95 D90 SW "#2" rebuild - Defender Source
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  #1  
Old June 20th, 2010, 12:28 PM
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Paul D
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95 D90 SW "#2" rebuild

So I bought a burned out SW (that just happened to be #2) last year about this time with plans of just putting a 300TDi in it and slowly fix or swap out all the damaged parts..... But after it arrived the burn damage was worse than I thought it was going to be so I decided to tare the whole thing apart and build it back up....

So I sold my Black ST to fund the build and started tearing it apart and buying parts...
found a center dash kit with a 300 wiring loom, a 300TDi 75k miles (new cluch and head gasket, Zues timing gear (does anyone have fitting instructions for this?)), rebuilt R380, 1.4 LT230, new (used)seats, new doors (all 3), and sent the body parts to the paint shop and roll cage parts to the powder coater....Frame got galvanized and all new suspension parts with a 3" lift, curry Johnny joined rear links and the 300 TDi motor mounts I made and welded them to the frame before galvanizing it. New SS brake lines, drilled and slotted rotors and new calipers, FOX shocks, Rovertym HD SS steering arm, HD pan hard rod, radius arms, springs, and shock mounts.

I have just recently received all the powder coated parts back and am starting to get body parts back from paint...so it's about time to kick it back into 3rd gear..

Was planning on posting this long ago but could never find the time....there are still parts I am looking for and I have a lot of stuff that’s not going back on this one so l will be posting it up some time soon.
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  #2  
Old July 16th, 2010, 10:41 PM
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Paul D
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Well I finally blew off work and got some things done on the project...

Got the Zeus timing gear in as well as the new water pump, headgasket, and clutch.....removed the turbo and exhaust manifold to make room for the stage 4 VNT Allard turbo and goodies that are on the way.... put the engine in the frame and hooked the trans and gearbox to it as well.

then last night found some tim to put the bulkhead and sliders on..... dynomated front and back of the bulkhead and started fitteng the new TD5 center dash.

Meanwhile my new AC unit showed up from ECR so I'm gonna put that in sometime soon...

here are some pictures.... what ya think? O ya I got my new fan in the mail today and put it on.... thanks Jim.
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  #3  
Old July 17th, 2010, 12:19 AM
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Looks great!

Are you going to run a custom exhaust? I noticed you still have the V8 crossmember. What did you do to the bulkhead to combat the surface rust from the fire?

Ron
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  #4  
Old July 17th, 2010, 12:48 AM
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I heard only bad things about the Zeus gears..........
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  #5  
Old July 17th, 2010, 11:23 AM
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Paul D
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Quote:
Originally Posted by evilfij View Post
Looks great!

Are you going to run a custom exhaust? I noticed you still have the V8 crossmember. What did you do to the bulkhead to combat the surface rust from the fire?

Ron
Custom big bore, free flowing exhaust is what I’m thinking... as for the bulkhead surface rust, I soda blasted it myself as did my painter, followed by a chemical bath, self etching primer, and paint. From what I can tell it should be good as new.

------ Follow up post added July 17th, 2010 09:32 AM ------

Quote:
Originally Posted by roverhybrids View Post
I heard only bad things about the Zeus gears..........
Ya.....I was on the fence for awhile on the timing gear, until I found one for cheap (must be because people are uncertain of there performance and reliability) and after much debate and research I decided to give it a go. It fit nice and tight and the case is a great cast, and all of the components are very nicely made.
So I guess I’ll be putting it to the test with and big turbo, exhaust, intercooler, and big ole tires… so we shall see…..
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  #6  
Old July 17th, 2010, 12:29 PM
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Quote:
Originally Posted by roverhybrids View Post
I heard only bad things about the Zeus gears..........


x2....

noisey etc. Personal preferance, rubber belt... BUT, if you got it cheap and all looks well made, you might be OK.

I'd tear it down every other service though and check all is still OK in the timing chest though.

keep us posted on the build though.... looks sweet!
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  #7  
Old July 20th, 2010, 11:14 AM
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Got the SS brake lines, and clutch line in and blead for now. Also got the accel cable in, and the rear light loom....now trying to figure out the other 4 looms I have. Well one is the main....it's in now, and two others are the front lights....got them in...guess some of this must go to the trans/t-case?

E-brake hooked up....

damn wires are everywhere.......
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  #8  
Old July 20th, 2010, 01:54 PM
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barry f
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Looks great. what did you do to the wheel wells to make them so black?
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  #9  
Old July 20th, 2010, 08:22 PM
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Did the burned 90 used to belong to Clarence? I used to live in Boulder and he had one the same color.

James
www.NoLimitX.com
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  #10  
Old July 20th, 2010, 08:29 PM
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Looks great- I love to see the rebuild on these rigs. Keep up the good work-



Quote:
Originally Posted by dogbite View Post
Well I finally blew off work and got some things done on the project...

Got the Zeus timing gear in as well as the new water pump, headgasket, and clutch.....removed the turbo and exhaust manifold to make room for the stage 4 VNT Allard turbo and goodies that are on the way.... put the engine in the frame and hooked the trans and gearbox to it as well.

then last night found some tim to put the bulkhead and sliders on..... dynomated front and back of the bulkhead and started fitteng the new TD5 center dash.

Meanwhile my new AC unit showed up from ECR so I'm gonna put that in sometime soon...

here are some pictures.... what ya think? O ya I got my new fan in the mail today and put it on.... thanks Jim.
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  #11  
Old July 20th, 2010, 08:38 PM
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Just curious:
Why does your ID tag just say "2"????

In all the 95 NAS 90 Wagons that I have seen they all say "302/500" or "420/500", that sort of thing.

Its cool, just trying to figure it out.
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  #12  
Old July 20th, 2010, 10:28 PM
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Lookin' good Paul! Mine encountered a big hail storm- in a week or so when it's back together maybe I'll take a trip up to Boulder and check it out in person.
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  #13  
Old July 20th, 2010, 11:27 PM
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Quote:
Originally Posted by bjf View Post
Looks great. what did you do to the wheel wells to make them so black?

The wheel wheels got sand blasted, diped, and rubberized undercote.

------ Follow up post added July 20th, 2010 09:28 PM ------

Quote:
Originally Posted by JPBrown View Post
Did the burned 90 used to belong to Clarence? I used to live in Boulder and he had one the same color.

James
www.NoLimitX.com
Nope...this one came from the East Coast just about a year ago.

------ Follow up post added July 20th, 2010 09:33 PM ------

Quote:
Originally Posted by ECR View Post
Just curious:
Why does your ID tag just say "2"????

In all the 95 NAS 90 Wagons that I have seen they all say "302/500" or "420/500", that sort of thing.

Its cool, just trying to figure it out.
Thats what it's always said.....a least thats how it was when I got it. Any guesses? I have read that #'s 1-3 may have had blank plates from LR? But this plate looks to be authentic so not sure. I know I like owning number 2!
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  #14  
Old July 21st, 2010, 12:10 AM
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barry f
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Cool, what were they dipped in and what type of rubberization
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  #15  
Old July 21st, 2010, 08:28 AM
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There is already some documentation on it here:

http://www.lrfaq.org/Defender/D90SW.db.1.html

Good old Rover... they never do things the same twice.
Have fun with the build up!!
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  #16  
Old July 21st, 2010, 08:44 AM
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So would it be this one?

SALDV3284SA974738'95SW 2/500Arles BlueOwner reported badge number is "2" not "4" as expected
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  #17  
Old July 21st, 2010, 10:46 AM
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Paul D
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Quote:
Originally Posted by ssbartley1 View Post
So would it be this one?

SALDV3284SA974738'95SW 2/500Arles BlueOwner reported badge number is "2" not "4" as expected
Yep that's her.

------ Follow up post added July 21st, 2010 08:48 AM ------

Quote:
Originally Posted by ECR View Post
There is already some documentation on it here:

http://www.lrfaq.org/Defender/D90SW.db.1.html

Good old Rover... they never do things the same twice.
Have fun with the build up!!
Ya thats where I read that "The numbering is a little screwy. When the owner of LRNA/04 first bought the Defender, it had a blank number plate. Then LRNA stamped \"LRNA/04\" on the blank plate. By #40 they were marked #40/500 and so on to #500. I don't know which D90 Station Wagon was the transition between LRNA/# and #/500. I also don't know if #1 through 3 still have blank plates or not."

http://www.lrfaq.org/Defender/FAQ.De...r_95D90SW.html
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  #18  
Old July 23rd, 2010, 08:47 AM
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Wow! IDK, that galvy chassis with the black powdered parts and the Fox shocks is perfect. Must be hard to put a body on it and cover that all up.

Need to add about how nice the components are and how good the fab work looks like the johny joints rear links.
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  #19  
Old July 29th, 2010, 10:56 AM
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Quote:
Originally Posted by jaygoss View Post
Lookin' good Paul! Mine encountered a big hail storm- in a week or so when it's back together maybe I'll take a trip up to Boulder and check it out in person.
anytime Jay just let me know. You still have my email?
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  #20  
Old July 29th, 2010, 10:58 AM
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Well I got the TD5 center dash mostly installed (still need so random hardware) with my new Elite A/C unit....
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