1991 Defender 90 Project - Defender Source
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  #1  
Old September 19th, 2016, 11:18 AM
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AdamSanta85
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Adam
1991 D90 SW
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1991 Defender 90 Project

In early August I took possession of my 1991 Defender 90 200TDI from Terni, Italy. I purchased it back in May of 2016, waiting nearly 3 months for delivery. I picked it up from the port of NJ.

It took me a while to find the "right" truck, and I hoped this would be it. I wanted a white, LHD, 200TDI Defender. I wanted something with a very clean body, the mechanicals I wasn't too concerned of. After looking at probably 50 trucks, I knew this was the one I had to have.

From what I saw in the pictures and stuff I read on DefenderSource, I knew there were some must have mods for me to do. I started acquiring parts while awaiting delivery those were

Nolden LED headlights
LED markers
Wheels and tires
Rear cargo mat
NAS steering wheel
Front brush guard

Picking it up from the shipping container:




------ Follow up post added September 19th, 2016 09:26 AM ------

Immediately installed some black Wolf wheels and 265/75 BFG AT2's. While I was fond of the white wheels, they offset and width were too weak for me. Instead of sitting sunken in the fenders they fill out the wheel arches now. Maybe ill go back to white wheels one day.

I also installed a NAS steering wheel and Terrafirma knobs






Time to install LED lights




New vs Old

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  #2  
Old September 19th, 2016, 11:32 AM
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1991 D90 SW
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Ollie my lab puppy loves riding around in the back





------ Follow up post added September 19th, 2016 09:35 AM ------

For peace of mind I installed a new timing belt, ancillary belts, all new fluids etc. Pretty easy job.



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  #3  
Old September 19th, 2016, 11:35 AM
rxcrwlr
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Rover Dude
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beautiful truck
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  #4  
Old September 19th, 2016, 11:39 AM
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AdamSanta85
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Adam
1991 D90 SW
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The suspension was pretty shot so I installed a bunch of new parts.

Bilstein shocks
OEM type springs
New upper and lower spring mounts
Steering damper
Super Pro bushing kit





You can see the galvanized front upper mounts peeking through in the last pic



------ Follow up post added September 19th, 2016 09:40 AM ------

First day on the beach!



------ Follow up post added September 19th, 2016 09:42 AM ------

Adjusting LT230 diff lock lever. My diff lock light wasn't coming out. Simple adjustment was all it took to get it working again. Getting to it, wasn't so easy.



------ Follow up post added September 19th, 2016 09:43 AM ------

Mud UK rear speaker installation. I also removed the headliner to have recovered. While it is out I decided to put sound deadener on the roof.




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  #5  
Old September 19th, 2016, 11:47 AM
SARTech
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P. Barber
1989/Defender 90
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Super nice, enjoy.
Are you happy with the Bilstein shocks and OEM springs? Im needing new shocks and springs.
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  #6  
Old September 19th, 2016, 11:59 AM
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1991 D90 SW
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New VDO gauges with green LED lights



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  #7  
Old September 19th, 2016, 12:32 PM
Al Blue4.6l
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Allen
2006 LR3
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very nice.
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  #8  
Old September 19th, 2016, 08:18 PM
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1991 D90 SW
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Started taking the fender off for the SD NAS style cage. Fender is half off maybe? Heater box has to come out? I have my doubts I can just pull the outer wing piece, but I am trying.
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  #9  
Old September 19th, 2016, 09:03 PM
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Quote:
Originally Posted by AdamSanta85 View Post
Started taking the fender off for the SD NAS style cage. Fender is half off maybe? Heater box has to come out? I have my doubts I can just pull the outer wing piece, but I am trying.
Pull inner and outer as one piece is how I did it.
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  #10  
Old September 19th, 2016, 09:08 PM
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1991 D90 SW
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Quote:
Originally Posted by evilfij View Post
Pull inner and outer as one piece is how I did it.
Heater box come out? The intake for it up top seems attached.
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  #11  
Old September 19th, 2016, 09:40 PM
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Originally Posted by AdamSanta85 View Post
Heater box come out? The intake for it up top seems attached.
Pretty sure I just unscrewed the intake from the top of the fender and the intake from the side of the heater box but I can't remember as I sit here.
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  #12  
Old September 20th, 2016, 08:03 AM
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Quote:
Originally Posted by evilfij View Post
Pretty sure I just unscrewed the intake from the top of the fender and the intake from the side of the heater box but I can't remember as I sit here.
Ok thanks I'll let you know tonight. My goal is to get fender one cut and ready to go back on.
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  #13  
Old September 20th, 2016, 09:52 PM
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And she is off. Was it easier then pulling the whole fender? Not sure. Heater box stayed in, duct for it came out. At least I don't have to align my headlights again? Perfect opportunity to install the stainless door hinge bolts I got from Series Defender as I have bulkhead access from the inside now.
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  #14  
Old September 22nd, 2016, 11:49 PM
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1991 D90 SW
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Finally got one side basically done. This job isn't for the faint of heart. Too late to turn back now. Drivers side starts tomorrow.
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  #15  
Old September 23rd, 2016, 12:17 AM
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Nice work.
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  #16  
Old September 23rd, 2016, 12:42 AM
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David Frank
1995 ST #2615
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Killer cluster! Nice find in terms of a great truck with nothing but potential. Looking really good!
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  #17  
Old September 23rd, 2016, 01:15 AM
classic4x4
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Justin
1986 Defender
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cute pup you got there
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  #18  
Old September 23rd, 2016, 01:36 PM
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1991 D90 SW
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Mantec tire carrier just showed up. Think I am going to wait until I am done with cage to install.

Passenger side complete including stainless hinge bolts.
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  #19  
Old September 23rd, 2016, 01:37 PM
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All done
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  #20  
Old September 24th, 2016, 07:59 PM
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Got the other side done today. Much easier the second time. Also got the stainless door hardware done and new front brush guard installed. Feeling good ready to cut that rear bulkhead out.
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