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  #1  
Old September 28th, 2015, 09:25 PM
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Grover freed from the Feds. Now what?

I recently got my Defender 110 back from two and a half years in the Federal Pen. Click here to see the whole story: Grover and the Angry Feds.

Great. So I got it home and started looking and taking pictures. Now, it was no cream-puff to begin with. It leaked a little at the sunroof and in the back, but not in the dash. In the pics, the putty you see ner the windscreen is my handiwork. So it was slightly rough before, but drive-able. But now, I am overwhelmed by the issues. From what I can see, here is the state of Grover:
  • Stream leaks rain down through the entire dash
  • Rusted floorboards
  • Stream leaks rain through sunroof at left and right
  • Bucket leaks rain in right rear roof
  • Rust around hinges
  • Peeling/cracking windscreen trim
  • Blown turn/hazard relays (replacement in-progress)
  • Splitting tires, right front deflates.
  • Rust in engine/bay
  • Rust on underside of bonnet
  • Rust on frame (appears to by surface?)
  • Dead unchargeable battery (no problem)
  • Broken stereo antenna (no problem)
  • Slipped diff-lock (fixed)

Even with all that, Grover does run and does move. I'm trying to get it worthy of a state inspection so I can get the plate legal again.


So, now the plea for help...I need to know what needs to be done to make the vehicle drive-able again without significant rain pouring in and relatively safe and reliable. I know, I know...no such thing in a Defender, but if I can, I want to preserve this convict survivor.

So if you would look at my detailed pictures, just let me know what you think I should do to fix it. I'm looking for close-to-stock repair/replacement. Like the following:
1. New tires, brand XXX bought from YYY for about $$$
2. New bulkhead bought from YYY for $$$, take to a shop to have them ZZZ.
...

Here is a link to the pics: HELP GROVER!. Pics are hi-res if you click to zoom.

Thanks in advance for helping me and my pitiful Grover. Once I (hopefully) get some advice from you wise Roverites, I'll summarize and decide if I can afford it.
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  #2  
Old September 28th, 2015, 10:04 PM
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IMO, that rust is much older than 2 years....cant blame the Feds for that...


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  #3  
Old September 28th, 2015, 10:31 PM
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I did acknowledge some of the rust was there before (including some putty I applied). I'll dig up a couple "before" pictures. I'm claiming that 2.5 years sitting outside made it much worse, ir maybe just exposed what was already there. Regardless, I'm still looking for advice on how to fix it.
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  #4  
Old September 29th, 2015, 09:01 AM
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I went back and looked at the "before" pictures and in each case, there was some rust already there. Sitting so long just made it all worse. Enough to bring rain down through the dash which I see as the biggest problem.
Here is an example.


So again, what should I do to get it back in shape (better than before)?

Thanks,

Fin
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  #5  
Old September 29th, 2015, 09:13 AM
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Quote:
Originally Posted by JSBriggs View Post
No, that looks like Aarons newspaper and bondo trick. I might have to go dig for that thread.

-Jeff

Well....I'm not saying it is or isn't....some pretty shoddy repairs come from across the pond, too--- OP, did you find any newspaper yet?

If so, is it from Wilmington?

Anywho...there are repair pieces for that area of the bulkhead.

.
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  #6  
Old September 29th, 2015, 11:32 AM
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I'm looking for details on those repair pieces. What, where, and how much? Is there a checklist of what needs to be done?
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  #7  
Old September 29th, 2015, 11:44 AM
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Bulkhead Right Hand Drive - YRM Metal Solutions
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  #8  
Old September 29th, 2015, 11:47 AM
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A lot of answers depend on what work you'll be doing yourself.

Lots of videos here
https://www.youtube.com/results?sear...ulkhead+repair


.
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  #9  
Old September 29th, 2015, 11:47 AM
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Take the wings, windshield, bonnet and the floor boards off. You can then strip/sand back the paint and see what you have to deal with and see if you can repair in place or not.
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  #10  
Old September 29th, 2015, 12:00 PM
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Quote:
Originally Posted by JSBriggs View Post
No, that looks like Aarons newspaper and bondo trick. I might have to go dig for that thread.

-Jeff
Please do.

Is that spray on bed liner on the inside of the footwells? Used to probably cover that rust. That bulkhead looks pretty bad but like Jeff said, that started longer than 2 years ago.
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  #11  
Old September 29th, 2015, 12:02 PM
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YRM metal sells the repair pieces.

It does not look terminal by any means. I would just figure out what it needs for an inspection and drive it around as is after fixing the inspection issues. The leaks should be easy enough to mitigate. New vent seals ($20 each, buy the series style), I have no idea about the sunroof, but I would check to make sure the drains are clear.

Some rubbing compound and/or polish will bring the paint back to acceptable levels of shine.

------ Follow up post added September 29th, 2015 12:03 PM ------

On tires, if you want to keep it stock, 235 85 R16 is a great size for a 110. I would buy BFGs, but I am a conventional sort of guy. I might also look for a set of stock steel wheels too.
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  #12  
Old September 29th, 2015, 08:32 PM
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To all who responded: Thank you for the great advice! I would try to do as much by myself as possible, but I can't weld.

The bed-liner coating all over was an add-on when I got it. It may have covered up issues, but I won't know until I dig deeper (as advised here). I'll also let you know if I find dang newspaper.

What is a BFG tire? BF Goodrich?

I'd appreciate any more input. How about the top where it meets the sides? Is it usually sealable? If so where? I've sealed the top everywhere I can think of and it still pours water into the back like it has a hidden gallon reservoir.

How about the frame? Powerwash, de-rust (Por-15?), and coat with something? If so, what?

Keep it coming. Thanks, Fin
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  #13  
Old October 1st, 2015, 06:57 PM
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Passed the state inspection and got a new plate! Any more advice please?
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  #14  
Old October 1st, 2015, 07:12 PM
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Drive it. Get the cobwebs out of it. Its bones must be stiff after sitting so long. Fix the stuff that breaks.
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  #15  
Old October 1st, 2015, 11:52 PM
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Quote:
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Drive it. Get the cobwebs out of it. Its bones must be stiff after sitting so long. Fix the stuff that breaks.
Yup.
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