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February 7th, 2016, 10:28 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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So. Enough whining and let's get going with this. Job 1: Measure twice and cut many more times than twice!!
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February 7th, 2016, 10:30 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Then let's get all the cross-supports lined up, epoxyed, bolted and ready to go.
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February 7th, 2016, 10:35 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Finally, let's isolate every metal joint and put everything together. Once it's all bolted and straight, let's apply anticorrosive compound and lizard skin to the entire bottom. Lizard skin is amazing. First, it obviously isolates sound (that's what it is primarily used for). Second, and in our case most important, it provides a moisture barrier, and because of the roughness of the compound it creates nucleation sites for water droplets and condensation, which reduce surface tension and make them drop and dry much quicker than flat metallic surfaces. If you think spraying the entire bottom of a 110 with lizard skin is a waste, try not doing it!
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February 7th, 2016, 10:44 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Seat Mounts
By now, I'm sure a couple of purists are gasping and going catatonic, because there's something not quite right with the middle-row seat mounts. Why does it look weird? What is this guy doing?
Well, this guy is 6 ft tall, which should fit comfortably in the front seat without raisers and extenders. However, Antonio (13) is ALREADY 6ft tall and shoe size 11. Alex (11) is 5'6" and shoe size 9.
Now we have a new issue:
There is just NO WAY they will fit in the middle row in a year or two, and there is NO WAY my wife will let them ride shotgun (even though she is "only" 5' 5"). So. We gotta move the middle row back *gasp*. All the guys are saying to me: "What is wrong with you?!? You will sacrifice off-road performance just to fit your freakishly large children?"
Uhhh. Yes! I suck at off-roading! So if I lose about an inch of wheel travel the one time a year I'll take my 110 off road vs. have to hear the three of them whine and complain on the 5-hour drive to our annual summer camping trip, or the 3-hour WEEKLY ski drives in the winter, that's really well worth it!!
So. Purists, please take a break (or a zanax). The rest of you enjoy watching the defilement of a virgin 110!!
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February 7th, 2016, 10:46 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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By the way.. the seats are AWESOME! They were a bit pricey, but Defenders Northwest did a fantastic job sourcing these amazing, Puma-style, black leather with silver stitching, heated seats. Hats off to them!!
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February 7th, 2016, 11:05 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Alright. So we have to move the middle row seats back about 4 inches. How did we come up with 4 inches? We used an evolutionary technique called growth projection protocol. Basically I got my dad, who is a huge dude (6' 4" and like 250 lbs), and happened to be visiting, to sit in the middle row and assume that's going to be the average size of my three boys!
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February 7th, 2016, 11:09 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Ok. After cutting the old mounts, now we have to fabricate new ones. And again, we are following the same standards: Stainless, insulate, lizard skin!
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February 7th, 2016, 11:11 AM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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By the way. Two really difficult things:
1. Keeping everything square while changing so many body parts. So the guys built this beast of a frame to make sure everything lined up. You can see it in the last picture.
2. Seat belts for the middle row required a re-design of the tensioner. Was not easy!
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February 9th, 2016, 04:58 PM
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Adam
1988 D90 RHD 19J
Member
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Join Date: Jul 2012
Location: North NJ
Posts: 527
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Don't forget to post the info on the A/C unit and how you mounted the new heater box...
__________________
America Runs on Dunkin'
Rovers Run on Diesel
2017 Range Rover L405 HSE TD6
2008 Range Rover HSE L322/MkIII - Gone but not forgotten
1988 D90 County RHD 2.5TD
2015 Porsche Cayenne TD
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February 10th, 2016, 03:21 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Roof
The next area was the roof. Our roof was in excellent shape, so luckily not much body work was needed. Here are the before photos:
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February 10th, 2016, 03:24 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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As we started removing the old white paint, some small defects became apparent. Luckily no major repair work was required.
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February 10th, 2016, 03:27 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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After repairing the small areas of rust the roof was primed, and sanded. Afterwards, and just as it was done for the undercarriage, lizard skin was applied. Finally, dynamat was used for final thermal and sound isolation.
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February 10th, 2016, 03:31 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Rear Quarters
Next up were the rear quarters. Those were a mess! Corrosion everywhere, nasty patches of bondo, lack of structural integrity. Here are the "before" pictures:
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February 10th, 2016, 03:35 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Given the sorry state of the rear quarters, we decided to take them completely apart and repair what made sense, but replace what could not be done with the standard of integrity, stability and appeal that we established. I would say about 30% of metal was replaced:
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February 10th, 2016, 03:38 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Following metal work, the rear quarters were put back together, primed and the joints were painted. I am very proud of how amazing those turned out after the state of disrepair they were on initially.
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February 10th, 2016, 03:42 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Hood
The hood was boring. Not a major area of trouble. Yawn. Here are the pictures:
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February 10th, 2016, 04:13 PM
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JT
D90 óriginalé
Member
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Join Date: Apr 2011
Location: DC/MD
Posts: 2,888
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great thread, nice build, I have garage envy
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February 11th, 2016, 03:07 PM
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AZ
LR 1984 110
Member
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Join Date: Mar 2014
Location: California
Posts: 307
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Here are the bodywork photos and modifications:
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