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  #21  
Old February 5th, 2016, 11:05 AM
Azarur
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LR 1984 110
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Here's the engine running. Not sure if you guys will be able to tell from the sound, but that's one smooth running 200 Tdi. BTW, I know that it looks like a 300. It's not, we just adapted the 300 cover to reduce noise.
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  #22  
Old February 5th, 2016, 11:10 AM
Azarur
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LR 1984 110
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Air Con

After the mounts were sorted out, it came time to look into the air conditioning system. Very quickly we passed on the original factory system. Why? Again, because I'm insane! So, we went instead with a Gen IV Vintage Air system. If you haven't looked into it, then you should. It's more compact and significantly more efficient than the LR systems. Furthermore, the controls are all servos, meaning you have a variety of options for dash-mounted or even lever-mounted switches.
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  #23  
Old February 5th, 2016, 11:12 AM
Azarur
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LR 1984 110
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Perhaps the most gratifying aspect of this project was how involved my kids were. Here's Alex fabricating the compressor mount for the Vintage Air System and the final product:
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  #24  
Old February 6th, 2016, 01:17 PM
vrivas
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Victor Rivas
1994 D90
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Your truck looks awesome, just sent you a PM.
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  #25  
Old February 6th, 2016, 09:01 PM
Azarur
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LR 1984 110
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Join Date: Mar 2014
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Finally, we replaced the turbo and put in a high-capacity intercooler. Decided to use orange piping for exhaust gases (why not!!!). Also added a k-type thermocouple to the exhaust port to be able to measure EGT. Other than that, and as I mentioned earlier, adding the 300TDi style cover to reduce knocking sound, no further modifications were made to the engine. Here are photos of the proces and the final engine bay.
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  #26  
Old February 6th, 2016, 09:11 PM
Azarur
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LR 1984 110
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Body Work

By far, the toughest part of the project was the body work. The vast majority of parts needed significant repair, and about a third of them had to be replaced, including all four cabin doors. We made an early decision to absolutely not cut corners, but at the same time wanted to keep as many of the original body panels. Yet another bad decision, because in order to give repaired parts the structural integrity that would be comparable to new parts, it took an insane amount of shop time.

But enough talk. Here are the process storyboards by major body area, starting with the favorite of all defender fans: The Bulkhead!!!

And this is how bad it was when we first removed the just stupidly bad web of wires:
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  #27  
Old February 6th, 2016, 09:13 PM
Azarur
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LR 1984 110
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More "before" pictures...
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  #28  
Old February 6th, 2016, 09:32 PM
Azarur
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LR 1984 110
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Doesn't look to bad right?
Ok. Let's take a closer look:
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  #29  
Old February 6th, 2016, 09:35 PM
Azarur
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LR 1984 110
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OK. So, it's bad...
Should we replace it? Of course not! That would be too easy!!!
Let's just rebuild the damned thing! I mean how bad could it really be?
Alright, first the footwells need to be completely redone, because they are rotten to the core, so, here we go!
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  #30  
Old February 6th, 2016, 09:38 PM
Azarur
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LR 1984 110
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The mid part is ok, so let's not worry too much about that.
But the top... ay ay ay.
Ok, so here we go:
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  #31  
Old February 6th, 2016, 09:42 PM
Azarur
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LR 1984 110
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OK. Bulkhead is patched up, heat-stress-relieved, measured and aligned. So now let's sand, prime and get ready to paint!!
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  #32  
Old February 6th, 2016, 09:55 PM
Azarur
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LR 1984 110
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Ok. So now the time has come to pick a color!!

First round of votes:
Me: Racing Green
Alex: Black
Antonio: Blue
Andrew: White
Wife: "Just finish the stupid thing already and leave me alone"

So, no winner. We eliminate the Green (because "who cares what dad thinks!!?") and the white because Andrew got bored and left. So run off vote:

Me: Blue
Alex: Grey ("I am allowed to change my mind between votes!!)
Antonio: Blue
Andrew: Grey (Me" I thought you left!", Andrew: "Alex gave me a bag of chips if I vote with him")
Wife: "If you idiots ask me again, someone is going to get hurt!"

Ok. So we have a tie, and no tie breaker. So let's do it again.

Me: Grey
Antonio: Blue and "Alex, if you say blue I'll let you play Xbox even though I had called it before"
Alex: Blue
Me: What??? You can't change votes again!
Alex: "Why not??"
Wife: "Good grief"
Andrew: "I'm hungry, can we leave already. I want to eat at Koto"
Alex: "Yeah, me too! I'll have the steak"
Antonio: "Oooh. Yes. I want the spicy tuna and shrimp tepanyaki"
Wife: "Let's go!"
Me: WTF???? I guess we'll paint it blue
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  #33  
Old February 6th, 2016, 09:57 PM
Azarur
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LR 1984 110
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OK. So with the color picking fiasco behind us, time to paint the bulkhead!!
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  #34  
Old February 6th, 2016, 10:09 PM
Azarur
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LR 1984 110
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BTW, in case anyone cares, the blue is the authentic land rover "Loire Blue Metallic."
I figured, we are being so liberal with how we are changing the car, the least we can do is pick a land rover authentic color!!
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  #35  
Old February 6th, 2016, 10:36 PM
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icnsltmfg
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Adam
1988 D90 RHD 19J
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Which particular model system did you use of the Gen IV? Does that system replace the old heater core and blower assy? Does it contain both the heater and condenser coil and thus blow cold air through the bulkhead and then through the existing (and if desired) additional vents in the dash or do you still have to mount a blower unit in the cabin?


Quote:
Originally Posted by Azarur View Post
After the mounts were sorted out, it came time to look into the air conditioning system. Very quickly we passed on the original factory system. Why? Again, because I'm insane! So, we went instead with a Gen IV Vintage Air system. If you haven't looked into it, then you should. It's more compact and significantly more efficient than the LR systems. Furthermore, the controls are all servos, meaning you have a variety of options for dash-mounted or even lever-mounted switches.
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  #36  
Old February 7th, 2016, 01:11 AM
Azarur
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LR 1984 110
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Quote:
Originally Posted by icnsltmfg View Post
Which particular model system did you use of the Gen IV? Does that system replace the old heater core and blower assy? Does it contain both the heater and condenser coil and thus blow cold air through the bulkhead and then through the existing (and if desired) additional vents in the dash or do you still have to mount a blower unit in the cabin?
I'll post the exact model on Monday. No need for the old core and/or blower. It all gets replaced by the Gen IV: it contains heater, condenser and blower. You can use existing duct work or (like we did) replace with 2" tubing and new vents.
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  #37  
Old February 7th, 2016, 07:27 AM
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LostChord
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Brian
86 D110 SW
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this is an amazing thread

thank you for sharing
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  #38  
Old February 7th, 2016, 07:40 AM
vrivas
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Victor Rivas
1994 D90
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Owning a 110 gets more exciting everyday! Unbelievable work and amazing attention to detail, looking forward to seeing it complete.
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  #39  
Old February 7th, 2016, 08:19 AM
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Iamkraig
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Kraig
1987 defender 110
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Quote:
Originally Posted by Azarur View Post
Ok. So now the time has come to pick a color!! First round of votes: Me: Racing Green Alex: Black Antonio: Blue Andrew: White Wife: "Just finish the stupid thing already and leave me alone" So, no winner. We eliminate the Green (because "who cares what dad thinks!!?") and the white because Andrew got bored and left. So run off vote: Me: Blue Alex: Grey ("I am allowed to change my mind between votes!!) Antonio: Blue Andrew: Grey (Me" I thought you left!", Andrew: "Alex gave me a bag of chips if I vote with him") Wife: "If you idiots ask me again, someone is going to get hurt!" Ok. So we have a tie, and no tie breaker. So let's do it again. Me: Grey Antonio: Blue and "Alex, if you say blue I'll let you play Xbox even though I had called it before" Alex: Blue Me: What??? You can't change votes again! Alex: "Why not??" Wife: "Good grief" Andrew: "I'm hungry, can we leave already. I want to eat at Koto" Alex: "Yeah, me too! I'll have the steak" Antonio: "Oooh. Yes. I want the spicy tuna and shrimp tepanyaki" Wife: "Let's go!" Me: WTF???? I guess we'll paint it blue

Well done! I really enjoy your "story" thread. My favorite part is the involvement of your family in the process. Unless you took notes on what you would eventually post, it sure seems like your memories of the process are tied to the time with your kids. This is the most enjoyable build thread I have read. Please continue the story as you have time.
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  #40  
Old February 7th, 2016, 11:24 AM
Azarur
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The Tub

After we got the bulkhead done, I assumed the worst was over.
Oh boy. Was I mistaken.

As I've said before, the frame was super solid, so I (wrongly) assumed the floors in general would be in ok shape. Of course corrosion is a bitch, and the fact that one specific part made of a specific metal is solid, that does not mean that another metal subject to the exact same set of conditions will be the same. In fact, anyone who has taken a class in electrochemistry knows that a metal with a certain electronegativity in contact with another metal with a different electronegativity in contact with a corroding fluid (i.e. water) will rapidly decay.

And we had ample proof of this! Every inch of the underside of the driver, passenger, middle row and tub floor was rotten to hell. So we basically had to replace everything. It was an interesting discussion. How do we make sure we have the absolute best material in terms of strength and corrosion resistance (for example stainless steel sheet) and at the same time prevent future corrosion when it will be in contact with the aluminum body panels? By the way, did you know the original choice by land rover to go with aluminum was a result of steel shortages in the UK in the 1940s and not the savings in weight usually quoted by people? Should we forgo stainless and go with thicker aluminum sheet needing more weight and giving up on rigidity? Should we use stainless and insulate the joints with epoxy? Given that the floor supports are steel we decided to stay steel throughout and epoxy the joints prior to riveting. Overkill? For sure! But hey, I'm not spending two years building this guy just to end up with a corroded floor in a year!!

Here's the before photos.
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