1987 Restoration 90 - Defender Source
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  #1  
Old November 22nd, 2010, 07:07 AM
seaswood
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Craig
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1987 Restoration 90

Restoration was just about the last thing I had in mind when I picked up this truck with a friend (welder).
So far he has repaired the doors with the RN door kits the bottoms of the doors were gone & the firewall on the drivers side that just did not look nice at all. There is another list of things to weld once I can get truck road worthy again, as the wheels have been off for last 6 months. Small hole in the right rear frame was bloody full of good english dirt as was the frame, where had to drill rear subframe to clean it out. And with winch bumper on the front the steering protector needs modification. The inside left frame is clear with just surface rust inside the right side is different since the wiring is in there confounding the removal of dirt.
Did just get the front wheels on again, when I get home they come off to swap brake line holders on top of swivel pins. & see if I have the correct brake lines. The rear hubs & brakes still await, rear differential now mounted in the front with 24 spline axles, rebuilt CV joints & teflon swivel balls from Bill Basin Rovers. Took the front apart went away for 3 mos. came back & with some head scratching the front axle was filled with oil before I left again.
OME heavy duty shoks installed in the front using same springs cleaned up, will determine height later.
Front prop shaft bolts to transfer case had bolts in backwards & cut off to fit in? That awaits to sort out seal properly. Rear propshaft is also out, rear differential in (front) & front to be in rear was also done by Bill Basin Rover with 24 spline & a ARB locker. Someone was kind enough to drop off a rear differential protector I purchased on D-90 at Badger in Dennis last summer, rear differential awaits. New motor mounts on transmission with new bolts for bracket to frame. The transmission you could not see covered in mud oil? Is now clean.
Oil change this winter once transfer case seal done.
Presently upper rear sides, windshield & top are ready for install. New heated windshield installed not an easy job & frame painted. Sides painted & repaired had holes punched in to drivers side & rubber seals reconditioned.
The roof was a used top from RN, the top itself is another project another day. I did get a front headliner from D-90 in Portland Ore last summer, still looking for the rear. The rear bed was removed as much as I could as the fuel tank was full with fill tube going thru forward bulkhead. I was only able to lift a few inches. Installed with new fittings stripped & painted in side & out the rear quarters still needing to be stripped & painted.
As do the sides of the firewall between doors & front fenders. Front fenders are off painted awaiting repairs under-neath to be finished. Seat box, sills removed stripped painted & reinstalled with new fittings. Seats were stripped & refitted with new Exmoor heated seat kits & badger seat covers.
I did galvanize the sill protectors, rear quarter strips holding rear lights & rubbing strips for the floor in the rear, at Baystate in Boston. Front doors will be torn apart this winter to galvanize frames & caps if anyone is doing a run to Baystate in 2011.
The paint is PPG with a self etching primer, sealer & topcoat. I found out the nozzle for the gun is important, 3 gun spray kit one seal broke & was swaping parts to use the one seal. Already through one gallon of top coat, 2 gallons of stripper &3 boxes of purple gloves.
The colour is as the tailgate was painted I purchased from RN and a new lift gate from Canada to be fitted original colour.
With no intention of restoring this truck approaching year 4, I will attempt to load photos of before & after repairs.
Any questions or thought anyone has to point out on this site has always helped somewhere.
Engine is a 2.5 NA removed the injectors had cleaned & reinstalled, set timing of valves. May do head once truck is drivable. Fan protector was removed cleaned reinstalled with new rubbers properly.
This truck was according to Sohill sent into Life September 1987.
Okay see how this looks.
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  #2  
Old November 22nd, 2010, 07:18 AM
seaswood
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Craig
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90

Adding a few more of fenders apart
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  #3  
Old November 22nd, 2010, 07:33 AM
seaswood
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Craig
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Seat box & rear stripped.
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  #4  
Old November 22nd, 2010, 07:46 AM
seaswood
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Photos of rear unpainted & unbolted.
Obviously time organizing phots needed.
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  #5  
Old November 24th, 2010, 08:13 AM
seaswood
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Craig
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Newer Left front fender, still awaiting right side from RDS.
May get to visit there next week.
Other fender parts painted.
Axle/suspension/differential for front end,
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  #6  
Old November 24th, 2010, 09:26 AM
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Good work. Love the bumper/brush guard combo.
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  #7  
Old November 24th, 2010, 11:58 AM
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Jamie Austin
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Quote:
Originally Posted by rijosho View Post
Good work. Love the bumper/brush guard combo.


x2! very camel-esque!
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  #8  
Old November 25th, 2010, 07:55 AM
seaswood
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Craig
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Repainting of rear box, trials of painting needing light to see.
Front end suspension togeather sort of, rear next this winter.
& rear sides more painting challenges.
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  #9  
Old November 25th, 2010, 09:41 AM
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Jim Cheney
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Why paint over window frames, hood latches, etc? If you're going to so much work to disassemble and restore, its seems a shame to cut corners on the small things, especially when you'll see those parts all the time.

Are you going to sand and re-coat?

Pretty thorough though!
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  #10  
Old November 26th, 2010, 07:23 AM
seaswood
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Craig
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Hood latches one is not working properly, needs to be removed repaired or replaced.
All the paint work with the exception of a original batch I do myself stripping, priming, sealer & top coat.
Then time for set up masking prep surface for paint, it all adds up to the precious time, spent.
The rear windows decided to paint the frames on the out side only, where the glass slides was taped.
Determined there was a good seal on windows except where I had to redo rivets & B200 sealer.
PPG paints once the top coat is on is relatively easy to recoat, this has been a learning process.
I believe there is a kit for the sliders? I have heard have not looked yet.

Photo of lift gate & tail gate, which was color shot by PPG brought it back again to recalibrate paint colour.
Seems to be more yellow in the paint I am using than tailgate. Or a different paint that shows colour different original series gate I assume. Final test will be when mounted to complete painted truck.
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  #11  
Old November 26th, 2010, 07:26 AM
seaswood
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Craig
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Quote:
Originally Posted by rijosho View Post
Good work. Love the bumper/brush guard combo.
Still have the brush guard that came with the bumper is a wrap around , I also like the trophy style function & purpose. Out of RN used yard.
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  #12  
Old January 9th, 2011, 05:46 PM
seaswood
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Craig
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90

Photos of Front Differential before & after Great Basin Bill.
Also shots of Windscreen & rear sides in place more fitament to do, new bolts etc.
Rear diff green monster goes in sometime as rear hubs come apart replace drum brakes.
Front door to meet the stripper if weather warms up enough.
I think Windscreen was painted 2 years ago lost track.
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  #13  
Old March 6th, 2011, 07:46 PM
seaswood
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Craig
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Brakes

Quote:
Originally Posted by JimC;
If you have any suggestions on removing hood latches I would appreciate advice, although seems will have to sacrifice a wrench heat it up and bend it to fit into hold nut on the inside. If i could of removed them i would of.
As it is one is bad, have a replacement & may just get another if i can get the bad one off.
And it is possible to put the brake line bracket on the wrong sides on top of swivel pins and consequently be confused about how to fit the brake lines. After it was pointed out they were wrong & I borrowed a brake bending tool and the calipers had vented spacer removed and we put a shorter bolt in the space where the cross link bar goes. Got new heavy duty cross bar and tie rod. Removing tie rod from bracket took blaster and heat. Next is cleaning prop shafts and installing rear differential
As for the window frames they were not original, installed previous owner not in best of shape actually but they were installed and tight near as I can figure. So instead of creating more work to remove they got paint also.
Yes lots of re-sanding repainting on this truck, as I learn how to paint.
And here I am told message too short? not sure why?:angry
Anyone know why message you have entered too short
Why paint over window frames, hood latches, etc? If you're going to so much work to disassemble and restore, its seems a shame to cut corners on the small things, especially when you'll see those parts all the time.

Are you going to sand and re-coat?

Pretty thorough though!
]Why paint over window frames, hood latches, etc? If you're going to so much work to disassemble and restore, its seems a shame to cut corners on the small things, especially when you'll see those parts all the time.

Are you going to sand and re-coat?

Pretty thorough though![/QUOTE]
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  #14  
Old May 12th, 2011, 10:55 AM
seaswood
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Craig
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Rear end

Continued work on rear end Front Prop is frozen, rear is apart but needs cleaning of splines to work properly.
Assuming drum brakes to have adjuster on the front & rear trail. From pics I took before taking apart.
If any one has advice on attaching springs on drum brakes, I am stopped there.
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  #15  
Old May 12th, 2011, 05:16 PM
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This is great.. almost makes me feel like I could do the brakes myself.. (need a little more nerve).. Keep posting, please..
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  #16  
Old May 12th, 2011, 06:15 PM
seaswood
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rear end

These are photos of springs I took out still had marking of HD Defender 90 Right & Left, they are the same I reinstalled along with the rear axle sanded down. A silly amount of time went into the prep, but oh well!

The brakes was the easy part, now can someone point me the right direction on how to adjust drum brakes?
I have the adjuster set on low least turn for now & figured out the spring install.
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  #17  
Old May 21st, 2011, 03:22 AM
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Turn the snail cam until the brake pad is dragging on the brake drum then back it off one click.
Nice looking rebuild job.
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  #18  
Old June 24th, 2011, 01:46 PM
seaswood
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Craig
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Rear end

Thanks
Photos of rear end & brakes Propshafts, engine mounts, fan, cooling hoses ongoing list to do.
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  #19  
Old June 24th, 2011, 01:59 PM
seaswood
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Craig
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Prop shafts

Anyone know what the middle prop is in photo, top prop is a 200TDI front prop bottom is rear new from RN proline
This truck had two front props installed front & rear marked FRC8390BW952 middle in photo the front prop appears to be frozen into eternity assuming i marked it properly. They were off a year before I had time to check out.
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  #20  
Old January 31st, 2012, 06:21 PM
seaswood
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wings

The job I really did not want to do was rebuild the wings as they were a mess & after buying a set of two new tops.
Painting them top & front bits I realized they would probably go to the PU I recently bought.
Come to find out the air box that was not even there had to be fitted with gasket. Since it was screwed thru a aluminum protector plate longer ss screws were required. New screws for fitting sides on with the fabric washer between the side & top.A tad bit different than the bolt & nut that they came with. New screws to fit to fire wall.
I ended up buying new proline props to replace the 2 front props in the truck.
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