Sam's Defender 90 restoration - Defender Source
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  #1  
Old December 3rd, 2013, 12:08 AM
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Sam
1994 NAS SW
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Sam's Defender 90 restoration

So as some of you already know I pounced on this truck that popped up on craigs list locally a few weeks ago. Its a 95 ST. The previous owner off roaded it pretty hard but it only has 68k miles. He was able to achieve a salvaged CA title status due to the fact that he rolled it over on some sand dune. He told me his insurance co compared the cost of replacing all the body panels with the blue book value and decided to just pay out the total value. He kept the truck and essentially did nothing to fix it after that other than beating out a few of the body panels.

Due to the fact that I like doing restoration work and it needs so many body panels anyway I've already started stripping it down to the frame for a complete restoration. This is a west coast truck so I'm not running into any major rust issues which is refreshing after my last build. The frame is in perfect condition with only minor surface rust in a few spots so I'm gonna send it to a place in AZ to be sandblasted and hot dip galvanized. I've got new body panels on their way from Safari HP. I'm gonna try to keep it fairly stock except for a few little upgrades I think will be cool. I'll just keep you in suspense for now. (Here's a hint: I'm not fond of manual transmissions)

I've never been a fan of white and although I'm nowhere close to paint yet, I'm leaning heavily toward a bonatti grey type color. I really like G4 orange too but thought it might be to obnoxious.
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  #2  
Old December 3rd, 2013, 12:11 AM
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Sam
1994 NAS SW
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Sam's 90

Here's where i'm at as of today.
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  #3  
Old December 3rd, 2013, 06:59 AM
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Don Bunnell
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Sub'd

You move fast! For a salvage NAS I think a color change would actually increase value. Although, done correctly and with a good color - which sounds like you have covered.
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  #4  
Old December 3rd, 2013, 08:14 AM
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Will Hedrick
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Originally Posted by One Ten View Post
Here's where i'm at as of today.
Nice work, Sir! And, great find! Keep the updates coming!
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  #5  
Old December 3rd, 2013, 11:28 PM
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We missed that one - Enjoy
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  #6  
Old December 5th, 2013, 07:47 PM
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Sam
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Started on the engine today. Previous owner put in a 4.2 ltr block. Internals look good so far. I'll have the heads hot tanked, shot peened, new valve stems seals and new valve springs. This engine will get new head gaskets, new head bolts, new valve cover gaskets, new rear main seal, new timing chain cover seal, and reseal the oil pan.

I'm also gonna switch all the ancillaries over to a serpentine belt set up from a 95 Disco. I hate the other set up. Ever try to change the power steering pump on that set up? No thanks
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  #7  
Old December 5th, 2013, 09:46 PM
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Keep those pictures coming! I'm about to replace my rear wing skins, so it will be great to know what to expect. Sub'd!
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  #8  
Old December 7th, 2013, 10:28 PM
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Are you going to dip the bulkhead too?
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  #9  
Old December 8th, 2013, 01:07 AM
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Sam
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Goodbye frame! Off to get sand blasted and hot dip galvanized. Next time I see it, it'll be shiny zinc.
Not doing the bulkhead. It's going to get painted then coated in and out with line-x.
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  #10  
Old December 8th, 2013, 08:35 AM
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Crap I was just in Vegas too. Cold as F.
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  #11  
Old December 8th, 2013, 09:53 AM
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Ahh!! After having done this before: galvanize everything steel if you can! Bulkhead included!

Looks great though
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  #12  
Old December 12th, 2013, 04:49 PM
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Since my frame is out getting galvanized and the engine is at the machine shop I decided to do some work on the rear axle. Cleaned it all up and repainted it. I used high heat spray paint on the calipers. Brand-new rotors and brake pads.
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  #13  
Old December 12th, 2013, 05:25 PM
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Why line-x all over the bulkhead?

lookin' good by the way...
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  #14  
Old December 12th, 2013, 05:52 PM
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Whoa! That looks great. I am in the process of installing my Toy axle on my galvy frame and I am going to paint the calipers, hub, and rotor hat. This will give me some motivation.

I would take off those dust plates tho. They seem to do more harm than good (as in holding moisture and dirt in).
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  #15  
Old December 12th, 2013, 05:56 PM
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Jason Lavender
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Quote:
Originally Posted by don View Post
I would take off those dust plates tho. They seem to do more harm than good (as in holding moisture and dirt in).
Ironically I always thought that too...BUT we found recently that they can be fairly effective oil/blowback barriers. I recently had a trans issue that literally blew MTL all over the place - only thing that saved me from replacing my brakes/rotors (in theory) was that the dust shield totally kept all the fluids off the brake setup.

Huff or Galpin had a similar experience recently with a leak as well if I recall...so we've been converted to looking at them not as dust shields, but as leak shields!
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  #16  
Old December 12th, 2013, 11:55 PM
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Sam
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Originally Posted by revtor View Post
Why line-x all over the bulkhead? lookin' good by the way...
I talked to Stephen at Safari HP. He told me that's what they do. I've seen it on some of his builds and it looks cool. Seems it would deaden sound and insulate against heat a little too.
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  #17  
Old December 13th, 2013, 12:07 AM
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Sam
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Like this
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  #18  
Old December 13th, 2013, 12:17 AM
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Originally Posted by One Ten View Post
Like this
i did the same thing but I laid down dynamat before the spray liner
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  #19  
Old December 13th, 2013, 10:15 AM
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Don Bunnell
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Originally Posted by nathanwind View Post
Ironically I always thought that too...BUT we found recently that they can be fairly effective oil/blowback barriers. I recently had a trans issue that literally blew MTL all over the place - only thing that saved me from replacing my brakes/rotors (in theory) was that the dust shield totally kept all the fluids off the brake setup.

Huff or Galpin had a similar experience recently with a leak as well if I recall...so we've been converted to looking at them not as dust shields, but as leak shields!


haha, leak shields. Never thought of it that way. That must have been a hell of a mess with the tranny to get fluid that far out to the axles! No need for waxoyl tho :D


The ones with this axle were so rusty I just tossed them. The ones that were on the 90 went back with the new owner.
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  #20  
Old December 20th, 2013, 09:24 PM
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Sam
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Finally got my frame back from being galvanized so now I can start making some progress!
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