91 D130 200TDi - Rebuilding to Import - Defender Source
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  #1  
Old April 11th, 2016, 07:57 AM
300tdi convert
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Michael Giddinge
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91 D130 200TDi - Rebuilding to Import

A few months ago, and after few months of looking at it ďtemporarilyĒ stored in my garage, I took on a D130 project which took some rationalization given how much was missing (no interior, no wings, no pickup tub.....). Upside was a solid frame, legit chassis no., and of course an original 200TDi.

The rational justifying the go ahead is that at the end of the day, you end up taking these erector set buggies pretty much apart anyway, replacing a bunch of stuff, making them rust resistant, and reassembling, so step one was pretty much complete.

I've known the car for 8 years and the PO had it for 10 years, so I know what it looked like in its original state before it was cannibalized for another project. It was a bit unusual in that itís a D130 crew cab pickup, but not a HiCap. The pickup tub was essentially the same rear tub of any 110 but not attached to the crew cab. Unfortunately, it was replaced with a box and discarded. I have since purchased a 3 door 110 tub and cut it down to a rough fit. That has been set aside until the crew cab is back on the chassis so the finish cut will hopefully result in even gaps with the rear of the crew cab.

A pic below including what I started with and a recent progress shot. I had access to a lot of odds and ends that came off of it originally, and additional bits through our land rover support group here in Cairo, so less incomplete than it appears. The current state is a sandblasted and epoxy coated chassis, OME suspension, new bushings and suspension bolts, a few galvied bits, and engine in place. Iíll go through the brakes and bearings next. I tried to get the bulkhead galvanized, but they wouldnít do it, so repaired the foot wells, and had it sandblasted and primed. Big order waiting at the port including puma doors, new wings, wiring loom and lots of little bits.

Given that itís being set up for import into the US, Iíll keep it pretty stock. The rock sliders will go for that reason, and the custom made roll cage will be further modified but will stay (in the name of safety of course). My plan is to import via Uncle Doug (again) sometime next spring.

So the question of the moment is color which was originally white. I had been thinking to go with Indus Silver for a newer look and a charcoal or black hood on the pickup bed. I am now leaning toward Scotia Grey, a tan hood, with white top and white wheels per the mockup below, although I think itís less green in actuality unless in the sun. A newer color but more classic with the white roof and wheels. Also a mockup for Grassmere which I like on a 90 but not wild about it on this setup. Secondly, Iíll probably leave the pickup tub cappings galvied (not painted). Thoughts on doing the same for the pickup tub corners and the crew cab cappings and corners?

Input /thoughts on the color and whether to paint cappings and corners would be appreciated!
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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  #2  
Old April 11th, 2016, 10:53 AM
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Yes on the galvy capping. No on the grey. Every effing car in america is grey. That red is awfully nice, vis Jason Lavender's 130. I would say go with the light green. Can't go wrong there.
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Old April 11th, 2016, 12:59 PM
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Too many pastel green ones here already. I kid. Green would be a god choice.
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  #4  
Old April 11th, 2016, 01:28 PM
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Green.
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Old April 11th, 2016, 01:53 PM
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keswick green

it really is a nice color with some blue undertones in it
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  #6  
Old April 11th, 2016, 01:57 PM
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If you are painting the truck yourself, think twice about metallic. My truck is 2005-2011 Zermatt Silver Metallic and having to spray down two-part single-stage basecoat metallic plus the metallic feather coat adds another day or two of work before spraying down the clear.

A two-part urethane single-stage color means you only have to wet sand the primer. It's also a lot easier to fix problems. Partially spraying a panel metallic is a non-starter. Just a thought.

I do like lighter metallics because they hide imperfections well, but there is a price to be paid.
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Old April 12th, 2016, 03:45 AM
300tdi convert
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Michael Giddinge
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Hi guys and thanks for the input

Good points on the metallic paint. I won't be doing it myself and one of the real challenges here in Egypt is getting a good match on the color which is x2 when considering metallic.

With that in mind, I'll likely stay with a solid color. I hadn't really though about Keswick Green and that may be a good fit. Grasmere is as a classic recently revived. I'm leaning toward one of those two now, either way with a white roof.

Any further thoughts on leaving the cappings and corners galvanized verses painting them?
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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Old April 12th, 2016, 06:29 AM
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New galvy cappings is a tough call. When redone they clumpy IMO and when left alone they may have too much patina next to new paint. Either way, hopefully you have in the budget to remove, paint, replace all applicable components. When two rovers stand side by side you can tell which ones have been done right.
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Old April 12th, 2016, 09:10 AM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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Quote:
Originally Posted by 1of40 View Post
New galvy cappings is a tough call. When redone they clumpy IMO and when left alone they may have too much patina next to new paint. Either way, hopefully you have in the budget to remove, paint, replace all applicable components. When two rovers stand side by side you can tell which ones have been done right.
Good points. On the cappings, I took another look at the galv work and agree that it's a bit rough and won't look good against the new paint. The mid-80s galv cappings and corners are classic, but they were a lot cleaner new than the galv work done here in Cairo.

The body is as disassembled as can be without drilling out spot welds. The front and rear bulkheads are on stands for real body work and painting. Rest is smaller and easy to handle, except for the roof which I was surprised to find is fiberglass. Still need to do something there so it doesn't get damaged while handling.

Plan is to have all the pieces primed, then and based on above discussion, re-install cappings and corners (also pre-primed) with a bead of seam sealer where appropriate. Then have everything finish painted and then reassemble. Any comments/suggestions here?

I have all new window and door seals as well as seals between major body parts. Also new floor section seals, bolts etc. Using almost all new zinc or SS bolts depending on where they are.
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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  #10  
Old April 12th, 2016, 09:33 AM
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Michael,
The more product between the dissimilar metals the better. The early trucks had the caps added after paint and those trucks have far less corrosion than the NAS 90's were there isn't even primer between the tub and the capping.
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  #11  
Old April 12th, 2016, 12:25 PM
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Stu Higgins in NZ does a nice job keeping close to original and well shy of a blown out of proportion restoration. His trucks turn out to be great drivers you can proud of without breaking the bank.
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Old April 12th, 2016, 01:31 PM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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Quote:
Originally Posted by Uncle Douglas View Post
Michael,
The more product between the dissimilar metals the better. The early trucks had the caps added after paint and those trucks have far less corrosion than the NAS 90's were there isn't even primer between the tub and the capping.
So I'll have a layer of galvanizing on the corners and cappings, primed, and the aluminum primed. Has anyone tried to use something like 3M seam sealer tape (08476) to help separate dissimilar metals, at least for body panels?
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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Old April 19th, 2016, 07:34 AM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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Location: Cairo, Egypt / Maine, USA
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My shipment arrived including the Puma doors: 2nd row black, one front white, and one front Keswick Green which turned out to be a great color sample for the build. My wife gave it a and therefore, Keswick green it is! Now I've got to find a suitable name other than Frank as dubbed by my wife (short for Frankencar).

On the brakes, found one drum absolutely full of sand and grease. I suspect an ultra-deep stuck in the dunes. All disassembled and cleaned. New bearings, seals and brake cylinders this weekend. Heavy duty drive shafts already there to go with the locker. Will install new stock flanges on the theory of letting the weakest link fail. What do you guys recommend to paint these? Just a quick cover of POR15 after assembly or before?
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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Old April 26th, 2016, 05:08 AM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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Everything I open up requires more than planned, anticipated, or hoped for. Sound familiar?

I've concluded that a timing belt kit "should" come with a crankshaft oil seal and I think some may. The britpart OEM version did not. Fortunately, a fellow addict had one lying around. A few bits of the belt in the timing belt case. I'm told due to the oil leak accelerating breakdown of the belt - is that the case? If so, a word of caution when thinking a minor oil leak isn't an issue, particularly if coming from the timing case drain hole. 341 NM for the crankshaft bolt? Really?

Bearings and seals - found one bearing had spun with excessive wear on the stub axle, and on the other side, deep and sharp groove where the inner seal rides (what a bucket of sand inside the drum will do). So, the rear axle will sit on jack stands until a friend comes from the UK with new stub axles in mid-May. Also, decided to use my heavy duty hubs.

Took the emergency brake apart, cleaned etc. All in good shape except seeping a bit of oil from the output shaft bolt only to find there is no felt seal at all. Also, prop bolts in bad shape, so will replace this weekend along with output shaft seals.
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1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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Old August 4th, 2017, 03:44 PM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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A bit of progress in the last year considering I have been working in a different country than the 130 is in. Hoping to import in two or three months.


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Mike

1989ish 110 300tdi (Bella)
1988 LR90 ST 200tdi (Shorty)
1991 D130 200TDi (TBN)
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Old August 4th, 2017, 03:54 PM
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Flippin Sweet!

Very nice looking build. I am a Keswick guy too.

I had never seen the 130 HCPU with integral bed. Bummer it is gone.
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  #17  
Old August 4th, 2017, 09:41 PM
300tdi convert
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Michael Giddinge
Late 80s 110 300tdi
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Not an integral bed, but separate like an old style US pickup. This isn't the original bed, but one that I built/cut down from a 110 3dr tub. I knew the truck with the original bed and it was pretty unique not being a HC version. PO put a box on the back and discarded the original bed, so I tried to recreate it. Looking forward to getting it stateside. Hoping that Egyptian bureaucracy doesn't rain on my parade.

Not going to compete with the latest EC Rovers 130, but I'm hoping to keep it for many years.
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1991 D130 200TDi (TBN)
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