My NAS D110 Rebuild - Page 2 - Defender Source
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  #21  
Old November 23rd, 2016, 12:56 PM
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Lesandjes
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AndrewT
'93 NAS D110
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So updating to the 2nd row Puma seats was a PITA. I read about it and first tried the method via that video that everyone has seen where they just shim the seat bolt mounts. Basically I saw no way to make that work. You could do it but the seat-back was still almost vertical and very uncomfortable so I didn't see that as something that would work. Cutting the tub seemed required though I hated doing this.....

I decided to use 4" square aluminum stock since that looked to be usable for the size of opening needed in the tub and it turned out to be just perfect in size:
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Made a box with rivets and designed it so that the tub metal we were cutting could be overlapped onto the tub insert - this is a shot of pre-fitting the piece and before finishing - not easy to do but with paint and some body joint compound its no worse then how the rest of the tub fittings and alignment came from the factory (you wouldn't believe how much seam sealer I had to remove from the body and floor panels when they came apart for painting - the gaps were almost 1/2" in places):
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The seat now sits in the correct recline position and there is barely enough room left there for everything to fit but it does:
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I have a lot more pics and this was not an easy job at all. Again Thanks to Abe for his great work here on the design and construction. I am sure there are other ways to do it and maybe better ways but this was actually pretty cheap and worked out fine in the end.
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  #22  
Old November 23rd, 2016, 01:15 PM
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Lesandjes
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AndrewT
'93 NAS D110
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The onto other smaller jobs to clean things up...

Had my old headliner redone and came out nice:
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Put in this Terrafirma overhead console for more mounting options and lights - will probably put a CB or equivalent radio in there soon:
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Shutoff switch for the winch inside the DS seatbox compartment - also replaced the battery with the Diehard shown:
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I put an auxiliary fuse block in the PS seatbox compartment - a lot of my aftermarket accessories wire there like the seat heaters, subwoofer, USB and DC ports, etc...
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Stealth winch solenoid and wiring under the ARB:
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Winch remote outlet mounted on the ARB:
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I don't have a pic but I also installed an on-board battery charger in the PS seatbox compartment - the plug is plumbed flush underneath so I can just plug in an extension cord when in the garage to keep it charged. I don't drive it every day and the alarm draws a decent enough current that it needs the charger.
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  #23  
Old November 23rd, 2016, 01:28 PM
NTXRover
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NAS Defender
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This is like binge watching an entire series on Netflix in one day. This is great!
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  #24  
Old November 23rd, 2016, 01:31 PM
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AndrewT
'93 NAS D110
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Before and After:
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  #25  
Old November 23rd, 2016, 04:03 PM
rmuller
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Ryan
1966 S2a 88" | 2006 LR3
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Looking great andy!
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  #26  
Old November 23rd, 2016, 04:10 PM
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Ted Baumer
1986 LHD 110
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Taking out the time between steps makes it seem so fast & easy!
Thanks for sharing the pics to show the journey.
I'll be looking back on this thread when I start mine.
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  #27  
Old November 23rd, 2016, 04:39 PM
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Oscar
D110
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Nice! You wouldn't happen to have made a template for the terrafirma overhead console clearance for the B hoop?
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  #28  
Old November 23rd, 2016, 07:23 PM
jason1st
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Jason Crandall
2006 LR3 2012 SC 1983 110
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Looks great.
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  #29  
Old November 23rd, 2016, 08:35 PM
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Ron Dade
97/D90 Soft Top
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Quote:
Originally Posted by Lesandjes View Post
Before and After:
Great looking truck! This NAS is nice.
Quote:
Originally Posted by Lesandjes View Post
I always liked the stock look of the truck so first order of business was to remove the 3" lift with new stock lift springs and also replace the 33" tires with 31s on the newly painted white rims - did a knuckle rebuild in between there as well....

Attachment 169449

Attachment 169441
Quote:
Originally Posted by Lesandjes View Post
The interior needed a lot of work obviously since everything was gutted. I ideally want to replace the stock NAS D110 dash as its complete crap - plastic and looks like sh&t but that endeavor gets expensive when you get into all of the integrated HVAC components that need to be addressed as well in that job so I stuck with what I had and did the best to make it work for now. Td5 (or maybe even Puma) dash will be done sometime in the future.

I had planned to replace the carpet but the guys at SafariHP and elsewhere convinced me thats a bad idea so I went with the heavy rubber mats and very happy I did. I don't want a repeat of what happened to me before.

Attachment 169553

Attachment 169561

I added two gauges to the stock lower dash trim for vacuum and a real temp gauge since the stock one has that signal conditioner and I had the space
Attachment 169569

I built this metal insert for the front of the cubby - its removable as it just sits in there but houses all of my aftermarket switches and also adds USB power ports and an LED battery indicator - the switch on the side lets me turn the power to that console on or off as its direct wired to the battery. The tray around the shifter is plastic from some place in the UK but gets me more outlets and also cup holders though its rather flimsy and I need to find a way to secure it down better.
Attachment 169577

I built the rear speaker boxes and wrapped them in carpet. The DS box also houses the ARB compressor.
Attachment 169585

Powered Punch Subwoofer sits in the back - I like my music but now need to upgrade the front amp as well as it needs more power
Attachment 169593

Sent from my SM-G920V using Tapatalk
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  #30  
Old November 24th, 2016, 07:01 AM
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Elbee
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Lance
1989 110 200tdi
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Nice build!
How long did the build take?
Also why didn't you convert the ARB lights to clear to match the rest?
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  #31  
Old November 24th, 2016, 07:29 AM
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Will Hedrick
Defender 90 & Defender 110
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Great work sir! Thanks for sharing!
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  #32  
Old November 28th, 2016, 07:22 AM
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Lesandjes
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AndrewT
'93 NAS D110
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Quote:
Originally Posted by BlackField View Post
Nice! You wouldn't happen to have made a template for the terrafirma overhead console clearance for the B hoop?
Sorry No I don't - but you do need to make one to get it right! Just play around with some cardboard....

------ Follow up post added November 28th, 2016 08:26 AM ------

Quote:
Originally Posted by Elbee View Post
Nice build!
How long did the build take?
Also why didn't you convert the ARB lights to clear to match the rest?
It took 4+ years working on and off - I thought I could get it done in 6 months once it came back from paint but it ended up sitting in my garage untouched for 18 months while I contemplated a diesel upgrade and Td5 dash and some other things which I finally decided to wait on. Once I started working on it part time it went faster though still some 3-6 mth stretches in there where work/travel and family obligations basically stopped progress. Plus it can be hard to motivate when the task list is endless so I'd be lying if I didn't admit part of it was procrastination-based.

The clear ARB lenses would be cool - I didn't think of that - will have to try and find some. I thought of making the front indicator lenses clear as well but can always change that later.

AndrewT
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  #33  
Old November 28th, 2016, 07:42 AM
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Lesandjes
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AndrewT
'93 NAS D110
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I should mention I glossed over a few things which were also done during the rebuild process - as I mentioned the drivetrain was basically new but I still had a fair share of mechanical issues to address before, during, and after the work especially since it sat for 3-4 years in there when the work was getting done:

- Went thru 3 coils - one replacement was DOA - second died after starting the truck twice - third one was OEM and still going strong
- Replaced fuel pump as the original stopped working somewhere in there
- Decided to replace the gas tank at the same time since was pulling it anyway for the fuel pump - glad I did this as it was getting nasty
- Replaced fuel sender to trace back why gas gauge wasn't working - forgot the rubber gasket and went to fill up the truck only to have fuel pour out the sender opening - had to drive it home 2 miles because it was dumping fuel all over the gas station parking lot - not good....I was sure my truck was going to burn down as others have in the past (though my oil cooler lines have been updated)
- Replaced gas and temp gauges
- Replaced AC compressor and dryer with new parts in hopes of getting the original AC system (which basically sucks) working to some minimum level - did get that done (replaced all the belts upfront as well) but cooling is not so great - I think its now overcharged but need someone with more skill to look at it (It did draw a good vacuum and leak-tested fine so maybe there is still hope there)
- Completely dis-assembled and then rebuilt the HVAC box in the engine bay - wanted to make sure all the stuff in there was functioning and clean and hopefully this will help in the AC repair as well

It was then running fine so I drive it around to start breaking it back in - breaking was the key word as every drive yielded something else that wasn't working. It was fine until this Summer then saw the temp raising beyond where I thought it should be - even on the aftermarket gauge which should be accurate - found a faulty thermostat and replaced that and had it pressure tested - good to go. Drove some more and more overheating so after a lot more trial and error I decided to just update the whole thing:
- Replaced water pump
- Fitted new radiator
- New viscous fan clutch
- Replaced most of the radiator hoses

Drove it and seems to be better but cooler out so who knows. I think I've drained the oil and coolant like 5 times now in the process. Getting good at it and don't want to go through that anymore....

Regards,
AndrewT
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  #34  
Old November 28th, 2016, 10:05 AM
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Lesandjes
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AndrewT
'93 NAS D110
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Great work sir! Thanks for sharing!
THANK YOU! Its an honor to have you comment here - for all you've done for the defender community!!!!
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  #35  
Old December 22nd, 2016, 10:53 PM
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Jon E
'92 110 200TDI
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Looking great!
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