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Thread: Defender Rust Repair

  1. 12th July 2009, 09:17 PM #1
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    Defender Rust Repair

    Well this job should have taken at least a month but with work, kids and other things that I repaired and replaced it took a little longer.

    A few months ago when we had all that rain I decided to put the old defender in the shed for a service and track down some of the water leaks and along the way I discovered rust.

    After pulling the whole dash and aircon unit out of the car a found the firewall had rust behind the dash and a new the floor on the passenger side had rust.

    I forgot to take a few pics before cuting some of the rust.





    Aaron & Jacinta
    1994 300Tdi Defender
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  2. 12th July 2009, 09:28 PM #2
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    Rust cut and ready for welding

    Well after cuting out all the rust I went and bought a sheet of 2mm 600x600mm sheet of steal and cut out new plates to weld in.









    Aaron & Jacinta
    1994 300Tdi Defender
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  3. 12th July 2009, 09:55 PM #3
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    Welding

    I would like to thank Dave (incisor) for his time and welding.

    A few pics of the welding and preparing for painting.























    Aaron & Jacinta
    1994 300Tdi Defender
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  4. 13th July 2009, 09:53 PM #4
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    Herculiner

    As usual plans change and I make more work for myself ..

    I thought I might paint the inside of the defender with that paint they use in ute trays.Anyway after looking at different options and products I decided on a product called Herculiner.

    Here are some before pics









    After herculiner from firewall to the rear door











    Aaron & Jacinta
    1994 300Tdi Defender
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  5. 13th July 2009, 10:04 PM #5
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    Random pics

    Just some other Random pics..

    I also used herculiner on the rear crossmember



    I also bought some sound proofing foam from clark rubber 10mm.

    Behind aircon



    Driver side



    My new floor mats my brother gave me (He works for Mack)





    Front of firewall



    Aaron & Jacinta
    1994 300Tdi Defender
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  6. 9th August 2009, 09:39 AM #6
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    Nice one Aaron

    That Herculiner stuff looks like the trick! I wonder if it would wear through any mats / carpet placed on top of it..

    I think I just found the solution to lining the back of my County!! Is it easy to get in Australia?

    dec
    Hercules: 1986 110 Isuzu 3.9 (4BD1-T)
    Brutus: 1969 109 ExMil 2a FFT (loved and lost)
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  7. 9th August 2009, 10:33 AM #7
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    Quote Originally Posted by flagg View Post
    Nice one Aaron

    That Herculiner stuff looks like the trick! I wonder if it would wear through any mats / carpet placed on top of it..

    I think I just found the solution to lining the back of my County!! Is it easy to get in Australia?

    dec
    I was interested too

    Herculiner Retailers Australia UTE LINER tub liner BED LINER rhino liner SPEEDLINER DIY


    We could look at a 4 buddies pack, I must ask my mates what a buddy is....
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  8. 17th August 2009, 06:30 AM #8
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    that looks pretty impressive Aaron - i think i know what i will be doing in a few weeks time - job well done
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  9. 17th August 2009, 07:07 AM #9
    aki Guest

    well done!

    impressive job! I like it, well done. axel
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  10. 17th August 2009, 07:20 AM #10
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    Nice work, i bought a tin of herculiner to do the back of my 110 too, i wasn't sure if i would have enough to do the seat box etc as well, did you use only 1 tin?

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