1983 110 rebuild...sort of... - Defender Source
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  #1  
Old June 18th, 2009, 04:09 PM
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George Kase
1983 110 200Tdi CSW LHD
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1983 110 rebuild...sort of...

Thought I'd start this thread to put a stake in the ground that I'm committing to actually doing this. Got a 1983 110 RHD with a 4 cyl petrol engine in it and am taking it apart to check it out, cleaning it up, replacing what needs replacing, putting in a 200Tdi and then, hopefully, putting it back together again.
The frame looks solid and the only areas of rust are a coupl of minor spots next to the floor boards and the bottoms of the door frames, but looks do-able. I'm thinking of repainting it also...maybe Arles Blue, maybe leave it white...
enclosed is a pic in progress (which has halted while I replace the U joints on the 95 D90)...note the giant yellow Tupperware container which the 200Tdi was shipped in from England...it'd make a great hot tub or something...
George
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  #2  
Old June 18th, 2009, 04:42 PM
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Looks to be in nice shape George. Good luck!
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  #3  
Old June 18th, 2009, 11:42 PM
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Todd Miller
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nice looking 110/ who did you get the engine from, CSW? What kind of price if you don't mind telling?
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  #4  
Old June 19th, 2009, 06:48 AM
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George Kase
1983 110 200Tdi CSW LHD
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thanks Ron...Todd the kit was around $2400 which does not include a trans since I'm using the LT77 that the truck came with...
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  #5  
Old June 19th, 2009, 05:24 PM
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Pat
1984 110 CrewCab 200Tdi
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On the safe side ...

Correct me if I'm wrong but the diesel LT77 is more beefed up than the V8 LT77 at least that is what I was always led to believe.

Cool project, you will love the 200tdi sweet little engine ! Good luck and let me know if you need pics of engine bay from a 200tdi.

Pat
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  #6  
Old June 19th, 2009, 08:32 PM
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George Kase
1983 110 200Tdi CSW LHD
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Pat...don't know that there were different LT77s...maybe someone more plugged into the history side would know...but, yes, would love to see the engine bay layout! I have a 300tdi and for this project I wanted something without a serpentine belt...folks that have 200tdi all seem to love em...plus...it was a bit cheaper...
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  #7  
Old July 15th, 2009, 09:54 AM
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George Kase
1983 110 200Tdi CSW LHD
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a little bit o progress

I finally got all the bolts off and have the body on jacks and saw horses..am going to try to hook up a couple of simple rope hoists this weekend and lift it a few more inches to clear the tires and then roll the chassis into the driveway for cleaning and painting...I will pull together for future seekers of knowledge a list of all things to disconnect prior to attempting to remove the body from a 1983 110 and post in a couple of days...
obviously, more to come!
attached are two pix of support/jacking scheme employed so far...rear of body supported by rope tied to ceiling joist.
Note lack of any rust on A-pillars and B-pillars...surprised me.
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  #8  
Old July 15th, 2009, 10:10 AM
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You have gone this far, you should get the frame blasted and galvanized.
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  #9  
Old July 15th, 2009, 10:17 AM
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I see some rust in the footwells, what are your plans for the bulkhead? Are going to patch it and paint it? Patch and galvanize? replace it?
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  #10  
Old July 15th, 2009, 10:22 AM
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George Kase
1983 110 200Tdi CSW LHD
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so far I'm planning on cutting out the footwell rot and patching...there is no rust anywhere else on the bulkhead and it looks like the footwell panels are easily patched...I'm not sure I want to dive as deep as stripping the whole frame and figuring out how to get it to a galvanizing place and then trying to figure out how to put it all back together...hell, I'm just thrilled I've gotten this far...
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  #11  
Old July 15th, 2009, 11:10 AM
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Quote:
Originally Posted by Gkase
so far I'm planning on cutting out the footwell rot and patching...there is no rust anywhere else on the bulkhead and it looks like the footwell panels are easily patched...I'm not sure I want to dive as deep as stripping the whole frame and figuring out how to get it to a galvanizing place and then trying to figure out how to put it all back together...hell, I'm just thrilled I've gotten this far...
The hard part is done Gkase. Being in the chicago area, I am sure there is a galvanizer nearby.
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  #12  
Old July 16th, 2009, 09:40 PM
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Dennis Lynch
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Jack on top of milk crate is great. Looks like something I would do
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  #13  
Old July 17th, 2009, 04:07 AM
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I believe that's illegal!
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  #14  
Old July 17th, 2009, 04:52 AM
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whats behind the five bar on the rear quarters ?
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  #15  
Old July 23rd, 2009, 06:13 PM
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George Kase
1983 110 200Tdi CSW LHD
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behind the five bar is just panel...guess someone thought it looked good at some point...here's the latest pic...got the new engine out of the crate and the old engine out of the 110...am now dealing with all the chassis surface rust and will strip the bulkhead of parts for cleaning and paint before putting the 200Tdi in to it...sent the fuel tank out for testing and cleaning...next comes the RHD to LHD conversion then bolt in the Tdi...
more to come...
George
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  #16  
Old July 23rd, 2009, 09:11 PM
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have to agree with Ron at this point you should galvanize the chassis.

You have 99% of everything removed you might as well go ahead and dip it.
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  #17  
Old July 23rd, 2009, 09:33 PM
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Quote:
Originally Posted by dave_lucas
have to agree with Ron at this point you should galvanize the chassis.

You have 99% of everything removed you might as well go ahead and dip it.
You can get the rest of the stuff off in a day, tops. Send it to be blasted and dipped. Should not be that much money. $1000 tops and worth 3x that in resale or avoided future headaches. And I know it is shipfitter's disease, but I would fix and dip or replace with new dipped the T-pieces. I can understand not disassembling the bulkhead and dipping it, but everything else ....

Ron
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  #18  
Old July 23rd, 2009, 11:51 PM
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It is so cool to see a Defender taken down to this stage. Must be very rewarding to know you did it! Hope you remember where it all goes.
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  #19  
Old July 24th, 2009, 01:41 AM
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George you really got it stripped down quickly. I am sure it will be gratifying when it all comes together.
I meant to call you back but I got my question answered today by Joe A.
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  #20  
Old July 24th, 2009, 05:35 PM
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George Kase
1983 110 200Tdi CSW LHD
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As for galvanizing...it just can't be in the cards for me...money and time won't permit...as for looking at it now that its all apart, here's a rather surprising observation as I review the past couple of weeks...it isn't as bad or complicated as you might think to pull it apart. It was totally overwhelming as I started out, but I just determined to keep at it one rusty bolt at a time and pretty soon, it was all apart. Its a rather ingenious design in that the driving systems and the coachwork are basically seperate. And if you have ever really worked on the Defender, like replacing a clutch or brake cylinder or starter...it is tough because there's stuff in the way, but once the body and doors are off of it, it really does become very straightforward to remove and replace stuff. I compare replacing the fuel tank from under neath on my D90 with taking out this 110s fuel tank and it was a piece of cake without the bodywork in the way...anyway, gonna see about putting new door frame bottoms in the front doors next...more pix to come...thanks for the observations and comments...as you all know, I wouldn't have even thought to try this 110 project without this great D-90.com resource!
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