Galvanized rear frame restoration and other things - Defender Source
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  #1  
Old January 16th, 2015, 10:08 PM
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William
1994 NAS Defender 90
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Galvanized rear frame restoration and other things

Well I got my restoration project done and I couldn't be happier. Things done:

- Cut out old rear frame and replaced with new galvanized rear frame and cross member and spring mounts and had it colored black
- Replaced fuel pump, painted fuel tank skid plate and all tank mounting hardware black
- Blasted and repainted rear lower step bumper black
- Replaced tub tube mounting bars
- Replaced brake lines with custom made lines
- Blasted and repainted rear stabilizer and shock mounts black (also new bushings)
- Replaced and welded in new rear diff cover to fix slight leak
- Replaced all wiring to brake lights, turn signals and side markers
- Installed rear mud flaps
- Installed new Warn M8000 Winch (into factory bumper under mount)
- Installed OEM 1994 Land Rover Brush Guard purchased from forum member
- Installed OEM 1997 Land Rover light bar purchased from forum member (The LR lights I also purchased will go on soon)
- Completed rust proofing of inside frame cavity and full outer frame and under carriage WaxOyl rust proofing treatment
- Replaced ignition switch and loose connecter (now starts instantly)
- Replaced door dome light switch

I under estimated the amount of work in disassembly and installation of the new rear frame but don't regret for a minute doing it. All the other work has now made this Defender look and feel like new. Only remaining things for me to do is to fix some broken dash bits, install new Exmoor seats and seat box covers and this is done!
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  #2  
Old January 16th, 2015, 10:58 PM
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evilfij
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Looks good? I wonder what caused the dent in the frame? I bet it was a forklift at the factory.
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  #3  
Old January 16th, 2015, 11:01 PM
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Zack
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Great work Will! Glad you painted the galvy xmember too... I think it looks better that way
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  #4  
Old January 16th, 2015, 11:23 PM
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Jon Ruti
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Looks great Will! Especially that brush guard!! Will or anyone else - do you know the part number/where to source your under bumper winch cradle/mount? Always loved how it hides underneath the front bumper.

Also, are your rear mud flaps genuine or another brand? I like how plain & simple they look.

Great thread, I'm looking to pretty much do the exact thing with my local mechanic Chris from Rovertek.
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  #5  
Old January 17th, 2015, 12:14 AM
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William
1994 NAS Defender 90
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Thanks! I don't know the part number for the winch mount but I agree it looks so much better hidden like this with the OEM mount. Also the mud flaps are not factory and come from RoversNorth in VT. I agree and like the plain look.

And yes I love the brush guard! Looks great with my new light bar that is in near perfect condition and not rotted out like the original one that came on it when I bought it.
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  #6  
Old January 17th, 2015, 12:30 AM
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David Frank
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Looks great! Those mud flaps DO look good! And for what it's worth, they are currently on clearance at Rovers North! ;-)
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  #7  
Old January 17th, 2015, 09:31 AM
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William
1994 NAS Defender 90
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Here is what the Defender looked like with the rear end fully removed.
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  #8  
Old January 17th, 2015, 09:41 AM
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Quote:
Originally Posted by jruti View Post
Looks great Will! Especially that brush guard!! Will or anyone else - do you know the part number/where to source your under bumper winch cradle/mount? Always loved how it hides underneath the front bumper.

Also, are your rear mud flaps genuine or another brand? I like how plain & simple they look.

Great thread, I'm looking to pretty much do the exact thing with my local mechanic Chris from Rovertek.
They're our NAS 90 replicas - http://www.roversnorth.com/ProductDe...EFENDER-NAS-90

galvanized/powdercoated with stainless hardware
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  #9  
Old January 17th, 2015, 10:03 AM
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I thought these pics looked familiar. Didn't you already do this? Looks good though.

http://www.defendersource.com/forum/...ad.php?t=58272
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  #10  
Old January 17th, 2015, 10:03 AM
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Congrats nice work -looks amazing. What was your paint/topcoat on the xmember, frame, rear step, brush guard, etc? I assume you used the galvy rear chassis offered by RN - that is a solid addition tho their lineup. That is great that you found a good welder. Its my understanding that welding galvy is challenging. You have to grind away the zinc to get good welds and the fumes can be brutal. I also like the look of the painted fiberglass HT
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  #11  
Old January 17th, 2015, 12:32 PM
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wmatos1001
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William
1994 NAS Defender 90
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Quote:
Originally Posted by rijosho View Post
I thought these pics looked familiar. Didn't you already do this? Looks good though.

http://www.defendersource.com/forum/...ad.php?t=58272
That was the first picture earlier December. The work just finished and I picked up the vehicle yesterday. Took a while but they did a great job and I had a fair amount of other minor things done that I didn't post.

------ Follow up post added January 17th, 2015 12:37 PM ------

Quote:
Originally Posted by Rufus View Post
Congrats nice work -looks amazing. What was your paint/topcoat on the xmember, frame, rear step, brush guard, etc? I assume you used the galvy rear chassis offered by RN - that is a solid addition tho their lineup. That is great that you found a good welder. Its my understanding that welding galvy is challenging. You have to grind away the zinc to get good welds and the fumes can be brutal. I also like the look of the painted fiberglass HT
Thank you very much. I'm not sure on what they used for paint but I do know the shop I used sent it out to a shop that had experience painting galvanized metal. I didn't have to paint the brush guard it was in very good shape. The front bumper was also painted. I did get the gavly chassis from RN.

As for the welding I think they did a great job there as well. I witnessed some of it and wish I had taken some pics of the welds prior to coating it over with WaxOyl. It was nice work. The other thing to keep in mind is the RN galvy frame also goes into the existing frame rails quite a bit. So there is a fair amount of overlap between the two that adds rigidity I would imagine.

I had the work done at Brit Bits which is largely a British car restoration shop near where I live in NH that specializes in MG's, Triumph, etc. I can say they are not inexpensive and not quick but do quality work and are extremely friendly to work with. I had a great experience with them.

Thanks for all the comments. I'm happy to have the vehicle back and see the finished work and actually enjoy it!
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  #12  
Old January 19th, 2015, 07:57 PM
BrianKelley
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Brian Kelley
94 Defender 90 NAS
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Here's a shot from my rebuild with a look at how the galvy crossmember welds look. I took the grinder to each section of the x-member, going up about 3 inches on each side.
Interesting to see how some rebuilds i've seen on the Forum opt to leave the tub on when cutting off the old crossmember. Not that there are any shortcuts with this repair whatsoever, but with the tub off, i found that you can have easier access to weld, and also see if any other gremlins are lurking that need fixing
Nice job, hope my 94 D90 comes out looking this good.

P.S. how did your rewiring of the rear lights go? I'm thinking of doing the same, just wondering if you're doing an entirely new wiring harness, or just new connectors?
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