'87 110 Refresh, Restore, Rebuild and Update - Defender Source
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  #1  
Old December 12th, 2015, 08:23 PM
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Eric Wages
1988 D110 300tdi/R380
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'87 110 Refresh, Restore, Rebuild and Update

Hi folks,

I bought a 110 back in March with the hope of having a decent runabout truck. After poking around a bit, I found it needed more work than expected, so it's been getting a bunch of work done to it.

In no particular order, I've rebuild the transfer case, installed a 300TDI/R380 transmission, rebuilt the floors, cleaned up some rotted out chassis chunks, custom seatbox work, rebuilt the footwells, refreshed the guts of the doors, and more. So, a lot

Here's an album of the photos (so far): https://goo.gl/photos/f7qmQKZVY3rfiwL56

Hope to have it on the road come springtime.

The list still to do:

- Finish the work on replacing the cappings
- Replace the bulkhead (already have it!)
- Replace left front brake line.
- Replace some interior trim bits
- Clean up wiring. Add radio.
- Swap out to stainless windscreen and door hardware
- Replace fuel lift pump
- START TRUCK!
- Repaint the truck
- Swap over to LED lights
- Add rear LED work light
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  #2  
Old December 13th, 2015, 08:05 AM
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1of40
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Wow, Congrats on the progress thus far and sticking to it. It can be a labor of love sometimes.
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  #3  
Old December 13th, 2015, 08:35 AM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by 1of40 View Post
Wow, Congrats on the progress thus far and sticking to it. It can be a labor of love sometimes.
Thanks. I'm not against hard projects. With my other love (rally racing) that's given me quite a knack for welding and fixing things. The LR is a whole new thing though, it doesn't "make sense" when compared to say, a Subaru.

Subaru? You can take apart a whole car with an 8, 10, 12, 14, 17, 19, and 32mm wrench? The Defender? Every damned tool in the toolbox, plus a bunch of custom stuff.

An no captive nuts. Floor the love of god, why are there no captive nuts!!!!?!
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  #4  
Old December 13th, 2015, 07:21 PM
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Brian
86 D110 SW
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Very impressive - some of you guys have crazy skills
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  #5  
Old December 13th, 2015, 08:17 PM
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Ted Baumer
1986 LHD 110
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cool progress pics

Nice job making a big project look easy!
Instead of one step at a time you are tackling a bunch at once and looks like a quality job.
Big props to ya!
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  #6  
Old December 13th, 2015, 09:40 PM
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I sure need to learn more wrench skills.
Good luck, you can come to my place and help me, I have lots of Canadian beer.
I will be getting my new to me MT82 and getting it in the truck when I get home.
The truck is looking nice, keep the pics coming.
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  #7  
Old December 14th, 2015, 01:20 AM
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Michael
1989 110, 1985 90 200TDI
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Thank you for sharing the photos. I need to work on the bulkhead myself. Where did you source your bulkhead and 300tdi?
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  #8  
Old December 21st, 2015, 05:47 PM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by DailyDrivenDefende View Post
Thank you for sharing the photos. I need to work on the bulkhead myself. Where did you source your bulkhead and 300tdi?
Bulkhead was a TD5 unit from lrdirect.com, so shipped from Europe. But throw in a bunch of other stuff, and it's not a bad deal on shipping.

BTW, I'm absolutely astounded how easy it is to get stuff from LRdirect. Overnight international shipping, which sound crazy expensive, but it's often cheaper (and faster) than ordering from the next state over. I'm all for giving local guys my business, but when someone has a part on a shelf and can't get it out the door, I find that inexcusable.

300TDI was sourced as a "complete" package deal from here (used). That said, I needed to source my own engine mounts and crossmember, fabricate a bracket for the seatbox (to change the LT77 to R380), buy a new transmission tunnel cover, and fab new floors.
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  #9  
Old December 21st, 2015, 08:17 PM
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William Ficner
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Quote:
Originally Posted by TheOneTen View Post
Bulkhead was a TD5 unit from lrdirect.com, so shipped from Europe. But throw in a bunch of other stuff, and it's not a bad deal on shipping.



BTW, I'm absolutely astounded how easy it is to get stuff from LRdirect. Overnight international shipping, which sound crazy expensive, but it's often cheaper (and faster) than ordering from the next state over. I'm all for giving local guys my business, but when someone has a part on a shelf and can't get it out the door, I find that inexcusable.



300TDI was sourced as a "complete" package deal from here (used). That said, I needed to source my own engine mounts and crossmember, fabricate a bracket for the seatbox (to change the LT77 to R380), buy a new transmission tunnel cover, and fab new floors.

Fast and cheap shipping in my experience as well for LR direct , but dealing with damaged or defective parts is like pulling teeth (had to deal with it twice now)
I guess that's the price you pay for the low cost and why I still buy some things for the North American shops.
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  #10  
Old December 22nd, 2015, 12:51 AM
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Michael
1989 110, 1985 90 200TDI
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Ordered a bunch of parts from LR direct as well last week. It seems cheaper than well known mail order companies when you are buying a bunch of stuff. Can't say much about quality as I haven't received them yet.

I have picked up parts from Rovolution as well with currency exchange rate in my favor. Good thing they got good snow this year. I got excuses to drive up do some fun snow stuff and on my way back pick up rover parts.

I have 200tdi on the way from UK. Decided to go that route instead of 300TDI.

Anyways, what Ga metal is the frame?
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  #11  
Old December 22nd, 2015, 08:08 PM
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Eric Wages
1988 D110 300tdi/R380
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Yanked the fenders off and stored them today and found even more fun with nicked wires. Taking a break/pause before I dig in deeper.

Found that my heater fan is done for, haven't researched how hard these are to swap out. Also, the strut tops look like they're starting to separate, so I'll need to replace those too.
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  #12  
Old December 23rd, 2015, 11:25 PM
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Eric Wages
1988 D110 300tdi/R380
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Got all of the bits and bobs off of the bulkhead and got it pulled out. Quite a feat, having never done anything like it before!

Pretty sure I'm a long ways from having it back on the road

Pro-am tip: If your bulkhead is so trashed that you're not going to reuse it, sawzall it off right above the side sills and then come back and mess with the bolts afterwards!
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  #13  
Old December 24th, 2015, 02:04 AM
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Michael
1989 110, 1985 90 200TDI
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Where did you source the bulkhead?

Looks like you are having fun. Are you working alone? Any tips?
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  #14  
Old December 24th, 2015, 10:47 AM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by DailyDrivenDefende View Post
Where did you source the bulkhead?

Looks like you are having fun. Are you working alone? Any tips?
Bulkhead came over from LRDirect in Europe. If getting just a bulkhead alone, it'll be pricey (about 500 shipping), but that's for *next day* priority overnight. Pretty amazing, honestly. I bought a bunch of other bits at the same time (cappings, some interior bits, gaskets, etc) so those things were basically thrown in for free on shipping since dimensionally, the bulkhead is massive.

Doing the vast majority of the work alone. My wife helped me yank out the bulkhead last night And she's done wonders on restoring interior bits (including refreshing the door cards).

Tips? Anything you think it's going to cost to do work, multiply it by 3 - in both time and money!

------ Follow up post added December 24th, 2015 11:50 AM ------

Bulkhead is out, now on to doing fun stuff like electrolysis rust removal on brackets and whatnot, and doing frame touch-up painting and rust cleaning.

I've gone and put up a webcam link so all of you fellow nutjobs can follow along with my cursing. (and yes, it has audio links too!)

Give 'er a whirl and let me know what y'all think.

Webcam: Live from the Dirty Rallysport Garage!

Example shots:

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  #15  
Old December 24th, 2015, 02:09 PM
DailyDrivenDefende
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Michael
1989 110, 1985 90 200TDI
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LOL. Seems like you are having fun. What is the part number for the bulkhead? Any mod required to do fit it on 110?

Thanks for all the answers. I will be doing my engine swap this coming Jan. See if I can get things lined up before that. Where are you sourcing bolts and nuts? I have been making trips to homedepot and lowes but that is getting old quickly .
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  #16  
Old December 24th, 2015, 03:22 PM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by DailyDrivenDefende View Post
LOL. Seems like you are having fun. What is the part number for the bulkhead? Any mod required to do fit it on 110?

Thanks for all the answers. I will be doing my engine swap this coming Jan. See if I can get things lined up before that. Where are you sourcing bolts and nuts? I have been making trips to homedepot and lowes but that is getting old quickly .
I haven't installed the bulkhead yet, as I *just* discovered a nasty surprise while doing some rust cleanup. Merry xmas to me! I get to do big frame repair... under the front outrigger, so that will need to be replace as well. Fun! Thankfully, Santa brought me a plasma cutter today.



As far as I understand, the required mods for the bulkhead are outlined here: Bulk Head
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  #17  
Old December 24th, 2015, 06:39 PM
DailyDrivenDefende
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Michael
1989 110, 1985 90 200TDI
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I saw you banging on it with hammer on the right front. I figured you found something.

What gauge steel are you using to patch up the frame? Part # for the bulkhead? I see multiple with different prices which one did you go with?
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  #18  
Old December 24th, 2015, 07:59 PM
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Eric Wages
1988 D110 300tdi/R380
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Quote:
Originally Posted by DailyDrivenDefende View Post
I saw you banging on it with hammer on the right front. I figured you found something.

What gauge steel are you using to patch up the frame? Part # for the bulkhead? I see multiple with different prices which one did you go with?
I ordered AHA710460 for the bulkhead. It's the RHD TD5 bulkhead which will fit with some slight modifications, mainly for wiring harness locations and small fixes. A link backwards in the thread points to where people have used a bulkhead for this.

The mess today was that I found out that about half of the frame is rotted away underneath the RHD outrigger. I've had to remove a bunch of crap to get access to it and now that it's exposed, it's time to start prep and cutting things out so I can patch it up. I'll probably end up making a C-type patch that wraps up and around area that I need to cut out, and then the outrigger will have to be trimmed by the thickness of the patch.

The LHD outrigger isn't as bad from what I can see with a boroscope. There's only one small hole through the steel that I can see whereas the RHD side was like swiss cheese. Horrific!

I'm going to patch with 3mm steel which is what I usually use for mounts on roll cage feet. It should be okay. I'll update later with lots of pics from my discovery and work today.
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  #19  
Old December 24th, 2015, 11:03 PM
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Eric Wages
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The 110 chose to give me a lump of coal for Christmas. Found a little damage to the outrigger that I figured, "hey, I'll patch that right up!"

Cut out the piece and woah! Found a bigger hole inside of the frame. And the only way to get at it is to cut the outrigger off.

And woah! Even MORE damage. Whee!!!

So, I'm starting to hack into this and attempting to get this fixed up. I'm no frame expert, so I'm just doing what I can. This is a tricky fix, as the frame is curved here, and regular "boxing" won't do. I'm replacing the steel, and am debating about coming back and doing another patch atop and lap welding. Thoughts?
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  #20  
Old December 25th, 2015, 06:57 PM
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Eric Wages
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Frame fixed. Not really knowing how to attack it, but using some engineering brainpower, I figured out that cutting across the face of the beam was bad. I cut into the frame with a couple of angled cutouts so that the frame could flex/bite against this, rather than having a straight shear line. We'll see how it holds up.

All patched up with 3mm steel.

Tomorrow, need to pull out the grommet for the wiring harness and spray the backside of the plate with primer to seal it all up nice and neat.
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