation with having the Freestyle alloys ? Mine did
so I've had to fit 30mm spacers. Using 235/85 tyres.


tomgregory2000 - 13/10/11 at 08:40 AM

quote:
Originally posted by NigeEss
quote:
Originally posted by tomgregory2000
quote:
Originally posted by NigeEss

I've got a 300tdi with autobox in a Disco I'm scrapping.
It's got the edc pump which can be made to work in a 90 or stick a manual one on.

Open to sensible offers.


Ive got myself a 1995 disco as my donor that came with 12 months mot and 6 months tax so am running that as my everyday car till i need the bits from it, so its a no from me


Can't blame me for asking



Is yours the EDC pump ? I've a fair bit of info for making that work.

Do your tyres scrub the chassis on lock and articulation with having the Freestyle alloys ? Mine did
so I've had to fit 30mm spacers. Using 235/85 tyres.


Its not got the EDC pump which was a nice supprise but even if it was i have the 300tdi that im removing from the 90

With the grizzly claws i did catch the radius arms but no body contact, with the alloys on there is no issue on body or chassis but i have 30mm spacers fitted and have adjusted the stops on the hubs

edit: mine has a 2" lift

[Edited on 13/10/11 by tomgregory2000]


tomgregory2000 - 23/10/11 at 12:31 PM

well i thought i would give a little update while at work

the start of removing bits off the bulkhead ready to be removed, they are heavy enough on there own
start by removing the pedals
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and just like that the brake pedal is off
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and now off with the clutch
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And removing the wiring
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Almost ready to remove the bulkhead
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And look its off
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tomgregory2000 - 23/10/11 at 12:35 PM

Its not looking too bad and rather sound, lets see if we can find any rust (there has to be some it is a landy after all)

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Oh look what i found on the offside front out rigger
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BUT the rest looks very sound which was a nice supprise
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Just everything has a nice light coating of mud


tomgregory2000 - 23/10/11 at 12:42 PM

Now with the bulkhead off the next challenge was to remove the steering wheel, was a bit of a b1tch to remove

Two home made pullers later and lots of swearing and
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Now i can remove the switch gear and look at removing the steering colum
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And its all off
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tomgregory2000 - 23/10/11 at 12:50 PM

And about this time i bought myself a rather nice mig welder and then set to work looking at the "rust" issue

Now i have not done any welding in 8 years, the last welding i had done was back at college

First job is to remove the rust back to good metal
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Im doing it in 2 pieces as there is a kink along one side

The first plate goes in
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And then time to fit the second one
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And then grind it all flat and make it look good
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tomgregory2000 - 23/10/11 at 12:55 PM

So lets take a look at the back end

I was planning to remove just the rear crossmember and replace that so lets see what hides under the multipull patches

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Its not getting any better
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So i decieded to remove the whole thing

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After
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Can you tell the difference?


tomgregory2000 - 23/10/11 at 01:17 PM

With the back end removed i decieded to make my own replacement with the help of the old man so while that is getting punched out ill remove more bits

Off with the dampers
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Fuel lines
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and then time to remove the bits still attached to the engine
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Almost free, just the oil cooler lines
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Then out with the rad and intercooler
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And off with the slam pannel/rad support
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More good condition chassis
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tomgregory2000 - 23/10/11 at 01:26 PM

The start of the replacement crossmember

First job is to weld on the tabs that fix onto the rear tub
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FINISHED!!!!!!!!!!
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yeh right

but it proves it fits and my measurements were correct
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Time to prep the chassis for the extensions
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Removing the outer skin of the chassis
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Mock up just to make sure its all going to fit
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And my towbar fixing spreader plate that is going to be fitted to the inside of the crossmember
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tomgregory2000 - 23/10/11 at 01:29 PM

Time to look at getting the engine and box out as the weather is good

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it was a case of removing the engine and moving the chassis out of the way and then plonking the heavy engine and box straight down

Look no engine
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tomgregory2000 - 23/10/11 at 01:32 PM

Went off to the 4x4 clearout at newbury and got myself an good condition bulkhead, only £265

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almost no rust on this one


tomgregory2000 - 23/10/11 at 01:37 PM

Now its time to look at the gearbox crossmember and see what lurks behind where it fits to the chassis as rust likes to form between the mating surfaces

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crossmember out
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its a good job im not using this one

ns chassis rail
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not too bad bit of surface rust but nothing major

os chassis rail a different story
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there should only be 4 holes in this section, not 5

Might as well remove the gearbox mounts as well
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tomgregory2000 - 23/10/11 at 01:42 PM

Lets get the hole repared

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weldings getting better
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and grind it flat
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stand by for more updates


Wheels244 - 23/10/11 at 01:52 PM

Looking good

You've made a good job of the rear crossmember.

I've just fitted a Disco rear axle for better brakes after reconditioning it.

I had to buy two new Terrafirma shocks thanks to the previous owner cross threading one of them leading to shearing of the threaded spindle on one of them.

I fitted a new adjustable A frame ball joint - and yes, the old one was a bitch to get out.

Made up and fitted new rear brake pipes.

Once that was done, I was turning the Landrover around and the steering drop arm ball joint shears - 5 hours to change yesterday ! You might want to look at yours whilst you've got such good access.

I put the finishing touches to it this morning, did a safety check, greased the prop shafts and steering arms etc then took it out for a test drive.

And then the clutch starts slipping ...............................


coozer - 23/10/11 at 03:02 PM

What size are them BF's on it at the moment please?


tomgregory2000 - 23/10/11 at 06:51 PM

the bf are no longer on it, sold um to a mate to fit on his disco, they were 245/75/16 about 31" overall height

too small for a defender but a nice size on a disco.

Its back to the 305/70/16 grizly claws while i work on it


Peteff - 23/10/11 at 08:48 PM

My friend's lad rebuilt a series 2a onto a galvanised chassis and replaced the engine with a 200tdi, I wired it for him with a new loom and some other bits. He can't afford to run it yet as he is not 18 till later this year and it's a lot of money to insure him.


tomgregory2000 - 25/10/11 at 08:32 PM

Another little update

Reinforcing plates inside the rear crossmember
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extensions taced in place
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And all welded
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tomgregory2000 - 25/10/11 at 08:39 PM

Now on with the back plate, no mud traps for me thank you

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And these are the jacking tubes and end covers
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Jacking tubes welded in place
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And the back plates in place, welded and blended in
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And the front of the jacking tubes ground down
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tomgregory2000 - 25/10/11 at 08:43 PM

And now for the reinforcing plates

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And fully welded in and plug weld holes drilled
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tomgregory2000 - 25/10/11 at 08:45 PM

now its time to fix it on to the rest of the chassis

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MakeEverything - 25/10/11 at 09:41 PM

Good bit of fabrication there mate. Spot on.


bertie_bas205 - 26/10/11 at 03:03 AM

It's a labour of love huh???

I have a few Landys myself.....

I dunno how to put pics up on here...

Are ye on the DIFFLOCK forum??

Keep up the good work,






Bertie.


blakep82 - 5/1/12 at 06:33 PM

any more photos?!


T66 - 5/1/12 at 08:01 PM

Reading this thread again, I really want another Landy.


Coming along really well


tomgregory2000 - 5/1/12 at 08:18 PM

i will try and update soon, have made some progress but not as much as i would have liked though


tomgregory2000 - 9/2/12 at 09:37 AM

Ok, ive managed to finally get some more photos from my camera onto my computer and then onto here

Now im a little disappointed with the progress but its taking longer than planned

More welding of the rear end, these are the towbar brackets
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Ive yet to do the welding on the underside of the chassis, this will be done when i flip the chassis over


tomgregory2000 - 9/2/12 at 09:41 AM

Now time to look at the new engine mounts (i hope these are in the correct place)

Old ones removed
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Cleaning up and marking out for the new ones
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Tack in place
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And then fully weld in, no going back
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Once agen the underside will be welded once the chassis is flipped over


tomgregory2000 - 9/2/12 at 09:47 AM

Now its time to remove the old axles

These ones are 10 spline axles and wont be used as i have a nice set of 24 spline ones from my donor disco

First off with the springs
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One free axle that just rolls out of the way
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Now time to remove the rear axle
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One chassis, no axles
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And as if by magic the chassis is flipped over (its a little heavy)
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And welded on the underside
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Hugh_ - 9/2/12 at 01:32 PM

Stunning, note to self, must do a landy project at some stage


MakeEverything - 9/2/12 at 01:45 PM

Me too, when iet my 200m2 workshop after the lottery win!


tomgregory2000 - 9/2/12 at 01:51 PM

You do needs LOADS of space,im using half of my back garden, garden is about 80' x 30' and half of the single garage. There are bits of landy everywhere

Ive got more photos to go on tonight as that progress only takes me upto the end'ish of last year.


tomgregory2000 - 9/2/12 at 07:27 PM

Ok, more update

Oh no where has my chassis gone
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Oh well lets go off roading till i can find my chassis, where did i leave it.....
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Right now i must try and find my chassis, its not the smallest thing to loose


tomgregory2000 - 9/2/12 at 07:30 PM

IVE FOUND IT!!!!!!!!!!!!!!!

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mmmmmmmmmmmmmmmmmmmmmmmmmmmmm shiny galvanised sexyness!!!!!!!

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tomgregory2000 - 9/2/12 at 07:33 PM

Now its time to hide the silver galvanised surface with a load of black paint to make it look as factory as possible

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Im missing some pics of it the other way up


omega 24 v6 - 9/2/12 at 07:35 PM

More photo's more photo's NOW


tomgregory2000 - 9/2/12 at 07:45 PM

Now with the chassis done its time to look at the axles which ive removed from my disco donor

I had the axles shot blasted and hot zinc sprayed, got to do things propperly and all that

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A few suspension components that have been painted
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And my new cranked trailing arms, thank you mr gwyn lewis, these are monsters, twin wall with a propper lifetime warranty
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First coat of thinned paint
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And now with the top coat
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tomgregory2000 - 9/2/12 at 07:50 PM

These are the rear hubs just cleaned up and painted and fitted with brand new genuine wheel bearings

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One side complete with drive shaft installed, 24 spline and nice and strong
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And now for the other side
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Yep it looks just like the other one


tomgregory2000 - 9/2/12 at 07:53 PM

Nice new a frame ball joint fitted
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these require a 20ton press to fit, the one that i have fitted is adjustable and greaseable so as it wears i can nip it up
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tomgregory2000 - 9/2/12 at 08:02 PM

Time to fit the rear axle to the chassis

First job is to put some wheels on it (i will not be using these tyres)
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On with the trailing arms
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Fitted with new galvanised spring seats
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And on with the new +2 springs (with the mandatory doing some work picture)
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Fitting it to the chassis, as you can see the marquee that i was building it in seems to be missing , it got damaged beyond repair in the strong winds at the begining of the year
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Thats all for now


omega 24 v6 - 9/2/12 at 08:12 PM

Hope you are going to keep us updated.
I WANT ONE


Bluemoon - 10/2/12 at 09:42 AM

I like the hot zinc spray something I thought of doing on the Indy chassis, found someone that would do it as well, wished I had (add's some weight and makes welding a PITA latter though)..

[Edited on 10/2/12 by Bluemoon]

[Edited on 10/2/12 by Bluemoon]


SeaBass - 10/2/12 at 11:10 AM

I'm lusting after a 90 ATM... I must be getting old. A mate keeps whispering Land Rover in my ear everytime I see him.


blakep82 - 11/4/13 at 08:43 PM

Whats happened?! Whats going on? News please!


Bluemoon - 12/4/13 at 09:09 AM

quote:
Originally posted by blakep82
Whats happened?! Whats going on? News please!


Tea break? Most projects seem to have one...


TimC - 12/4/13 at 03:39 PM

I'm still wrestling with selling my SIII 88". It hadn't run for two weeks up until last Sunday and I needed to take rubbish to the tip - it started in a heartbeat as it always seems to. Great trucks. I can only imagine that the coil-sprung models are even better.

If I didn't have a kit car project, I'd be doing a retro-style Landy.


DarrenW - 12/4/13 at 04:40 PM

Seems to be a bit of time lag / thread revival here, but a great resto project nevertheless.


Ive got a fully rebuild and re-chassis'd 90 Defender. Fantastic vehicle but probs going to sell it soon.