A Ghost is Born: The D-100 Project, Part 1 - Defender Source
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  #1  
Old March 26th, 2011, 10:52 AM
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Dave Johnson
'91 RRC
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A Ghost is Born: The D-100 Project, Part 1

INTRO
I wanted to start documenting the process of merging my 1992 RRC County with my 1963 2A SWB and since a few others look to be doing something similar, i thought i would keep my notes here. I will be adding as i go along and will try to keep the posts brief and interesting. If you have any questions, or I leave out anything, let me know....I have attached a couple of pics of how it looks today at the 80% complete stage, but will post some of important milestones...

SUMMARY
As a summary of the build, I re-used my RRC 100" frame, 3.9 with 115K, ZF Auto - rebuilt at 110K, BW transfer case, and the OME suspension that was already on the vehicle.

I re-used the tub, wings, doors from my 2A, and then filled in the rest with D90 parts including starting with a new TD5 style bulkhead (Highly recommend - if you can swing it..so nice to have a solid and sqaure foundation to work from). Everything came from members/vendors from this forum...

The goal was to have a good trail rig that had the classic look and simplicity of the Series, with the 100" wheelbase (the perfect length IMHO), EFI V8, coils, disc brakes, P/S...and was tolerable for the long road trip to get the rover events and trail rides.

Rolling Chassis
I was thinning out my fleet last summer and my 92 RRC drew the short straw. I was the second owner of this beauty and it was mechanically solid, but cosmetically it was the worst of the lot. In fact, it had been sitting in my driveway for the better part of the last 5 years, after I began driving a 1991 RRC as my daily Rover. So I began taking it apart to sell of bits that I thought were valuable. The interior was beautiful and everything worked, so I figured I could get some good cash for much of it as parts.

Mistake #1 - I wasn't planning on a hybrid at this point, so I went through a lot of the teardown "junk yard style" and hacked up things that I would have like to have kept in tact - wiring harnesses, cooling lines, etc.

After getting the vehicle gutted, I towed it out to a friends shop and we used his tractor to pull the body off the frame (pic attached)..again the plan here was to get this thing parted out...until I saw the vehicle stripped down to a rolling chassis and then the idea was hatched.

With a 1963 2a SWB that was long overdue for a new frame and a solid frame staring me in the face, the project was born.

I towed the rolling chassis back to my humble garage and began getting it ready to start its life as a donor. I pulled off everything that would not be needed (again, made a couple of mistakes in this area).

I POR'd the entire frame.
I also took the opportunity to clean up the motor, replace some weathered components and service all 4 wheels. New wheel bearings, rotors, calipers and pads - much of which was already in my spares pile for a rainy day or emergency repair.
I serviced the tranny break (for the first time - ever I think)
I put my detroit locker in the rear, along with the heavy duty Great Basin axles.
I ran new brake and fuel lines to the approximate locations for tidying up later.

With all of this prep work completed, we towed it back out to my friends shop where we hadmore room to work, and a larger assortment of tools.

Coming Next....Keeping the 100" Wheelbase, and Where to Mount the Bulkhead...
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Dave J.
'91 RR Classic
'01 RR 4.6 HSE - Gone!
'00 Disco 2 - Gone!
'95 Disco 5-Spd - Gone!
'92 RR County SWB - Gone!
'63 2A SWB - Gone!
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  #2  
Old March 26th, 2011, 01:33 PM
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Jason
71 SIIA, 03 RR, 94 D90 (PO), 83 110
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Cool!

So how do you fill the gap and what cappings do use?

Wish I had the guts to start something this ambitious!

------ Follow up post added March 26th, 2011 12:59 PM ------

couldn't tell on the iphone; looks like you did a hinged door?
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  #3  
Old March 26th, 2011, 02:28 PM
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marcus
Puma 110 xs. Td5 110 xs for sale
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great stuff.

would love a 100"

anyones esle got a 100" defender on here?
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  #4  
Old March 26th, 2011, 06:11 PM
rondo
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Rondo B
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Quote:
Originally Posted by T1G UP View Post

anyones esle got a 100" defender on here?
Yup, got one right here.

As for filling the gaps, because of the unique aluminum Rover used its best (and of course easiest) to just use another panel and cut a patch out of it. Are you really going to hinge the patch panel suicide style? That's unique.

Why'd you go with a Series windshield?
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  #5  
Old March 26th, 2011, 06:27 PM
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Jeff Payne
'83 110 3 Door
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Would it be any easier to use a 110 three door tub for the rear? It would probably need trimming on the rear and the front.
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  #6  
Old March 26th, 2011, 08:44 PM
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Dave Johnson
'91 RRC
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Yes...we filled the gaps between the doors and the tub with a spare/old series door, cut down to size...we re-used the stock galv capping since it was meant to snug up to the tub anyway...and we had extra hinges lying about so we made a suicide door on the driver side...that is held captive by the drivers door by a strip of steel....the passenger door is going to be a flat panel that is removeable for reasons to be discussed later...

We swapped the windshield this week - one pic in the post shows it is now fitted with a d90 windscreen...

More to come shortly...including better photos, parts to look out for if you think you may do this, as well as mistakes we made and tips...glad it is helpful...
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Dave J.
'91 RR Classic
'01 RR 4.6 HSE - Gone!
'00 Disco 2 - Gone!
'95 Disco 5-Spd - Gone!
'92 RR County SWB - Gone!
'63 2A SWB - Gone!
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  #7  
Old March 27th, 2011, 12:52 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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So with the D90 front clip and windshield there is really very little series in there right (rear tub and doors)? Could you not fit the motor with the series breakfast?

If I ever do something like this I think it would be nice to retain the series front end. Undecided on the windshield as defenders are much better, especially for tall people.
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  #8  
Old March 27th, 2011, 01:28 PM
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Reese
97 D90 ST and 93 D110
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http://www.defendersource.com/forum/...ad.php?t=29646

Have you checked out a 4x4 is Born videos on the link above?? Its sounds like what you are building. Pretty cool.
Good luck.
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  #9  
Old March 27th, 2011, 08:08 PM
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Dave Johnson
'91 RRC
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Charles-I have seen others that retained the Series breakfast, but I imagine it was tough packing it all in there. We had issues even with the D90 front end - even with the extra deep grille surround it was tight and the radiator was a challenge too.

Reese-I will check out those videos, hadn't seen them before.
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Dave J.
'91 RR Classic
'01 RR 4.6 HSE - Gone!
'00 Disco 2 - Gone!
'95 Disco 5-Spd - Gone!
'92 RR County SWB - Gone!
'63 2A SWB - Gone!
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  #10  
Old March 29th, 2011, 01:57 PM
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marcus
Puma 110 xs. Td5 110 xs for sale
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Quote:
Originally Posted by rondo View Post
Yup, got one right here.

As for filling the gaps, because of the unique aluminum Rover used its best (and of course easiest) to just use another panel and cut a patch out of it. Are you really going to hinge the patch panel suicide style? That's unique.

Why'd you go with a Series windshield?
any pics rondo?
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  #11  
Old March 30th, 2011, 10:36 AM
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Dave Johnson
'91 RRC
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yes...i scrapped the whole seat box approach (mainly because the ZF tranny comes too far back) and laid down a flat, stainless floor with Jeep Bucket seats. We created a grid between the frame and some sliders for floor and seat support...will send some pics...
In my next segment I will discuss Mistake #2 - tearing apart my Series...i really thought i was going to transplant a lot of the 2A over - but at the end of the day i used very little and should have sold the series outright. Could have easily covered the cost of a used tub, door and wings...

The top (for now anyway) will be a stock surrey top...we are going to put roll bars in behind the seats and near the rear of the tub that align with the standard D90 cage
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Dave J.
'91 RR Classic
'01 RR 4.6 HSE - Gone!
'00 Disco 2 - Gone!
'95 Disco 5-Spd - Gone!
'92 RR County SWB - Gone!
'63 2A SWB - Gone!
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  #12  
Old April 7th, 2011, 10:11 PM
d110pickup
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Mike Pado
'97 D90 ST #1153
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Thanks for posting this build; I can't wait to see the remainder.
Mike
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  #13  
Old April 25th, 2011, 12:02 PM
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Bill Adams
66 109 sw 94 lwb
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Quote:
If I ever do something like this I think it would be nice to retain the series front end.
Pretty easy to keep the 2A look. You need to remove the sheet metal from the back of the breakfast. The rad has to fit between the wings (~24") and the only gotcha is the headlamps. I solved the problem by bonking the back of the buckets a little, but V2.0 of my build will have LED lamps so that the rad can go a bit more forward. Defenderizing a 2A conversion is, well, might as well build a Defender.
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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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  #14  
Old April 26th, 2011, 11:50 AM
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Bill Adams
66 109 sw 94 lwb
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Quote:
Originally Posted by JSBriggs View Post
Stage One hater...

-Jeff
I think Stage Ones were made from the (already ruined) Series 3, not a 2A.
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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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