86 110 pickup shop truck project - Defender Source
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  #1  
Old August 20th, 2013, 10:13 AM
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Mike Sandone
1984 Defender 110
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86 110 pickup shop truck project

The goal of this project is to turn this beat up 110 into reliable, left hand drive, turbo diesel shop truck.



This is the is the starting point for the new shop truck project



The previous owner had the body improperly sand blasted and every panel buckled and warped



the only part of the truck that was really any good was the rust free frame



The tear down begins



Incomplete 2.5 diesel is removed






The body is completely dissembled in about a day. 300tdi motor mounts are welded in.



The surface rust on the frame is ground down and the frame is waxoyled.



Smashed front axle housing will need to be replaced



Rear differential was filled with muddy water, it needs to go too






Truck cab was straightened out and repainted Alaska white



A decent bulkhead was sourced and bead blasted, this one only needed floor pans and minor rust repair






Since the replacement bulkhead was from an air con Rover I had to cut out the holes for the vent flaps and form a lip around the aperture for the vent flap gaskets to seal on



Etch primed, 2k urethane primed then painted in Alaska white acrylic enamel









The tub was straightened out as best as possible



Bulkhead, tub and top go back on the frame


Right hand drive heater box needs be converted to LHD position


All the rivets and spot welds are drilled out


It is cut on this line


All the individual parts that make up the heater box


The cut piece is flattened and the bent in reverse


The heater controls are removed and reinstalled on the opposite side


When reassembled it will look like this. Also a d shaped cut out needs to be made for the heater core pipes to exit on the opposite side. The cut out piece can be welded where the piped exited previously.


I opted to buy a new blower motor housing for about $65


The lower bracket also needs to be flattened and bent in reverse. When done it will look and function just like a LHD box except for the now upside down Land Rover label
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  #2  
Old August 20th, 2013, 10:57 AM
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Mike Sandone
1984 Defender 110
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Vdo gauges are installed in place of the stock gauges



The dash wiring harness needs to be slightly changed to work with the VDO gauges


The key to a clean install is having all the Land Rover correct connectors and crimping tools


a properly installed spade terminal just like from the factory


A nice clean dash harness


All the correct terminal covers
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  #3  
Old August 20th, 2013, 11:04 AM
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Don Bunnell
'86 110 3dr ST
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I will be keeping an eye for pointers on my build. Love the cleanliness of the VDO setup.
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  #4  
Old August 20th, 2013, 11:58 AM
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Doug Crowther
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Nice work. You have to wonder wtf was going through the sand blasters mind after he ruined the first panel but kept going ?
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  #5  
Old August 20th, 2013, 12:05 PM
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Dollars to donuts the sals will be fine with a couple oil changes and a new pinion seal.
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  #6  
Old August 20th, 2013, 12:13 PM
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Robert Ragland
1994 Defender 90
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Quote:
Originally Posted by Uncle Douglas View Post
Nice work. You have to wonder wtf was going through the sand blasters mind after he ruined the first panel but kept going ?
Wondered the same thing.
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  #7  
Old August 20th, 2013, 12:23 PM
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Mike Sandone
1984 Defender 110
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Quote:
Dollars to donuts the sals will be fine with a couple oil changes and a new pinion seal.
No, they ran it like this for a while. Every bearing was pitted, even the splines on the axles where worn to a razor edge.

Here is the way I converted the lower dash to LHD



Cut out made to steering column



Ducting put in for heater box



Top cover cut down and heater cable position moved to opposite side



Upper dash support had a cut out made for the heater cables and a square section cut out for air flow from the vents which was then tack welded onto the other side behind the dash



It all went in like this
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  #8  
Old August 20th, 2013, 12:27 PM
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That is too bad about the sals. On the plus side, axles and bearings are cheap. I think I gave away my spare sals carrier, but if I find it I will let you know.
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  #9  
Old August 20th, 2013, 03:15 PM
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Dan Prasada-Rao
1963, 109 Station Wagon
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Quote:
Originally Posted by JSBriggs View Post
I like the fact that the body is rippled. It guarantees this will be a workhorse, not a showhorse.

Keep it comming.

-Jeff
I couldn't agree more.

Salisbury's are not too hard to rebuild and axle shafts are easy to get or to have made. I had some front Salisbury shafts made for me by Moser.
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  #10  
Old August 21st, 2013, 09:53 AM
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Peter
1970 Series IIa 105
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Quote:
Originally Posted by Uncle Douglas View Post
You have to wonder wtf was going through the sand blasters mind after he ruined the first panel but kept going ?
Yeah just amazing.
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  #11  
Old August 21st, 2013, 10:23 AM
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87 Ex-MOD 110
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Very nice, Mike. I know that you're running a shop but where did you source the parts in that little plastic parts bin? I would love to score some LR spades and Genuine rubber plugs and grommets.
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  #12  
Old August 21st, 2013, 10:56 AM
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Bill Adams
66 109 sw 94 lwb
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Quote:
Originally Posted by chris snell View Post
Very nice, Mike. I know that you're running a shop but where did you source the parts in that little plastic parts bin? I would love to score some LR spades and Genuine rubber plugs and grommets.
All available from autosparks.co.uk in the UK or from Britishwiring.com here in the USA.
There's not much they do not stock. I love shopping at both websites. Super fast shipping.
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

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  #13  
Old August 21st, 2013, 10:59 AM
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Mike Sandone
1984 Defender 110
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Quote:
Very nice, Mike. I know that you're running a shop but where did you source the parts in that little plastic parts bin? I would love to score some LR spades and Genuine rubber plugs and grommets.
http://www.britishwiring.com/

At a minimum on a 25 year old Rover I'll replace every snap connector on the headlight and taillight harness http://www.britishwiring.com/Single-...tor-p/c311.htm.
If the bullet connectors are corroded it's worth replacing them too http://www.britishwiring.com/Crimpin...ire-p/c314.htm
You need this tool but it's a pleasure to use http://www.britishwiring.com/Ratchet...ool-p/tt85.htm
I also add some dielectric grease since these connections are in no way waterproof.

My favorites are these locking spade terminals http://www.britishwiring.com/1-4-Pos...nal-p/c219.htm. Perfect for use on anything that might vibrate loose like the fuel cutoff solenoid, sending units etc.
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  #14  
Old August 21st, 2013, 11:03 AM
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Jimmy
1995 D90 SW #365
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Quote:
Originally Posted by chris snell View Post
Very nice, Mike. I know that you're running a shop but where did you source the parts in that little plastic parts bin? I would love to score some LR spades and Genuine rubber plugs and grommets.
Looks like the stuff from British Wiring.
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  #15  
Old August 21st, 2013, 11:17 AM
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Mike Sandone
1984 Defender 110
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Yes, this one http://www.britishwiring.com/Ratchet...nals-p/pr4.htm.
Very nice tool, perfect crimp every time.
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  #16  
Old August 21st, 2013, 11:34 AM
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Damn, that's awesome. I bought a custom wiring harness for my old D90 from British Wiring. They are good guys.
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  #17  
Old August 22nd, 2013, 10:26 AM
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Mike Sandone
1984 Defender 110
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Bent up all new brake lines for the truck, the only good use for the original brake lines is as a template for new ones.




A roll of brake line and some fittings is cheap insurance, under $50






rolled a disco axle into place temporarily


new bullets and snap connectors on tail light harness. Also taillight harness rewrapped in harness tape http://www.britishwiring.com/Harness...ack-p/c453.htm


NOS engine harness for 65 amp alternator
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  #18  
Old August 22nd, 2013, 10:40 AM
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Mike Sandone
1984 Defender 110
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I tried out these led lights


I like the fact that they are completely sealed units


They are noticeably brighter




However I ended up switching back to normal Land Rover lights; this is a work truck.

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  #19  
Old August 22nd, 2013, 11:12 AM
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Bill Adams
66 109 sw 94 lwb
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Hmm I gotta get some of those Plano boxes. I'm getting tired of fishing around in the bottom of cardboard for parts....
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #20  
Old August 22nd, 2013, 01:32 PM
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Mike Barnett
110
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Who sells those LEDs?
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