Suggestions & Advise Please - Rebuilding 1997 Def 90 300

[landroverclan]

Hi All ;

I really need your help and advice in rebuilding my Def 90. My initial
aim is just to get it up and running for now, and necessary repairs
and refurbishment as and when required. My early observations (please
add yours as well as I surely do miss lots of things !!) are as
follows :-


1- Lots of missing parts i.e. alternator, belts, brake caliper, master
cylinder, steering rod etc.etc.  These I am sourcing right now.
2- Previous driver mentioned that the gear box is not in good
conditions. actual problem unknown.
3- Part of chasis and rear members badly corroded and rusty. I plan to
dismantle panel by panel, and repair the chasis by addtional welding
with stiffener plate etc., probably galvanise it.  But how to go about
it i.e. dismantling work, i have no idea. I have taken out the bed,
but the difficult part is to 'break' all those welded spots.
4- Engine conditions unknown.  Probably last on the road was in
September 2005.


I have my own facilities of welding and all those tools and resources
(grinders, air compressor, water jet, welders, fitters, riggers/
helpers, 50 tonne rig etc. etc.).
So whatever work related to steel i.e. repair/welding the chasis, fabrication of steering guards etc. can be done using my surplus steel plate etc.
Time is not a factor, as I will only do this when my resources are
free.  That's why i want to do it right the 1st time (if there's ever
the right way to rebuild LR).
For the engine, gear box etc., my freelance mechanic will do it as and
when the parts are available.


I am still reading all those related subject in the previous posting. Apologies if my question is repeating what have been discussed before. But u can help me by pointing to the right direction.


So guys, please help me and advise me based on your experience no
matter how small or BIG it is. I do appreciate all the help.


Please follow the links below for the photos.


http://www.picasaweb.google.com/hishamclanpiling


I Thank You !!


Cheers

[Nick666]

Why not just get a new chassis galvanised and stick it all on that? Sounds like you're pretty much going to have to take it apart anyway so that's the 'best' route I'd have thought (from a complete noob's point of view anyway!)

Also, for later, maybe galvanised cappings since if it's anything like mine they're about the only bit that's going at the moment.

[landroverclan]

Nick and all ;

Here u can't get any factory galvanised chasis for LR, my options are only these :-

1- repair the chasis by welding, add steel plate, wire brush it and send for hot dip galvanising (maybe about RM$2.00 per kilo, probably 30pence/kilo).

2- buy a USED chasis from chop shop, and galvanised it.

Best option is no. 1, subject to further detail checking of the chasis once dismantled. If it's really bad, then option 2.

Guys, any tips how to dismantle and expose the chasis further ??

[Cassillis]

I told you you'd get a reply on here. Wait a while and there will be some more advice along soon.  I'm not qualified to comment as I'm still learning my way around these vehicles.  :roll:

[SteveG]

Have a look at the tech archive here...
http://forums.lr4x4.com/index.php?showforum=15

You'll find plenty of articles on replacing rear crossmember, stengthening chassis, chassis repairs, outriggers etc that should help you.

What welds are you talking about? I'm no expert but lifting off the body is a bolt off job.

Cheers

Steve

[07DefenderSeb]

Nick and all ;

Here u can't get any factory galvanised chasis for LR, my options are only these :-

1- repair the chasis by welding, add steel plate, wire brush it and send for hot dip galvanising (maybe about RM$2.00 per kilo, probably 30pence/kilo).

Where are you in the world?

[landroverclan]

I'm in Kuala Lumpur, Malaysia.
And the world is getting smaller each day.

[landroverclan]

Have a look at the tech archive here...
http://forums.lr4x4.com/index.php?showforum=15

You'll find plenty of articles on replacing rear crossmember, stengthening chassis, chassis repairs, outriggers etc that should help you.

What welds are you talking about? I'm no expert but lifting off the body is a bolt off job.

Cheers

Steve

Steve, thanxs a lot for the link, great help, now need to look for the related subjects.

Normally welding with electrode using diesel driven welding set, or the one using wire/coil, MIG i think. Me no expert as well, but my welder is.

All the bolts and brackets are probablly rusted and bent, maybe need to grind it off or oxy-cut.

[SteveG]

there's an index at the top of section that should help

Have fun

Steve

[landroverclan]

Hi all !
I have dismantled the roof and the rear portion (see photos).
What shall i dismantle next ??
I need to open up everything as i need to repair the chasis, all panels to be sent to the panel beater etc.
Surely some of u done this before, maybe too easy for the experts, but this is my 1st time ha..ha...ha...!!

Cheers !!