Tub/Bumper/Jumpseat Redo - Defender Source
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  #1  
Old October 30th, 2009, 10:09 AM
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Don Bunnell
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Tub/Bumper/Jumpseat Redo

I decided to change up the rear seat configuration in my 90 and evilfj had some jumpseats for sale. Looking at how to mount, I realized I needed to make some seatbelt brackets - so I used some angle and flat iron I had laying around and got them made up

A few weeks earlier I had pulled the fuel pump to try and solve a rough running issue. And ended up breaking bolts and noticing the bumper didn't look too healthy.

So combining the two thing, this turned into a "Might as Well" project. Might as well do the following:

- Get a new Tank Guard (thanks Safari Rovers - this item is dialed!)
- Pull bumper, sandblast and powdered
- Get the rear sway blasted and powdered
- Get brackets blasted and powdered
- Looking at ECR site for jumpseat info I noticed they used DynaMat on a lot of the builds so it must work
- Fill in the holes in the tub from the bench with Devcon Aluminum puddy
- POR-15 frame in the tank area
- Chassis Black frame over the POR-15

Some pics I put up on my site:

http://bankbikes.com/D90/Tub_Project/
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  #2  
Old October 30th, 2009, 10:30 AM
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Charles Galpin
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Nice. I love the picture with the little girl peeking at you.

Tell me about this putty please. How big of a hole can you span?
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  #3  
Old October 30th, 2009, 10:52 AM
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Jim Cheney
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Nice, those mounts are better than OEM for sure.

You know you can put a twist in your brake line to keep it from rubbing on the chassis?
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  #4  
Old October 30th, 2009, 12:53 PM
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You need to pull those plates off and paint them and then I would put rubber between them and the tub. Otherwise, looks great!
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  #5  
Old October 30th, 2009, 01:14 PM
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Don Bunnell
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Quote:
Originally Posted by cgalpin
Nice. I love the picture with the little girl peeking at you.

Tell me about this putty please. How big of a hole can you span?
That's actually my 3 year old son poking his head thru. I'm at home with him so he's usually has a project going on next to me. He help tape up although he had pieces all over the place.

Devcon is pretty slick stuff - http://www.devcon.com/products/produ...1&familyid=107

I filled in holes probably 15mm across - it could have been bigger if I used something harder behind it like plastic instead of masking tape. It's not cheap but overall I'm happy with it. Buckon37's posted about it.

Follow-up Post:

Quote:
Originally Posted by JimC
Nice, those mounts are better than OEM for sure.

You know you can put a twist in your brake line to keep it from rubbing on the chassis?
Thanks - I took a while to figure out how I wanted them. Just keep measuring/fitting/unfitting/cutting. Toook a while but I wanted them to be safe and strong as possible.

Will put a twist on the brake line - thanks for the tip!

Follow-up Post:

Quote:
Originally Posted by evilfij
You need to pull those plates off and paint them and then I would put rubber between them and the tub. Otherwise, looks great!
O, the plates were pulled off and sent to powder with the bumper (hence the Might as Well scope). I have to say the powder hid all my flaws in shaping - they look almost pro-made

Didn't think of the rubber but that sounds like a smart move. Would something like a bicycle tube work or it need to be thicker?

Seats are so nice - thanks again. It's taking me forever to install but I'll be stoked when it's all buttoned up. Trying to get everything done for Rausch Creek next week.
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  #6  
Old October 30th, 2009, 01:14 PM
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Quote:
Originally Posted by don
That's actually my 3 year old son poking his head thru.
oops. Very cute nevertheless!

Thanks for the info on the devcon.
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  #7  
Old October 30th, 2009, 01:23 PM
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Bicycle inner tube would work fine. Cut it about 1/4in bigger all the way around for the ones under the bottom of the tub and the top should be fine over the carpet.

Glad you like them. They were really in perfect shape. I only sold them because I found a set out of a 1997 SW to match my 1997 SW front seats in my series truck.
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  #8  
Old November 3rd, 2009, 12:42 AM
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Don Bunnell
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I'll add pics in the next day or so.

Over the weekend:

- Got everything tape off, sanded, Marine Clean, Metal Ready
- Etching Primer on all the frame and rear cross
- POR-15's Chassis Paint - what a pain in the ass using the brush. Next time I would use a spray from Eastwood.


Today:
- Sanded the rear cross and a bit of frame and then finish coated with the Chassis Black
- Waxoyl 120-4 areosol in as many holes in the frame I could get
- Got the tank reinstalled with new rubber breather and new fuel filler hose
- Installed the alloy Safari Rover guard although I had to enlarge 2 holes to get it to line up. It does look so nice all put together

Still need to reinstall the bumper, replace and replace the driver side rear seal. Might start the Dyna-Mat if I have time tomorrow.
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  #9  
Old November 7th, 2009, 10:15 AM
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Don Bunnell
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Added more pics:

http://bankbikes.com/D90/Tub_Project...CleanUp_06.jpg
Drivers side rear w/ everything but the exhaust bracket installed

http://bankbikes.com/D90/Tub_Project...CleanUp_07.jpg
Passenger rear all buttoned up

http://bankbikes.com/D90/Tub_Project/D90_Bumper_01.jpg
Bumper from the rear

http://bankbikes.com/D90/Tub_Project/D90_Bumper_03.jpg
Bumper/Gase Tank skid plate view

http://bankbikes.com/D90/Tub_Project...oy_Skid_01.jpg
Safari Rover's nice piece of alloy product

http://bankbikes.com/D90/Tub_Project...d_Guard_02.jpg
I didn't want to get all my nice new stuff snotty at Rausch so tried to fab a quickie mud guard. It needs some work (actually redone completely) but I think the concept is good. I left the driver's side free to compare.

More pics: http://bankbikes.com/D90/Tub_Project/
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  #10  
Old November 9th, 2009, 09:22 PM
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Quote:
Originally Posted by don
Added more pics:

http://bankbikes.com/D90/Tub_Project...CleanUp_06.jpg
Drivers side rear w/ everything but the exhaust bracket installed

http://bankbikes.com/D90/Tub_Project...CleanUp_07.jpg
Passenger rear all buttoned up

http://bankbikes.com/D90/Tub_Project/D90_Bumper_01.jpg
Bumper from the rear

http://bankbikes.com/D90/Tub_Project/D90_Bumper_03.jpg
Bumper/Gase Tank skid plate view

http://bankbikes.com/D90/Tub_Project...oy_Skid_01.jpg
Safari Rover's nice piece of alloy product

http://bankbikes.com/D90/Tub_Project...d_Guard_02.jpg
I didn't want to get all my nice new stuff snotty at Rausch so tried to fab a quickie mud guard. It needs some work (actually redone completely) but I think the concept is good. I left the driver's side free to compare.

More pics: http://bankbikes.com/D90/Tub_Project/
Looks great!
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  #11  
Old November 22nd, 2009, 12:22 PM
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Looks great Don. I would not even bother with the rear sway bar. You will not notice a difference and its not needed at all.
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  #12  
Old November 22nd, 2009, 04:41 PM
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Quote:
Originally Posted by TDI Guy
Looks great Don. I would not even bother with the rear sway bar. You will not notice a difference and its not needed at all.
Eh, I like mine a lot.
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  #13  
Old November 22nd, 2009, 11:59 PM
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Don Bunnell
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Thanks Randy - I've been lacking on getting the seats back in and finishing the project. With this warm weather I've been riding my bike too much and was in FL then NC for a week. Off to VT next week. Maybe I'll get it done before Xmas.

I took off both sways for the trip to Rausch/Rovers on the Rocks. I can't say for certain but I think it helped a bit - felt like I was getting thru sections a little more easily. Ron - what's your opinion on the front sway? Keep both on or just rear?
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  #14  
Old November 23rd, 2009, 07:24 PM
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I would say if you want a sway bar, just the front but Both my trucks have none and they feel great on and off road. One has 3" lift and a 3 link up front and the other 2". They both ride great without them.
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  #15  
Old November 23rd, 2009, 07:30 PM
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They feel great until your wife drives them. I run a front on my 90, and plan on putting the rear back on the 110, party because it has no front sway mount.
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  #16  
Old November 23rd, 2009, 07:48 PM
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Your project looks great and is inspiring. Don and TDI... you guys do all your own work? The blasting and powdering too? I recently geared up for a rear door project for my 97 SW and the bottom of the rear cross member was rotted. The more sanding and grinding I did the more I wanted to shed a tear. I need to find a shop that I can trust to do some work and thought you could advise. I live in Edison so anywhere in the metro area is worth a look.
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  #17  
Old November 27th, 2009, 11:44 AM
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Don Bunnell
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Quote:
Originally Posted by minch77
Your project looks great and is inspiring. Don and TDI... you guys do all your own work? The blasting and powdering too? I recently geared up for a rear door project for my 97 SW and the bottom of the rear cross member was rotted. The more sanding and grinding I did the more I wanted to shed a tear. I need to find a shop that I can trust to do some work and thought you could advise. I live in Edison so anywhere in the metro area is worth a look.
Thanks - I've seen Randy/TDI's work in person and it blows away my stuff - so clean and complete.

I wish I had a sandblaster and powder set up but I bring it to some local places. Both the sandblast and powder guy are in Middletown so it might not be that far of a drive from Edison. There must be some places that do it closer to you - seems like a lot of business in that area.

What are you looking to do for your cross member? Take the whole thing out and weld in a replacement? I have a buddy that is a really good welder that might be able to do it. Or try to prep as much as you can and bring it to a welding place. I've done that for some projects that I don't have time to bring to my friends house and the better I prep the better the weld job comes out.
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  #18  
Old November 27th, 2009, 09:33 PM
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I prefer both sways, but I drive my D90 like my lotus.
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  #19  
Old February 23rd, 2010, 03:45 PM
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Don Bunnell
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Wow - I am slow.

Finally got the jumpseats installed.

List of things done from the last pics:

- Dynamat the whole rear tub - expensive but makes things so much quieter
- Because I couldn't get a LR rubber load mat when I was putting it back together I went with indoor/outdoor carpeting from Lowes. I think it was $25 for an ample sized. I figured if I totally snotted it up I could replace it for nothing and for the dogs and kids the carpet might be a little nicer.
- I cut my old load mat so the rubber piece lays in the middle.
- Per ECR's site suggestion I taped washers above the Dynamat and under the carpet.
- Per Evilfij's suggestion, I cut up a rubber bicycle tube and put that in between the plates and the tub. PITA but I'm happy I did it.
- The angle brackets are impossible to see/take pics of but worked out well.

http://bankbikes.com/D90/Tub_Project...t_seatbelt.jpg
The best shot I could get of the angle bracket for the seatbelts

http://bankbikes.com/D90/Tub_Project...mpseats_01.jpg
Looking in from the back

http://bankbikes.com/D90/Tub_Project...mpseats_02.jpg
Looking in from the passengers seat

http://bankbikes.com/D90/Tub_Project...om_bracket.jpg
Brackets from the rear tire view. I might get longer M10 bolts so I can fit washers in there.

http://bankbikes.com/D90/Tub_Project...mpseats_up.jpg
Looking in from the back with the seats up
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  #20  
Old February 23rd, 2010, 04:46 PM
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Nice work Don.
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