Atakans_rebuild_1988_D90_3.5 v8(rrc low comp) - Defender Source
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  #1  
Old August 30th, 2015, 02:24 AM
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Atakans_rebuild_1988_D90_3.5 v8(rrc low comp)

Hi Guys,
this is my first attempt at a rebuild and a thread too. the car is a 1988 d90 RHD running a 3.5 v8 off an RRC. i am not a mechanic and also i am not to technically informed but my goal is to be a involved as possible and learn and do what i can. guess I will see how it goes, any technical advice and other forms of advice will be highly appreciated.
Location - Nairobi, Kenya

------ Follow up post added August 30th, 2015 09:33 AM ------

okay im busy trying to figure out how to get pictures up.
meanwhile heres a little general info:
1. got the car early this year, run it as it was trying to get to know it better.
2. in order to make the drive more pleasent sent it over to the shop to get the clutch replaced, turned out the tansfer box was also swimming in oil, got that bit sorted out too. she was a little more drivable now.
3. the more i drove the more i knew needed to be changed, started picking out quotes from different shops and having a look at their work. wasnt pleased at all with the lack of attention to detail and the tendancy to cover up problems like paint over rust and forcing old bolts etc. decided to try and micromanage the project:
a) remove all carpet and trim find out whats lurking underneath
b) strip body to chassis and have a look at that
c) strip dash for replacement / repair
d) strip old terrible fire hazard harness and start on a new one
e) engine?gearbox?transfer?
f) get rid of the rock hard robbs magic dampers and couils
g) replace all bushes
h) new seals all round
i) bolt and nut rebuild
j) find a good yellow paint
k) eventually make up my mind on what yellow to slap on
l) all the other stuff i forgot about
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  #2  
Old August 30th, 2015, 03:47 AM
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Andrew
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Hey Atakan! I'm excited to see your progress! Perhaps AA Yellow.
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  #3  
Old September 2nd, 2015, 02:12 AM
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Strip down

stripping 'er off! (hope these pictures show)
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  #4  
Old September 2nd, 2015, 02:50 AM
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Looks like a great project. Don't worry about lack of experience, the Land Rover teaches you to work on it!
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  #5  
Old September 2nd, 2015, 01:13 PM
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Thanks Jim, will try not to be too worried!


so took out the carpet and the trim and obviously the body needs some work, rust found on front floor and door bottoms rotten bad, rear door seems salvagable.

dashboard = rotten!

Harness and wiring = amatuer training ground? very very dodgy, hazards occasionaly would choose not to blink and remain lit, lights all cracked and connections all made with tape and no plugs or sockets.

but to be honest i expected much worse.

pics of dashboard:
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  #6  
Old September 2nd, 2015, 01:30 PM
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started dash rebuild, lower dash that is. i had expanded polyethylene foam that i used to insulate my warehouse its got a 10mm profile and very dense, and hard to collapse or tear, decided to use this as the underlay in place of the low density foam that comes stock. might be interesting to experience its heat insulating properties as well,
again just an experiment.
Bonded it with some high temperature contact bond, left it in the sun for couple of days and tried to peel off repeatedly but is bonded shut.
the foam has a layer of aluminium in both ends making it smooth and easy to bond.
also had the curiosity and help from my niece! as seen in on of the pics below!

i also did line the edge of the lower dash with 5mm self adhesive rubber strip so elimitate any dust ingress or vibration possibilities when mounting.
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  #7  
Old September 4th, 2015, 02:57 PM
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so.....
i got new doors PUMA doors.
during install discovered the pillar is rusty and warped.
while installing the mechanism on the door used 3M double sided seld adhesive rubber strips on the metal to metal areas. was afraid that the mechanism will protude but fitted quite well.
eventually i would like to have power windows but the new door set i got came with manual winders.
this exercise of installing the doors and having to change the strikers and pillar(A or B post?) slowly led to a full take off of the body.
pics below,
i had a tin of black touch up paint and sprayed the hinges... no surprise its already chipping off! will have them powder coated or something later!
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  #8  
Old September 4th, 2015, 03:17 PM
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Seat box and floor out
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  #9  
Old November 23rd, 2016, 03:00 PM
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So its been a while, i started a thread and exercise without thinking of a tru way forward.
truth is i have worked on this truck only when completely free and having a working driving td5 didnt help either with the speed of this build.
so basically this is what i have done:

1. stripped to chassis, cleaned and etched it and painted with stone chip gravitex. so grateful the frame was intact!
2. complete bolt and nut replacement, i think only a total of 3 bolts werent shot!
3. Took out the 3.5 and chucked in a 3.9 off a RRC MY 1993. Sounds smooth?
4. LT77 developed a leak ended up mating the auto box which has a borg warner on it. i had to cut and redo the front propshaft.
5. Sound and heat insulated the Footwells and bulkhead and will get around to the foot well too. i had this fatmat product lying around and used that and have no feedback yet althout the plan is to use hadura over that and then rubber mats.
6. While the body was off i upgraded to puma axles and stock suspension and coils, for some reason my tyres look more offset now than earlier... running 265s.
7. Roof wasnt straight had to get that sorted and now means i will have to repaint it, matter of fact ill have to repaint the whole damn car with all the scratched and nicks its developed.
8. Many many parts on this car are off a puma or brand new, i have a very interesting parts source here, was looking at circa 40 110 passenger doors brand new today...
9. hmmm what else... new timing chain for the 3.9, radiator resized and re-cored (RRC radiator)
10. bosch external fuel pump...
11. ill try think of what else
now to post some pics

------ Follow up post added November 23rd, 2016 11:01 PM ------

Quote:
Originally Posted by JimC View Post
Looks like a great project. Don't worry about lack of experience, the Land Rover teaches you to work on it!
you were and are absolutrly right! the amount of knowledge aquired is immense. may be one day ill be in the league of some of the guys on this forum
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  #10  
Old November 23rd, 2016, 03:20 PM
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atakan
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defender 90 1988
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  #11  
Old November 23rd, 2016, 03:41 PM
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  #12  
Old November 23rd, 2016, 04:15 PM
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Rock'n the 3.9L...nice!
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  #13  
Old November 23rd, 2016, 04:18 PM
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Quote:
Originally Posted by Grover View Post
Rock'n the 3.9L...nice!
Thanks! Big difference fron the 3.5. Want to have it on the road soonest and see how it feels on a proper drive. As it is i have a 4.2 lying around as well
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  #14  
Old November 25th, 2016, 08:09 AM
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For no being technically informed it looks like your doing a great job.
I love all the pictures
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  #15  
Old November 25th, 2016, 08:17 AM
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Quote:
Originally Posted by Milkman View Post
For no being technically informed it looks like your doing a great job.
I love all the pictures
Thanks alot! I have had ALOT of help. Thngs like wiring, engine setup etc were done by proper mechanics with me trying to learn as much from them.

The idea is that when this one's done i will have enough confidence to take on my td5 which is in need of major tlc.

We have run into an issue now. The 3.9 wont run for more than 20min. Just sputters off. Felt like it was burning rich.

Changed the timing chain but asked my mechanic friend to have a look at what ive done before I close it up.

So far the major suspect after scouring the forums seems to be the coolant temp sensor as its running rich yet MAF and TPS have been checked.
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