Around Australia Touring Defender Build

[Bushman83]

Hey everyone

Thought I’d finally get around to writing up the work I’ve done over the last 6 months on my Defender 110 in preparation for a trip around Australia. Basically I’ve spent the last seven years saying maybe next year… next year…. next… Of course it’s never happened and as I’m turning 29 this year, decided to make this trip a reality. I decided to give myself 2 years to prepare for a 1-2 year trip around Australia beginning in January 2014. :)

So 3 days after Christmas 2011, I began stripping and improving my gorgeous 1993 Defender 110. She is mostly standard with a few things I’ve added since buying her in 2006. You can see my truck as she was in this tribute video I produced.

My Land Rover Defender 110 Tribute - YouTube

(http://www.youtube.com/watch?v=pQTcToAFi0Q)
http://eftel.com/%7Emrlewis/defender/defend.jpg


Here’s the interior as it was.

http://eftel.com/%7Emrlewis/defender/rear.jpg




And after stripping everything and hosing out. :D

http://eftel.com/%7Emrlewis/defender/clean1.jpg



Some minor rust in the usual places. :(

http://eftel.com/%7Emrlewis/defender/rust.jpg


I began removing the rust from the bottom of the doors and welding in new sections and using a 3 part rust remover for everything else.
http://eftel.com/%7Emrlewis/defender/doorrust1.jpg
http://eftel.com/%7Emrlewis/defender/door-rust.jpg


Dynamat

To reduce the noise and make my truck comfortable for thousands of kilometers, I bought 4 boxes of Dynamat Xtreme. Installation was easy but took a few weeks to complete. This made a very noticeable difference in the ride quality with the ability to talk at a reasonable level without yelling, and actually being able to listen to the radio without it cranked. :D

http://eftel.com/%7Emrlewis/defender/dynamat1.jpg

http://eftel.com/%7Emrlewis/defender/dynamatroof.jpg



The roof was also covered and then closed cell foam added for insulation. The difference in interior temperatures has been quite dramatic.:)
http://eftel.com/%7Emrlewis/defender/roof-foam.jpg


Electronics were next on the list and I had some minor surface rust behind the dash which I wanted to remove before it spread. Off with the dash.

http://eftel.com/%7Emrlewis/defender/dash00.jpg



I’m very thankful I did too, as I discovered a major short in one of the high current wires which had its insulation melted through with 2 smaller wires. This was promptly ducktaped up.



The rusty dash was pulled apart and sent to the powder coaters, along with dynamat installed internally.


http://eftel.com/%7Emrlewis/defender/defender2012-073.jpg

http://eftel.com/%7Emrlewis/defender/dash2.jpg


I took the opportunity to replace the plastic binnacle mount with a metal Raptor Engineering unit. This alone removed a lot of rattle.
http://eftel.com/%7Emrlewis/defender/binnacle.jpg


Raptor Engineering Dash

Next the raptor dash was installed. Quick and easy. Sorting out the wiring took some work though. I added several extra wires for later additions.

http://eftel.com/%7Emrlewis/defender/raptor00.jpg

http://eftel.com/%7Emrlewis/defender/raptor2.jpg

http://eftel.com/%7Emrlewis/defender/raptor1.jpg

All the accessory wires are routed between the seats ready for a Mulgo Ex-box.

http://eftel.com/%7Emrlewis/defender/raptorwires.jpg


More to come….


Brett

[Bushman83]

The Completed Raptor dash and Mud Mudpod. :)

http://eftel.com/%7Emrlewis/defender/raptor4.jpg

The dash has 2x 12V sockets, CD Player, Engine Watchdog TM2 block head temp gauge, Thermoguard pyrometer, Icom IC-400PRO 80ch UHF :D, voltmeter, oil pressure and boost gauges.

http://eftel.com/%7Emrlewis/defender/digitalgauge.jpg


The Mudpod has the Mudstuff rear wash/wiper carling switch and 3 x carling light switches from customrockers.com.au.
http://eftel.com/%7Emrlewis/defender/rockers.jpg

I also added VDO tacho and temperature gauges to the binnacle. Unfortunately I'm having lots of trouble finding an adapter for the VDO temperature sender to fit in the 200tdi sender hole. Anyone know the exact size for the Landrover unit?

http://eftel.com/%7Emrlewis/defender/gauges.jpg

Should have the Mulgo Exbox installed this weekend so as to finish the dash.

Also forgot to mention that while each of the doors was off dynamat was added and a sheet of closed cell foam. This gives excellent insulation through the doors for noise and heat! Highly recommended! :)

Had the rear axles and flanges replaced with Hi-Tough uprated axles, as I will most likely be fitting an ARB rear locker in the coming months.

http://eftel.com/%7Emrlewis/defender/hituffaxle.jpg

More to come...

[steveG]

Great work, and thanks for sharing the photos.
The dash looks awesome.

Looking forward to the next installment :D

Steve

[Bushman83]

A good weekend.. got the Mulgo Exbox installed and the wiring connected to the fusebox. I added 2 12V sockets to the rear, one of which will power the Engel fridge. The box unfortunately seems awfully close to the transfer lever, with only mm's to spare to successfully change back into high range. I did mount it a little differently by leaving the original plate underneath due to all the soundproofing and insulation I added there.

http://eftel.com/%7Emrlewis/defender/mulgoexbox.jpg

The fuse box is fused with a maxi-blade 70A fuse next to the battery.
http://eftel.com/%7Emrlewis/defender/fuse.jpg

So finally, after 6 months of work I now have the passenger seat back in and new marine carpets. Looking a little too clean and flash for a Defender! ;)

http://eftel.com/%7Emrlewis/defender/front.jpg

As the drivers seat was constantly spreading old foam dust everywhere on my new carpets, I replaced the inner foam. Not too pretty looking for a 19 year old seat! The cover was washed while it was off.. took about 7 buckets of washing before the water ran clean. :o

http://eftel.com/%7Emrlewis/defender/seatold.jpg

New vs. Old.

http://eftel.com/%7Emrlewis/defender/seatfoam.jpg

Next I will be looking into getting the roof lined with marine carpet. Thought I might take it to a professional to get done so it lasts the distance.

[mylosh]

Wow!
Thats a huge amount of work! :-) looking good!
Arb or ashcroft lockers?
Nice wiring too!

[GyroLandy]

Looks great! I have a '94 Defender and started this weekend with stripping the cab.

What does the Mulgo Exbox do?

Where did you get the foam for the seats?

What is foamcell. I am looking at using Nuwave 8kg/square meter ($200 for 1.23m x 3m) for noise and E-therm from Thermotec($350 for 30m x 1.35m).

If I may ask how much Dynamat did you use and what was the cost.

[Bushman83]

Wow!
Thats a huge amount of work! :-) looking good!
Arb or ashcroft lockers?
Nice wiring too!

I'm thinking ARB lockers as service and parts are available Australia wide should I need help with anything along the way. :)

[isuzurover]

I'm thinking ARB lockers as service and parts are available Australia wide should I need help with anything along the way. :)

IME parts usually need to be ordered in for ARB. So it would be just as quick to get parts from the UK/US.

That said, most options are reliable and the need for replacement parts is rare.

Working on an open centre vs working on one of the various locker brands is no different.

[Bushman83]

Looks great! I have a '94 Defender and started this weekend with stripping the cab.

What does the Mulgo Exbox do?

Where did you get the foam for the seats?

What is foamcell. I am looking at using Nuwave 8kg/square meter ($200 for 1.23m x 3m) for noise and E-therm from Thermotec($350 for 30m x 1.35m).

If I may ask how much Dynamat did you use and what was the cost.

Best of luck with your progress! :)

The Mulgo Exbox is simply a neat little unit for moving all your electronics and engine computer up higher from under the seat box in post TD5 Defenders, or in my case (200tdi), a tidy place for adding a secondary fusebox and storage. It also raises the cubby box higher so it can be used as an armrest.

The seat foam was bought off ebay from garyclr4wd (http://myworld.ebay.com.au/garyclr4wd/?_trksid=p4340.l2559). Land Rover Defender New Front Seat Base Foam-Exmoor | eBay (http://www.ebay.com.au/itm/Land-Rover-Defender-New-Front-Seat-Base-Foam-Exmoor-/251076038268?pt=AU_Car_Parts_Accessories&hash=item3a754c4e7c)

I used 4 36sq ft Dynamat Extreme bulk packs for covering all the door internals, floor, roof, and firewall, with 2 layers on the footwells and transmission tunnel. Cost for 3 boxes was $582 from Amazon. One box was lost in the post so was sent a replacement, only for the lost box to appear 3-4 months later. I think 4 boxes are needed to do a 110 wagon properly.
Amazon.com: Dynamat 10455 18" x 32" x 0.067" Thick Self-Adhesive Sound Deadener with Xtreme Bulk Pack, (Set of 9): Automotive@@AMEPARAM@@http://ecx.images-amazon.com/images/I/51kuYyLihFL.@@AMEPARAM@@51kuYyLihFL

Not sure about the foam you're using. I got mine from Clark Rubber. 12mm closed cell.. about 2-3 sheets of around 2.5m x 1.5m or so. Can't remember the exact price but probably around the $400 mark. They covered the inside of the doors and the roof.

[GyroLandy]

Thx, how long does it take to get here if you order via Amazon?

Did you do a heatshield of some kind first or does the Dynamat provide heat insulation as well as noise deadening?

[Bushman83]

Thx, how long does it take to get here if you order via Amazon?

Did you do a heatshield of some kind first or does the Dynamat provide heat insulation as well as noise deadening?

Shipping took around 4-6 weeks from memory. The Dynamat was applied first and then closed cell foam for insulation. Dynamat is mainly for noise deadening. I also used foil coated foam in a few places such as under floor mats.

[modman]

I drilled and tapped my old sender for the 1/4 npt vdo sender
Cut the terminal off first using a hachsaw, the 'guts' then fall out and it drills easy in a vice:)
Dc

[Bushman83]

Ok.. I haven't had much happening lately, but my 2 Gullwing doors from Mulgo arrived last weekend so spent a couple hours Sunday morning installing them. They look great! Well worth the money.

http://userweb.eftel.com/~mrlewis/defender/gullwing1.jpg
http://userweb.eftel.com/~mrlewis/defender/gullwing2.jpg
http://userweb.eftel.com/~mrlewis/defender/gullwing3.jpg

Made a quick video on the installation. An easy job. :D
Land Rover Defender Gullwing Door Upgrade - YouTube

Next up will probably be the installation of 2 ex-army storage boxes.

[mike_ie]

I also added VDO tacho and temperature gauges to the binnacle. Unfortunately I'm having lots of trouble finding an adapter for the VDO temperature sender to fit in the 200tdi sender hole. Anyone know the exact size for the Landrover unit?

This information might be a bit late in coming, but if memory serves correctly, you'll be needing a 5/8" UNF male to 1/8" NPT female adaptor to plug a VDO sender into a 200TDI. Though, as mentioned, you can drill out the old sender and tap it out to receive the 1/8" NPT sender.

[Bushman83]

Ok.. had a good day and installed a couple of ex-army tool boxes. Bought these off Ebay.
http://userweb.eftel.com/~mrlewis/defender/box0.jpg

Spent a weekend stripping them down and slightly modifying them. Sent them off to the powder coaters and here they are.. like new!
http://userweb.eftel.com/~mrlewis/defender/box1.jpg
Added marine carpet to the tops...
http://userweb.eftel.com/~mrlewis/defender/box2.jpg
And installed in the rear...
http://userweb.eftel.com/~mrlewis/defender/box5.jpg
http://userweb.eftel.com/~mrlewis/defender/box4.jpg
http://userweb.eftel.com/~mrlewis/defender/box3.jpg

Also went to clark rubber and finally got around to making a new rear mat. Only took me 4 years to do it! :D
http://userweb.eftel.com/~mrlewis/defender/mat.jpg

Next up, probably add the wiring for 2 LED overhead map lights.
:)

[Chops]

G'day Brett, your cars looking good mate. Those boxes look purpose built for the back of the wagon. Top work.

[weeds]

Good luck on the trip around aus.....half ya luck

The boxes will be good for unimportant stuff and the stuff you need handy on top

[chunk]

This is a great thread Bushman keep the updates and pics coming, fantastic job done so far. My first Land Rover was a 200 tdi Defender, I remember my first trip to Queensland from Wollongong two young kids and wife with me, turned the radio up so I could hear it and never heard them the whole trip:twisted: Needless to say I didn't have it for very long:(

[Bushman83]

Ok.. I've always wished for better interior lighting in my Defender... and today is Part 1 of 3 of ensuring I have it! :D Installed 2 LED directional spotties on to a mount I knocked up which rivets into the roof frame.
http://userweb.eftel.com/~mrlewis/defender/light0.jpg
http://userweb.eftel.com/~mrlewis/defender/light1.jpg
http://userweb.eftel.com/~mrlewis/defender/light2.jpg
Am awaiting a new 900mm LED strip for the rear. :)

[easo]

That last shot looks like a promtional shot for a new defenders, following closly.

Easo

[Bushman83]

Next up on the agenda was to install the Thermoguard sensor for the Exhaust Gas Temperature gauge... of course it was never a simple matter of unbolting the turbo and drilling a hole! Snapped one of the studs off and rounded a nut... so was forced to take the whole manifold off. Decided to take it to a Turbo specialist to get it serviced and fix the broken studs....

http://userweb.eftel.com/~mrlewis/defender/turbocharger.jpg
... $1400 later :eek: she's fully overhauled. Good as new so that's one less worry when I'm deep in inland Australia.

Took the alternator off and will replace it and the water pump now seeing I have easy access to that area. Just to be sure.. to be sure... to be sure... ;)

[strangy]

Nice effort. Thanks for the updates. Almost up to the body reassembly if my DC a few extra ideas from your work now. Thanks.

[Bushman83]

Ok.. so it's taken over 1 year for me to begin editing the footage I shot along with the photos I've been taking of my upgrades, but better late than never! :D Enjoy!

Land Rover Defender Expedition Camper Upgrade Part 1 - YouTube

[Bushman83]

Part 2 now complete.

Land Rover Defender Expedition Camper Upgrade Part 2 - YouTube

[damzy]

Thanks Bushman83 for the inspiration to get keep these old Landys going. I also have a 200tdi 94' 110 an just drove it from Syd to Perth an back around the south coast. It went great with only a few minor breaks along the way. I plan on dyna matting mine soon as well as it reached 47 degrees on the Nullabore an the gearbox was hot enough to cook off, but the 200tdi didn't even get hot. These vids a real inspirational thanks again.

[elshano]

What a brilliant build thread! With the amount of care and thought you've put into the build I'm sure you'll have a trouble free trip mate. Kudos to you!

[Bushman83]

Part 3 now complete. Have been buying up some more parts. Will be busy soon with their installation. :)

Land Rover Defender Expedition Camper Upgrade Part 3 - YouTube

[zeroland]

Awesome. Thanks for keeping us posted.

[Bushman83]

Ok.. so my parts have arrived.

I've installed a new 70amp Letrika alternator.
http://eftel.com/~mrlewis/defender/alternator.jpg

The new parts:
http://eftel.com/~mrlewis/defender/parts.jpg
Terrafirma uprated steering rods. New power steering pump and box. An Allisport uprated double core intercooler. A Blue Sea Systems dual battery Automatic Charging Relay. And a new seat foam base.

http://eftel.com/~mrlewis/defender/boabtank.jpg
I have a Boab 48L tank for water storage during those long periods camping.

http://eftel.com/~mrlewis/defender/bonnetprotector.jpg
A new bonnet protector to strengthen the bonnet so I can stand on it with my tripod and shoot more films.

http://eftel.com/~mrlewis/defender/seatrails.jpg
And some Mulgo seat rail extensions.

Will be a busy month as I get around to adding on all this gear. :)

[Bushman83]

Defender Seat Foam Replacement - YouTube

[Bushman83]

:( Everything is at a halt at the moment. Took my Defender in to get a new timing belt and the mechanic found the nose of the crankshaft was stuffed as someone had previously used a cut off piece of drill bit in place of the correct woodruff key to hold the pulley in place. This has gradually worn out the groove which means for safety's sake, requires an engine rebuild. :mad:

Searching for options now.. looks like a $7000+ job at this point. On the plus side I guess i'll have a "new" engine so won't need to worry about that when I'm deep in inland Australia.

Funny thing is that only weeks before I was staring at my engine thinking how great it would be to have a new one for the trip... careful what you wish for. ;)

[TeamFA]

Ouch...

You wouldn't contemplate doing some or all of the engine work yourself? You strike me as a pretty hands-on guy...

[Bushie]

Time to upgrade ??

http://www.aulro.com/afvb/complete-engines-sale/174696-defender-300tdi-engine-gearbox-transfer.html#post1912821

No idea what would be involved, but it's a Land Rover :D:D


Martyn

[Bushman83]

Thinking about it. If I buy a stripped rebuilt engine from the UK I can save a couple thousand removing the engine and transfering the parts myself... but means taking a week off work and a lot of messing around.

Just have to wait for a quote from the mechanic and weigh things up.


Ouch...

You wouldn't contemplate doing some or all of the engine work yourself? You strike me as a pretty hands-on guy...

[Bushman83]

already thought about that, but it seems I would need to weld new mounts on the chassis and replace most of the engine bay parts... really want to keep things original. There are a couple 200tdi engines for sale but really have no idea how good they are... may have the same issue a couple years down the track.


Time to upgrade ??

http://www.aulro.com/afvb/complete-engines-sale/174696-defender-300tdi-engine-gearbox-transfer.html#post1912821

No idea what would be involved, but it's a Land Rover :D:D


Martyn

[manic]

Certainly with a 200tdi, you should get a short block sent over from Turner UK. They do great work, you need to be sure of it with such a big trip on the horizon.

Swap it in yourself and it will give you a chance to check on all the other bits and bobs that may be hanging on in there. You'll be more familiar should any bush repairs come your way.

At least that's the way I would do it.

- edit: I'd be tempted for a full 200tdi engine sent over with a performance cylinder head... not many 200tdi heads about and this way you dont have to send one for exchange... you can then turn your current 200tdi into a spares bin.

[jboot51]

You should be able to find volunteers for an engine swap day.
A few extra hands would make it easier.

[simonmelb]

:( This has gradually worn out the groove w

Surely a good fitter would be able to come up with a solution with the engine in place to solve this problem?

I would ask a good machinists/engineer to take a look if the rest of the engine is strong.

Cheers
Simon

[agrojnr]

There is a bloke in the UK atm who can send a running complete 300 or 200 for around 1500 plus import duties most have around 90ks on them

Adam

[Reads90]

Surely a good fitter would be able to come up with a solution with the engine in place to solve this problem?

I would ask a good machinists/engineer to take a look if the rest of the engine is strong.

Cheers
Simon

I had it on a 200tdi back in 1994.

The key went we noticed it when the garage changed the timing belt.

Umm the garage used metal glue to glue the pulley back on and I sold the car. Before I lt needed another timing belt Mmm

But not difficult to change the crank. That is what I would now days and rebuild the rest of the engine at the same time.

Rebuild yours, easy to do. Better the devil you know.

[Bushman83]

Ok.. latest news is my dad and I will attempt to make a custom woodruff key which should remove any play on the harmonic balancer. This will spare me an engine rebuild for the time being.

The bonnet protector was powder coated and installed.
http://eftel.com/~mrlewis/defender/bonnetprotector1.jpg
http://eftel.com/~mrlewis/defender/bonnetprotector2.jpg

Video 4 is now complete...

Land Rover Defender Expedition Camper Upgrade Part 4 - YouTube

[GyroLandy]

I noticed you have a switch for engine bay lights, what did you use LED strips?

[erosion]

Awesome thread dude, been fun reading and learning from your efforts.
So far I've dynamatted the interior and put roof insulation in :)

[Bushman83]

Yes,will be an LED strip similiar to what I used in my storage boxes.


I noticed you have a switch for engine bay lights, what did you use LED strips?

[Bushman83]

I've installed my Mulgo seat rail extensions. They make a pretty big difference.. though I'm only 180cm, so having them all the way back isn't necessary. My legs havn't been as cramped during the longer 3+ hour drives which is great news :)

Land Rover Defender Seat Rail Extensions Upgrade - YouTube

[Pickles2]

Bushman....What an awesome thread......You are obviously VERY handy....I mean, that dash...bits & wires everywhere?!! Is there anything you can't do?
Well done, & thanks for sharing. Pickles.

[DiscoMick]

Really enjoying this thread.
Floor insulation is on my top-do list, once I stop the water leaks and get some welding done..

[Bushman83]

I installed my Allisport double core intercooler in my 200tdi last week and had it dynotuned today with full fuel anneroid and boost pressure setting.

My radiator frame needed to be modified with the edges of the frame cut off on the intercooler side so it would fit properly.

http://eftel.com/~mrlewis/defender/intercooler1.jpg
http://eftel.com/~mrlewis/defender/intercooler2.jpg
http://eftel.com/~mrlewis/defender/intercooler3.jpg
http://eftel.com/~mrlewis/defender/intercooler4.jpg

The standard numbers are with the uprated intercooler already installed, but nothing else touched. With a professional tuning the results are
Approx. 54hp to 69hp = 27.7% increase in power
455lb to 590lb = 29.6% increase in torque.

Don't know how accurate those horse power numbers are. Seems awfully low seeing the original spec for the 200tdi defender is 107hp! Maybe 20 years has taken its toll.

Allisport claim that "The greater cooling capacity will allow up to 27% increase in power and torque in the lower and mid-range revs and improved throttle response". So from the above that's an accurate estimate... Couldn't ask for more than that.

Haven't driven too much yet but the results are noticeable! More power and torque up hills and smoother acceleration. Will need to go for a long drive and test it out. :)

http://eftel.com/~mrlewis/defender/dyno-defender.jpg

[slug_burner]

There will be a difference between the power measured at the crankshaft and that measured at the wheels. A few losses through the drive train, I think the front and rear diffs account for approx 15-20% loss.

The absolute power and torque are academic, if the system is linear then the improvement as a ratio is good enough.

[Bushman83]

2 more completed videos of my past work :)

Defender Bonnet Protector Installation - YouTube

Defender Intercooler Upgrade - YouTube


Things have slowed down of late with work taking my spare time.. but have made a start on my fridge mount and bed platform in the back.

[Disco Muppet]

Top thread, certainly got me wondering "What if I'd gotten a Defender..." :D
Nice work mate :cool:

[bilbo5]

Fully agree with you Muppet, that Bushman83 has put in some great work. Hope his journey goes well.:)

Got some catchup to do to reduce decibels in Fender vs Disco. but not so much as to hear ears ringing. Gotta hear the machinery working!

[VladTepes]

Great thread !

[Bushman83]

Just another video of my Decal removal. Have been busy the last few days welding bits and pieces up to install the HF radio. Will have some pics in a few days.

Defender Decal Removal - YouTube

[jerryd]

Just read your build thread from start to finish, excellent work :BigThumb:

I'm doing a similar rolling restoration and have been wondering if it's worth putting soundproofing behind the dash as you have done. Did you notice much difference after you fitted the dynamat to the firewall ??

[Bushman83]

Just read your build thread from start to finish, excellent work :BigThumb:

I'm doing a similar rolling restoration and have been wondering if it's worth putting soundproofing behind the dash as you have done. Did you notice much difference after you fitted the dynamat to the firewall ??

Thanks mate.. Can't quite remember now. Every little bit helps but it won't make the car sound quiet! If you have easy access now then do it. I found adding formshield insulation on all the floor mats and footwells cut out a lot of noise. That could be an alternative to dynamat on the firewall. :)

[Presto]

I'm following your thread with anticipation of each new post - great work!

My concern over fitting dynamat is trapping water/moisture and encouraging rust, so I like the idea of insulating the removable floor mats so you can dry it all out.

Thanks for the tips on removing the decals! I have also found a 'Caramel wheel' very useful in the past for small stubborn areas of sticker/glue. They are available from the likes of Autobarn. :)

[Bushman83]

Knocked up a couple things recently in the workshop..
Built an antenna mount for the HF radio.
http://eftel.com/~mrlewis/defender/hf-antenna-mount-bracket.jpg
http://eftel.com/~mrlewis/defender/hf-antenna-mount.jpg

Also built a fire extinguisher bracket for the rear. This uses 2 of the original bolts, requiring only 1 hole drilled.
http://eftel.com/~mrlewis/defender/fire-bracket.jpg
http://eftel.com/~mrlewis/defender/fireextinguisher.jpg

Also made a dual battery tray out of 3mm plate steel and 25mm RHS, plus a couple tabs on the bottem for bolting through.

http://eftel.com/~mrlewis/defender/dual-battery-mount0.jpg
http://eftel.com/~mrlewis/defender/dual-battery-mount.jpg

More to come... :)

[Chops]

G'day BM,
Damn, I like your extinguisher bracket, looks good, and I'm assuming easy for others to see from outside the car in an emergency, God forbid.

[JAG811]

Hi Brett,

Love the build / restoration.
And thanks a lot for recording everything you've done. It's been a great help for me to organise my restoration, as well as a great motivator to get out and actually do the work involved.

When I bought mine I wanted to instantly get the decals off so when I saw your entry I started on mine.

The only thing I wanted to add was I had no fitting on the end of the hair-dryer, and realised that by keeping the next 1-2 inches of the decal heated well, the glue heated up and came off with the decals. I wish I'd worked that one out right at the start.

Thought I'd just mention it for anyone else trying it.

Keep up the great work and awesome videos.

Cheers,

Jon

[Bushman83]

Thanks Jon
You make me wonder now about whether if I had removed the hair dryer attachment I wouldn't of had such a hard time in places... good to know. Thanks

[Bushman83]

Continuing on...

I replaced the old rear work lamp which would fill with water and would draw about 4 amps...
http://eftel.com/~mrlewis/defender/oldlight.jpg
with a new LED lamp. Current draw 1.4amps. MAJOR IMPROVEMENT! :D
http://eftel.com/~mrlewis/defender/led-light.jpg

I made and installed the HF radio transceiver body mounting in the rear
http://eftel.com/~mrlewis/defender/hf-transceiver-mount1.jpg
http://eftel.com/~mrlewis/defender/hf-transceiver-mount2.jpg

The dual battery tray was installed
http://eftel.com/~mrlewis/defender/dual-battery-mount1.jpg

The rear area had 5 and 20mm formsheild installed for insulation and was covered with marine carpet.
http://eftel.com/~mrlewis/defender/interior-carpet1.jpg
http://eftel.com/~mrlewis/defender/interior-carpet2.jpg

To help in keeping the car cool I had the windows tinted with the top quality heat reduction film from my local car tinting place. Before.
http://eftel.com/~mrlewis/defender/tint-before.jpg

After.
http://eftel.com/~mrlewis/defender/tint-after.jpg

I'm liking it so far as it's not very dark but seems to be doing its job. Car was cooler this afternoon than typical. :)

Onwards!........

[Bushman83]

Began lining my roof with marine carpet. I used Quick Grip gel to glue it on.
http://eftel.com/~mrlewis/defender/roof-carpet1.jpg

Did it in 3 sections over 3 days to make it easier to do it alone. Looks really good. :)

http://eftel.com/~mrlewis/defender/roof-carpet2.jpg
http://eftel.com/~mrlewis/defender/roof-carpet3.jpg

Added an LED light strip as the courtesy light.

http://eftel.com/~mrlewis/defender/ledlightstrip.jpg

Also began installing a few bits for the HF radio. Made a speaker mount out of some angle.

http://eftel.com/~mrlewis/defender/speakermount.jpg
http://eftel.com/~mrlewis/defender/speaker.jpg
Speaker mounted. Uses 2 existing holes to mount the bracket.
:)

[Bushman83]

Completed the new roof lining today finally after having removed the original 22 months ago! :D

Built a rear backing out of scrap 3mm aluminium sheet.
http://eftel.com/~mrlewis/defender/roof-carpet-5.jpg

Added marine carpet and purchased a pair of Sony 4in speakers.
http://eftel.com/~mrlewis/defender/roof-carpet-6.jpg

Installed along with an extra LED light bar in the rear.

http://eftel.com/~mrlewis/defender/roof-carpet4.jpg

A quick test of the speakers gives the rear a greater depth of sound. Looking forward to a long drive. :)

[Bushman83]

Ok, I've completed my dual battery set up. I used a Blue Sea Systems Automatic charging relay. This is rated up to 500 amps continous so is plenty if I need to combine batteries to jump start the vehicle or for added power during winching operations (assuming I ever get around to installing my winch ;)). I'm using a Full River 120 a/h deep cycle AGM battery. This is probably the largest you can fit in a defender.

http://eftel.com/~mrlewis/defender/dual-battery.jpg

All connections are 2B&S battery cable. The relay has a manual override (The yellow knob on top) so that in the event the primary battery is too low to operate the dash mounted switch, you can do so manually. Also allows for the batteries to be locked off so batteries can not be connected.
http://eftel.com/~mrlewis/defender/dual-battery2.jpg

This is the dash mounted switch. Leave it on Auto and when the relay senses a charging voltage it will connect the batteries, and disconnect them again when the voltage drops below the set point. Flick to on to join batteries to jump start vehicle etc...
http://eftel.com/~mrlewis/defender/dual-battery3.jpg

As the dual batteries sit too high to put the original steel cover on underneath the seat I made a rubber/foam/carpet sandwich to protect the terminals from shorting on the seat base and still add some sound proofing from the road noise coming through the battery compartment.

http://eftel.com/~mrlewis/defender/dual-battery-mat.jpg

I added an Anderson Plug which connects to the deep cycle to power my 600w inverter. Technicaly the plug is only rated to 50amps but my inverter can draw up to 60 amps. As I only use the inverter to charge batteries etc there shouldn't be any problem with overloading the plug.

http://eftel.com/~mrlewis/defender/anderson-plug2.jpghttp://eftel.com/~mrlewis/defender/anderson-plug1.jpg

I finally installed the Engine bay lights. Used an LED strip and "P clips" pop-riveted in place.
http://eftel.com/~mrlewis/defender/engine-bay-lights.jpg
http://eftel.com/~mrlewis/defender/engine-bay-lights2.jpg

For added safety I installed 2 Life Hammers. These are used to smash out a windscreen and cut through a seat belt should I drive off into a river or roll over etc.
http://eftel.com/~mrlewis/defender/life-hammer-1.jpg

Installed 1 in front

http://eftel.com/~mrlewis/defender/life-hammer-2.jpg

and the other in the rear

http://eftel.com/~mrlewis/defender/life-hammer-3.jpg

[jerryd]

Those life hammers look like a good investment, can you buy them locally ??

[justinc]

LifeHammer Original Emergency Tool [LH01] - $25.90 : Fusion Gear, Your Way Beyond Professional (http://fusiongear.com.au/lifehammer-original-emergency-tool-p-328.html)

jc

[Bushman83]

Life Hammers also available on Ebay. I bought mine from here: Lifehammer Original Auto Emergency Escape Tool | eBay (http://www.ebay.com.au/itm/LifeHammer-Original-Auto-Emergency-Escape-Tool-/200960475013?pt=AU_Car_Parts_Accessories&hash=item2eca2d7f85)

[JAG811]

Truck looks great Brett !!!

[Bushman83]

Thanks Jon. It's finally starting to feel like home. Everything has come together nicely. :)

[VladTepes]

How did you manage to glue that carpet up without making a big bloody mess and getting it stuck at an odd angle etc ? Good effort I reckon.

Also what did you use to glue the closed cell foam onto the dynamat with ?

[Bushman83]

How did you manage to glue that carpet up without making a big bloody mess and getting it stuck at an odd angle etc ? Good effort I reckon.

Also what did you use to glue the closed cell foam onto the dynamat with ?

I used Kwik Grip Gel for the carpet and at the time used standard Kwik Grip for the foam.. though in retrospect using the gel for both instances would have been easier.. less mess etc..

The glue was applied to the first 20cm of the roof and carpet to oversized carpet pieces so the excess could be trimmed off the edges later and allow for any missalignment. Align this first part square and the rest is easy. Once the first part is glued together the carpet is stuck to the roof allowing more glue to be applied for the next odd 20cm. A small roller was used from the centre of the roof rib working outwards on each side... then repeat again till you make it all the way to the end. Then using a sharp stanley knife, trim the excess off at the edges and touch them up with glue as necessary. Doing it in 3 sections is a lot easier..

I used 1 3.2kg tin and most of a 400g tin to complete the roof carpet. The carpet tends to soak in more of the glue.:)

[VladTepes]

How did you get such a neat fit around the roof ribs ?

[Chops]

How did you get such a neat fit around the roof ribs ?

You could use a spatula to push it into the internal corners,,

[Bushman83]

How did you get such a neat fit around the roof ribs ?

The foam takes up most of the difference in height of the ribs to the roof, but as there was 3 seperate sections, I folded a lip around each rib before laying the next section on top.

http://eftel.com/~mrlewis/defender/roof-carpet-7.jpg

[lux201]

Mate, I love the truck and I love the build, you are very much an inspiration!

[Bushman83]

Finally got around to finishing off my fridge mount. Made out of 25mm RHS.
http://eftel.com/~mrlewis/defender/fridge1.jpg

Powder coated and installed.

http://eftel.com/~mrlewis/defender/fridge2.jpg

Strapped in and ready to go. I made it so the top of the fridge was flush with the top of my storage boxes, so when I build the bed section the fridge can form part of the bed area if necessary. It also serves to keep the fridge high and dry during deep water crossings. Learnt a few things from my time on Cape York about that one! ;)

http://eftel.com/~mrlewis/defender/fridge3.jpg

I installed 2 tiedowns. The one on the right replaced the original bolt, and bolts through a metal bracket. Rated to 230kg each with backing plates to spread the load.

http://eftel.com/~mrlewis/defender/tiedowns.jpg

The footwell area is where all my water and/or fuel will be stored. This keeps the heaviest weight between the 2 axles. Also allows easy access to jerry's through the rear drivers side door.

I can just fit 5 jerry's = 110L water or fuel. :)

http://eftel.com/~mrlewis/defender/jerrys.jpg

[Bushman83]

I completed my engine bay lights installation a few weeks back. Someone asked me how I did it so here is the video.

Defender Engine Bay Lights Installation - YouTube

https://www.aulro.com/afvb/

[lux201]

I completed my engine bay lights installation a few weeks back. Someone asked me how I did it so here is the video.


Awesome mod!
I have been considering this for a while. I have however been reluctant due to the consideration of potential heat damage to the led lights but I guess so long as it is fused it should be safe.

Thanks for another inspiring vid :D

[Bushman83]

Thanks mate.. yes the heat issue has been brought up. I only put the strip on the non-turbo side and don't believe it would get that bad where it is located... worst case scenario is I ruin a $4 LED strip from ebay with free postage from china! ;) Not much of a loss... and obviously it is fused to protect against anything major occuring.. I'll let everyone know if it ever fails.
Thanks


Awesome mod!
I have been considering this for a while. I have however been reluctant due to the consideration of potential heat damage to the led lights but I guess so long as it is fused it should be safe.

Thanks for another inspiring vid :D

[Cornholio351239]

What did you use as under bonnet insulation? The insulation on my defender is hanging off on the turbo side. Thanks.

[Bushman83]

I used SB1 SOUND INSULATION UNDER BONNET 1.5M X 1M SELF ADHESIVE from rarespares.net.au. Cost was about $70. It did make some difference but don't expect miracles.


What did you use as under bonnet insulation? The insulation on my defender is hanging off on the turbo side. Thanks.

[Bushman83]

Defender Dual Battery System Installation - YouTube

Completed the video for my dual battery system.

[landiematt]

Once again you have done a great job mate and very informative. It may well end one of the best defender set ups around. Not they are ever finished.
Matt.

[Wicks89]

Hey mate,

As ever I'm very impressed! You mention in your vid that you used paint left over from painting your chassis, can you talk he through how you did it?

[Bushman83]

Thanks mate. To paint my chassis I started by giving it a wash to get off the easy stuff. I then used Degreaser and a wire brush to remove the oil stains and caked on crud. This was washed off and allowed to dry. I followed up with a light sanding using 400 grit sand paper to remove any flaking or surface rust.

It's not possible to paint the whole chassis as things are in the way, but you can get a decent bit done. By removing the floor panels and each tyre in turn you can access a bit more. I did 2 coats using the chassis black paint. Came up really well. :)



Hey mate,

As ever I'm very impressed! You mention in your vid that you used paint left over from painting your chassis, can you talk he through how you did it?

[Bushman83]

Vehicle Dependent Expedition Guide book review - YouTube

The Vehicle-dependent Expedition Guide has been a great help during my vehicle upgrades. It's been referenced many times during the last 2 years. Here's a quick video book review of it.

[DiscoMick]

I also got insulation from Clark Rubber. They have various thicknesses in rolls and you just decide what length you want. It did make a difference and it was pretty cheap and convenient as the store is only 15 mins away, but I only did the front footwells and I can't comment on how it compares for effectiveness with the other options available.

Sent from my GT-P5210 using AULRO mobile app

[VladTepes]

Does it hold water (literally) or not. I don;t want anything that can encourage rust....

[DiscoMick]

A bit late to worry in my case after I belatedly discovered the windscreen had been leaking and the water running into the driver's footwell for years, causing rust. Now fixed, but the effects remain.

Sent from my GT-P5210 using AULRO mobile app

[Wicks89]

thanks for the info brett!

Did you just use black killrust paint or something special? With regard to the insulation question above my plan is to combine the insulation to the matting, not the metal, whereupon I can just drag it all out and let it dry after I invariably swamp it.

[Bushman83]

No mate... nothing special.. just the "Chassis Black" sold at Supercheap.


thanks for the info brett!

Did you just use black killrust paint or something special? With regard to the insulation question above my plan is to combine the insulation to the matting, not the metal, whereupon I can just drag it all out and let it dry after I invariably swamp it.

[Bushman83]

Land Rover Defender Expedition Camper Upgrade Part 5 - YouTube

Part 5 video now completed. :)

[lux201]

oh, I like that! definitely doing this to my rear interior!!

Thanks again, you have been an inspiration throughout my entire defender build!

[VladTepes]

Love the fridge idea....

[Bushman83]

Land Rover Transfer Case Sump Upgrade - YouTube

I installed a Global Roamer increased capacity cooling finned transfer case sump. Should help keep things cooler during those heavy periods of offroading or while driving through inland Australia.

http://userweb.eftel.com/~mrlewis/defender/global-roamer-1.jpg
http://userweb.eftel.com/~mrlewis/defender/global-roamer-2.jpg
http://userweb.eftel.com/~mrlewis/defender/global-roamer-3.jpg
http://userweb.eftel.com/~mrlewis/defender/global-roamer-4.jpg
http://userweb.eftel.com/~mrlewis/defender/global-roamer-5.jpg

Fished out 3 fairly large pieces of steel from the old transfer case sump.. hoping they're not that important! ;) Any ideas? Is this the beginning of the end?
http://userweb.eftel.com/~mrlewis/defender/transfer-shard.jpg

In other news, I've purchased a Long Range Automotive 65l drivers side sill tank. Seems like a well made unit.
http://userweb.eftel.com/~mrlewis/defender/long-range-automotive-defen.jpg

[TeamFA]

Hey, I like that sump.

It would make it a hell of a lot easier to remove with a jack, too...

[VladTepes]

Do you think the sump is a bit more susceptible to damage now? as it not as tucked away.

I don't like the look of those bits you found in the sump ! Start saving for a tcase rebuild.

[Bushman83]

Indeed. The instructions even state it can be used to jack from when removing the transfer case. It is a fairly solid unit.


Hey, I like that sump.

It would make it a hell of a lot easier to remove with a jack, too...

[Bushman83]

No, the new sump is not really that low. Still sits above the chassis rails and other parts such as the handbrake drum are still lower.


Do you think the sump is a bit more susceptible to damage now? as it not as tucked away.

I don't like the look of those bits you found in the sump ! Start saving for a tcase rebuild.

[peter_yqm]

Those 'pieces of metal' look suspiciously like part of the high/low selector fork, .........?

[Presto]

How big are they? Pic doesn't really give an idea of scale....

[County3.9]

Nice job! Where did you get the sump and tank from? Also, how much did they cost?

[Pateyw]

Ashcroft sell them can't recall cost purchased with underdrive

[Bushman83]

http://userweb.eftel.com/~mrlewis/defender/transfer-shard2.jpg

How big are they? Pic doesn't really give an idea of scale....

[Bushman83]

I purchased the sump from British Offroad but they are also listed on ebay. Cost about $150. Tank was purchased from TJM selling at $1149.50.


Nice job! Where did you get the sump and tank from? Also, how much did they cost?

[peter_yqm]

Item 7 below:
71678
looks like 'one leg' of the part. Does it engage/disengage without issue?

[Bushman83]

Thanks. Yes for now it still does. Will have to keep an eye on it and maybe rebuild the transfer box later to be on the safe side.


Item 7 below:
71678
looks like 'one leg' of the part. Does it engage/disengage without issue?

[T.Middo]

wow. just read from start to finish. what can't you do. wish i had just 1/10th of your tech no how.

[Bushman83]

Gradually ticking a few more things off my to do list. I took some measurements of my rear door and had a local aluminium mob cut up 2 pieces to fit out the rear door with a kitchen table. Only $99!!! A precut one from a Land Rover parts supplier usually cost over $160 without a fold down table.

http://eftel.com/~mrlewis/defender/rear-door-table-defender.jpg

Bought a few bolts, latch and s/s hinges.. had it all powder coated and installed.

http://eftel.com/~mrlewis/defender/4wd-rear-door-table.jpg

Still need to make up some straps to hold it at the right level. Had 2 army pouches lying round which make an awesome secure storage area for odd cooking bits and spices. Just screwed on with washers backing. Very strong.

http://eftel.com/~mrlewis/defender/defender-rear-door-table.jpg

:)

[steveG]

Wire fishing traces make good straps for rear door tables. Cheap and strong.

Steve

[NWTASD2]

Not sure if this has been posted in this thread.

I enjoyed it for some ideas anyway.

Cheers

Overland 4x4 Land Rover Discovery TD5 - YouTube

[DiscoMick]

Lot of good ideas in that, thanks for posting it.

Sent from my GT-P5210 using AULRO mobile app

[rar110]

Gday Brett

I'm looking at a budget reversing camera like you fitted.

Do you still recommend the camera set up you bought?

Which of the below cameras would you recommend?

NEW CAR Reversing Rear View Camera FOR Heavy Equipment Vehicles IR Night Vision | eBay (http://www.ebay.com.au/itm/221127729712'ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649)

4pin CCD Reverse Backup CAR Truck Camera With IR Night Vision AND Waterproof | eBay (http://www.ebay.com.au/itm/4pin-CCD-Reverse-Backup-Car-Truck-Camera-With-IR-Night-Vision-And-Waterproof-/390794148699?pt=AU_Home_Personal_Security&hash=item5afd257b5b&_uhb=1)

Very helpful tutorials, thanks.

[Bushman83]

Thanks mate... If I were to do it again I'd get the 4pin camera just as there is less wiring. You will get a neater installation when running the cable along the roof channel and down the front pillar, compared to having wires run down the rear quarter glass. Just be sure the monitor you buy is compatible. You'll need to track down a cable as well... 5 meters may be enough. Measure up your runs with some string to check first. The 4pin listed is "non-mirror for front view". You might need a mirror one.. check before you buy.
Regards



Gday Brett

I'm looking at a budget reversing camera like you fitted.

Do you still recommend the camera set up you bought?

Which of the below cameras would you recommend?

NEW CAR Reversing Rear View Camera FOR Heavy Equipment Vehicles IR Night Vision | eBay (http://www.ebay.com.au/itm/221127729712'ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649)

4pin CCD Reverse Backup CAR Truck Camera With IR Night Vision AND Waterproof | eBay (http://www.ebay.com.au/itm/4pin-CCD-Reverse-Backup-Car-Truck-Camera-With-IR-Night-Vision-And-Waterproof-/390794148699?pt=AU_Home_Personal_Security&hash=item5afd257b5b&_uhb=1)

Very helpful tutorials, thanks.

[rar110]

Thanks mate... If I were to do it again I'd get the 4pin camera just as there is less wiring. You will get a neater installation when running the cable along the roof channel and down the front pillar, compared to having wires run down the rear quarter glass. Just be sure the monitor you buy is compatible. You'll need to track down a cable as well... 5 meters may be enough. Measure up your runs with some string to check first. The 4pin listed is "non-mirror for front view". You might need a mirror one.. check before you buy. Regards

Thanks for that tip. I didn't pick up that a reversing camera might be formatted as forward facing. Bit of a trap.

I'm having trouble finding a small TFT orcs screen. Most seem to be 7".

[Bushman83]

I built some mounts to install a 130w solar panel on the roof.

http://eftel.com/~mrlewis/defender/solar-panel-mount.jpg

The mounts include a 10w LED floodlight on each side so I can easily see street signs or bush tracks at night.

http://eftel.com/~mrlewis/defender/solar-mount.jpg

The panel fits really well on the front slope of the roof.

http://eftel.com/~mrlewis/defender/solar-panel-defender.jpg

The panel produces a good 6+ amps, plenty to keep my fridge running 24/7.... hopefully! ;) Panel connects via regulator to my secondary battery.

http://eftel.com/~mrlewis/defender/solar-regulator.jpg

Also installed my shovel mount on the side. Used my existing roof bars.

http://eftel.com/~mrlewis/defender/shovel-mount1.jpg

http://eftel.com/~mrlewis/defender/shovel-mount2.jpg

http://eftel.com/~mrlewis/defender/shovel-mount3.jpg

Hoping 2 Quick Fist's will be sufficient to hold it on over the corrugations.

[Chops]

Hi Brett,
I like your mod to hold the front of your shovel. With the Quick Fists, are you saying you're worried they wont hold ?
I priced these today down at our local TJM store,, $10 each :D. They only had one, so I did'nt get it, because I want two, so I'll just wait till they get more. Although I might copy your front mount ;)

[Bushman83]

Hi Brett,
I like your mod to hold the front of your shovel. With the Quick Fists, are you saying you're worried they wont hold ?
I priced these today down at our local TJM store,, $10 each :D. They only had one, so I did'nt get it, because I want two, so I'll just wait till they get more. Although I might copy your front mount ;)

Thanks. Just a tad worried the shovel might work its way rearward and come out of the front shovel mount.. although from giving it a good yank with my hand the 2 seem to have a gorilla grip of it.

[DiscoMick]

Hey Bushman I'm interested in your decision to go with a panel as large as 130 watts as my 80 watts seems adequate for running my 40 litre Engel. Did you consider a smaller panel to save roof space?

Sent from my GT-P5210 using AULRO mobile app

[Bushman83]

Hey Bushman I'm interested in your decision to go with a panel as large as 130 watts as my 80 watts seems adequate for running my 40 litre Engel. Did you consider a smaller panel to save roof space?

Sent from my GT-P5210 using AULRO mobile app

Hey mate. I really wanted something that was the full width due to the design of the mounts I was considering. Also, from my experience, my fold out 120w panels I previously used were not enough to keep my battery topped up enough when camping in one spot for 10 days running my engel. I figured since I'll be using lights, laptops and camera gear while travelling I'll just go for the big panel to be sure I keep my secondary charged.

[DiscoMick]

Fair enough. The longest I've stayed in one place with mine so far is five days. Obviously also depends on the season and amount of sunlight.

Sent from my GT-P5210 using AULRO mobile app

[Benz]

That is a top idea on the panel mount for the roof.
might use it some time in the future.

and good choice on going bigger on the panel. I think having a good 50% more then you need is a good policy to have (some might say it's a waste of money though), that being even more true when the panel is fixed down like yours is.
most of the time my fixed panel will only put out ~2/3rds what my fold out one will give me due to not facing the sun at the optimum angle

[Dinty]

I've had a 80W solar panel mounted on my 110 for over 23 years, and for about 5 years prior on my Series 3 S/wagon. It has and still is giving good service, just a wash down every now n then
https://www.aulro.com/afvb/
cheers Dennis
ps I also have a spare 80W that can be connected into the circuit as well,,. and the trailer well I've owned it for almost 30 years,,.

[Bushman83]

Thus far the panel always seems to be charging well enough regardless of the direction i'm facing, but yes.. having it bolted down does limit me if i'm shacked up in one place.. I may take my fold out 120w along if I have the space as a back up.

[Bushman83]

Defender LED Light Upgrade - YouTube

I installed a pair of RDX LED rear brake/tail lights to replace the original ones as my bulbs kept rattling loose. Sometimes both would fall out at the same time. Bought them off ebay from the UK. Works incredibly well! Highly recommended it! :)

[DiscoMick]

I've had a 80W solar panel mounted on my 110 for over 23 years, and for about 5 years prior on my Series 3 S/wagon. It has and still is giving good service, just a wash down every now n then
http://i659.photobucket.com/albums/uu319/DJM110/IMG_0926.jpg
cheers Dennis
ps I also have a spare 80W that can be connected into the circuit as well,,. and the trailer well I've owned it for almost 30 years,,.

Do you find 80W enough? What are you running off it? I ask because I'm thinking of doing something similar soon to run a 35 litre fridge and am wondering if 80 will be enough.

Sent from my D1 using overweight hamsters.

[Chops]

Another top notch insructional video Brett. Well done dude :D

I've had the guys complain about my lights, or lack there of,, I've been wondering if I should go with LED,,

[Presto]

I bought a full set of LED lights from RDX via ebay and I'm very happy with them. I do however have a tdi and found them a direct replacement, including the screw holes and electrical connections, so your need to re-wire and drill holes has me confused!

[Bushman83]

Another top notch insructional video Brett. Well done dude :D

I've had the guys complain about my lights, or lack there of,, I've been wondering if I should go with LED,,

Thanks mate. Definitely recommend it. Really no missing me now at night. My brake lights light up the bonnets behind me!

[Bushman83]

I bought a full set of LED lights from RDX via ebay and I'm very happy with them. I do however have a tdi and found them a direct replacement, including the screw holes and electrical connections, so your need to re-wire and drill holes has me confused!

300TDI's upwards are plug and play. Mine's a 200tdi so I missed out on an easy fit. Only took about 20 minutes per light though. :) Made a couple narration errors in the video.:( Otherwise love them.

[KeithMac]

300TDI's upwards are plug and play. Mine's a 200tdi so I missed out on an easy fit. Only took about 20 minutes per light though. :) Made a couple narration errors in the video.:( Otherwise love them.

Another great tutorial. Love all the things you have done, each one I am planning on doing to my 300 Tdi. Keep up the good work.

[Bushman83]

Installed my spare tyre bonnet mount today. Simply used some marine stainless hardware and a Boab tyre tiedown strap.

http://eftel.com/~mrlewis/defender/bonnet-mount1.jpg

This Should be plenty as I'm only carrying a spare tyre carcass to save on weight. Will be carrying an R&R beadbreaker should I need to change tyres over.

http://eftel.com/~mrlewis/defender/bonnet-mount2.jpg

All fitted up with my new Goodyear Wrangler Duratrac's in 235/85/16. Looking great.

http://eftel.com/~mrlewis/defender/duratracsdefender.jpg

Powdercoated my rims while I had the chance. Also installed a Sensatyre tyre monitor. :)

[Chops]

Brett, is there a way of locking that down so it can't be stolen?
I'd be worried some lowlife would nick it whilst I was in a shop or something. Even just a lockable chain or something, you know, like a bike lock (?) it would just give a bit piece of mind when not with the car.

[JamesB71]

Ive just spent the last hour reading this whole thread.

This may be the best thread Ive ever seen.... absolutely awesome job mate, and I really wish I had the funds to do something similar.

Thank you for all the hard work and sharing it for us.

[Bushman83]

Brett, is there a way of locking that down so it can't be stolen?
I'd be worried some lowlife would nick it whilst I was in a shop or something. Even just a lockable chain or something, you know, like a bike lock (?) it would just give a bit piece of mind when not with the car.
Actually there's not. Guess I'd better look in to some options. A bike lock should slow down an opportunistic thief.

[Bushman83]

Defender SuperPro Poly Bushes Upgrade - YouTube

Upgraded all my suspension bushes with a set of SuperPro poly bushes I purchased from APT. Really tightened up the whole feel of the vehicle and seemed to have reduced some of the driveline clunks.

[Toxic_Avenger]

Upgraded all my suspension bushes with a set of SuperPro poly bushes I purchased from APT. Really tightened up the whole feel of the vehicle and seemed to have reduced some of the driveline clunks.

I've always been led to believe that poly bushes were great for race cars, but life on rough use vehicles was not as good as the more supple rubber bushes from factory.
I've seen diff bushes from big name companies split and crack, but that was from race use, and lowered road-driven vehicles with stiffened suspension.

Have you got any feedback on how these poly bushes compare to new rubber (OE) items? (were your old ones completely shagged, or replaced as preventative items?)

[Bushman83]

I've always been led to believe that poly bushes were great for race cars, but life on rough use vehicles was not as good as the more supple rubber bushes from factory.
I've seen diff bushes from big name companies split and crack, but that was from race use, and lowered road-driven vehicles with stiffened suspension.

Have you got any feedback on how these poly bushes compare to new rubber (OE) items? (were your old ones completely shagged, or replaced as preventative items?)

You may be right although from my research Superpro have absolute praise on all the forum boards I read from those fitting it to their 4wd's. Other big name brands were criticised heavily for failing offroad. All the rest of my suspension set up is stock, so will be interested to see how well they fair. My bushes were at least 8+ years old which came when I bought it so repaced them all as a precaution. Were quite a few fine cracks in the rubber. I'm sure OE rubber is just fine when new. Will do a write up here or a video after some lengthy travel time on how they're performing.

[Toxic_Avenger]

You may be right although from my research Superpro have absolute praise on all the forum boards I read from those fitting it to their 4wd's. Other big name brands were criticised heavily for failing offroad. All the rest of my suspension set up is stock, so will be interested to see how well they fair. My bushes were at least 8+ years old which came when I bought it so repaced them all as a precaution. Were quite a few fine cracks in the rubber. I'm sure OE rubber is just fine when new. Will do a write up here or a video after some lengthy travel time on how they're performing.

Your review after some offroad time would be good.
Those hard(er) plastic compounds don't have much give at all, and are great for steering response, but when it needs to give under pressure, and can't, other things tend to take the load (the bush cracks, or linkages take extra load).
In the end of the day, new bushes are way better than old ones, irrespective of their composition!

[modman]

Toxic
Do an aulro google search on super pro bushes
They are a great duro and beat oe rubber hands down
The chassis to radius arm bushes even flex more than oe
Don't confuse sp bushes with nolathane branded or poly bush branded gear
Dc

[rick130]

Toxic
Do an aulro google search on super pro bushes
They are a great duro and beat oe rubber hands down
The chassis to radius arm bushes even flex more than oe
Don't confuse sp bushes with nolathane branded or poly bush branded gear
Dc


As Dave said, discussed to death on here over many, many years and almost universally praised.

I've been running one pair of SP bushes in the back of the Deefer for near twelve years and 240,000km and are still functioning fine, and with better articulation than the OE lower trailing arm to chassis bush.
Most all others have been progressively replaced with SP bushes since.

[Bushman83]

Defender Rear Door Table Installation - YouTube

Just the new video for my rear door table install I did a few months back.

[Mike1970]

Great thread. I'm looking forward to your trip.

[VladTepes]

Good stuff, as always

[nugge t]

Great build mate.

[singlecell]

Wow! That is some amazing work. Makes me feel the need to sell my D2a and get a defender for sure!
Let me know if your keen on a swap!! :wasntme:

[Bushman83]

https://www.aulro.com/afvb/

A pleasant surprise this afternoon :D After waiting over a month my set of Koni Raid 90 shocks have arrived. There were no rears in stock in Australia so some were ordered from Holland, made personally for me... ;)
These are seriously heavy. Nearly strained my back lifting them off the ground. The picture doesn't do them justice... they are HUGE!

[steane]

http://eftel.com/~mrlewis/defender/koni-raid-90.jpg

A pleasant surprise this afternoon :D After waiting over a month my set of Koni Raid 90 shocks have arrived. There were no rears in stock in Australia so some were ordered from Holland, made personally for me... ;)
These are seriously heavy. Nearly strained my back lifting them off the ground. The picture doesn't do them justice... they are HUGE!

:cool: I found them way too soft on the factory rebound setting and recently adjusted mine to max rebound. Handled sand dunes and corrugations 1000% better and are in no way over adjusted.

Not saying do the same but be prepared to adjust them to get it just right. Shame you have to pull them out to adjust:(

[Bushman83]

:cool: I found them way too soft on the factory rebound setting and recently adjusted mine to max rebound. Handled sand dunes and corrugations 1000% better and are in no way over adjusted.

Not saying do the same but be prepared to adjust them to get it just right. Shame you have to pull them out to adjust:(

Thanks mate. How much weight do you typically carry?

[steane]

Thanks mate. How much weight do you typically carry?

Mine is a Hardtop so there is a bit less weight in the back but I have a rear drawer/storage setup and second battery that adds about 150kg empty. So unloaded 150kg more than an empty Hardtop. That's 90% of my driving.

The rest is touring trips and the back is full, a second spare on the carrier, lots of wine :D, 60ltrs of water, tools, spares, food, camping gear etc. Probably add 400kg to the previous 150kg.

I run reasonably soft springs though, 180lb fronts and 270lb rears with air bag helpers that only get used when loaded.

With the Raids on the factory setting it was a bit of a marshmallow but with the rebound wound to max it is close to perfect.

If the rebound is too soft you'll notice it on the corrugations, they'll literally shake yourself and the Deefer to bits.:mad:

[Bushman83]

Got around to installing my 65L Long Range Automotive Defender drivers side sill tank last week.

http://eftel.com/~mrlewis/defender/1.jpg

To start with I had my standard fuel filler modified into a Y filler by a local welding fabrications shop. They use part of the filler that came with the tank to speed up the fab process. Was completed in 2 hours while I waited.

http://eftel.com/~mrlewis/defender/2.jpg
http://eftel.com/~mrlewis/defender/3.jpg

http://eftel.com/~mrlewis/defender/4.jpg

The installation was pretty straightforward although took some time. The biggest issue I faced was the tank's fuel sender fowled on the floor panel. Some 6mm spaces were added to lower the tank and bolt it up level. This unfortunatley means the tank now sits about 6mm below the chassis rail at its lowest point. Probably just the defender build variation coming into play, although the tank is mainly advertised for 300tdi/TD5 vehicles.

http://eftel.com/~mrlewis/defender/5.jpg
http://eftel.com/~mrlewis/defender/6.jpg

Found a nice spot for the included fuel pump to fit. Added an extra fuel filter for safety.

http://eftel.com/~mrlewis/defender/7.jpg

The kit came with a dual fuel gauge/transfer pump switch. Mounted nicely into my Mudpod.

http://eftel.com/~mrlewis/defender/8.jpg

With the extra 65L plus the 120L from my primary tank I now have 185L total fuel capacity. This should give me around an 1800km range on road as my 200tdi averages 10km/l. Had my tank compliance plated for $150 to make it all legal. :)

[jabber]

You are an inspiration for defender project motivation to all across the globe!!!

Keep up the great work!

[TeamFA]

Nice work. That sill tank is purdy...

We had a water tank made up similar to that (same shape, but didn't go back under and past the rear crossmember), and I made sure it was above the fore-aft chassis rail, and the rock slider (that's replaced the lower door sills). I'm paranoid about bottoming out on it, though I probably never would.

[Bushman83]

Nice work. That sill tank is purdy...

We had a water tank made up similar to that (same shape, but didn't go back under and past the rear crossmember), and I made sure it was above the fore-aft chassis rail, and the rock slider (that's replaced the lower door sills). I'm paranoid about bottoming out on it, though I probably never would.

Yes, that's my fear now. Will just have to be observant of any rocks passing the drivers side. At least if I did tear a hole in the sill tank I would hopefully still have enough in my primary to get me to the nearest town.

[DiscoPaul]

great thread mate and great work on the build, hope my discovery build will be half as good as yours!

[Bushman83]

http://eftel.com/~mrlewis/defender/10.jpg

As mentioned earlier I bought some Koni Raid 90's. I also decided to upgrade my front springs to a pair of Land Rover HD versions as my original springs were sagging badly under the weight of the new bullbar and winch. I decided to keep it simple and go with the Land Rover type rather than playing around with other brands and varying spring heights.

http://eftel.com/~mrlewis/defender/11.jpg

With the springs installed I gained a 40mm lift in the front getting the vehicle back up to level. I decided to leave the koni's at standard setting and see how they go.. thus far I feel the rear could benefit from some tweaking but that's without a load in the back. Otherwise happy with the ride.

Also installed a APT Fabrications steering guard. Had to modify the bash plate slighty due to it hitting my pair of non-standard recovery hooks I added to the chassis.

http://eftel.com/~mrlewis/defender/9.jpg
http://userweb.eftel.com/~mrlewis/defender/13.jpg

:)

[Bushman83]

I finished off my winch installation. The cheapy winch I bought didn't have long enough cable to reach my battery box, plus it uses a pathetic 3B&S (25mm) cable... A little too small for my liking. So I purchased some 0B&S (50mm) cable and a blue sea systems isolation switch and busbar. Managed to find a car audio place nearby who could solder and crimp the connections for me.

http://eftel.com/~mrlewis/defender/winch3.jpg

The battery switch is rated to 300amps continous and 500amp intermittent. Plenty enough to handle a winch.

http://eftel.com/~mrlewis/defender/winch4.jpg

The switch is fitted in my Mulgo Exbox.

http://eftel.com/~mrlewis/defender/winch2.jpg

I used the busbar to connect a short lead from the winch to the larger cable. This means I'm getting maximum current and voltage up to the winch. The 3b&S over a short run will then be plenty to power the winch.

http://eftel.com/~mrlewis/defender/winch1.jpg

My parents bought me an awning for my birthday so installed that this afternoon. It's an Aldi special. Seems well enough made. Bolted straight up to my roof bars. 2.5m x 2m.

http://eftel.com/~mrlewis/defender/awning1.jpg
http://eftel.com/~mrlewis/defender/awning2.jpg

:)

[dcale]

Great thread!! How much 50mm did you need? I like your setup and was thinking of doing the same.

[Bushman83]

Great thread!! How much 50mm did you need? I like your setup and was thinking of doing the same.

Thanks. I purchased 4 metres of each red and black. This was plenty to run the full length without worry along the top of the chassis rails. Bought mine from here:
RED Battery Cable 0 B S Auto Starter Wire Alternator Jumper Leads Tycab 250Amp | eBay (http://www.ebay.com.au/itm/RED-BATTERY-CABLE-0-B-S-AUTO-STARTER-WIRE-ALTERNATOR-JUMPER-LEADS-TYCAB-250AMP-/271367353579'ssPageName=ADME:L:OU:AU:3160)

[Brett1066]

Awesome thread and great work. Given me plenty of ideas for my 300tdi, now just need the time and $$$. Good luck with your trip, will be watching with interest.

[NJB]

Hey Brett hope the planned trip is on track, you mentioned fitting 2 non standard recovery hooks, what where they and how did you fit them.

[Bushman83]

The installation video for the APT Fabrications steering guard.
Defender Steering Guard Installation - YouTube

[Bushman83]

Hey Brett hope the planned trip is on track, you mentioned fitting 2 non standard recovery hooks, what where they and how did you fit them.

hi mate. They are just recovery hooks you can buy from any 4wd store rated to 10000lb/4500kg. You can see them in the steering guard video listed above. Just bolted on the front of the chassis. I think I used an extra small backing plate on the inside of the chassis for added mounting strength.

[Bushman83]

Latest news... Was all packed to go camping for the long weekend. Made it as far as Kilcoy when my gearbox went BANG Grrrrrrr....... So I'm up for a gearbox rebuild. While I'm at it I'm doing the transfer case as well. Booked in for Friday to get the boxes off and dismantled. Estimate thus far is $4000 + parts.

That's gonna take a good chunk out of my travel money but will at least give me the confidence and peace of mind to tackle anything as I have been worrying a bit about my boxes anyway. She'll be like a new car!

I also handed in my leave application at work last week. If it gets approved come Christmas day, I'll be on 14 months leave!!! The big trip will be a go. Still so much I haven't planned travel wise, but really just want to wing it as much as possible and let the journey unfold and be guided by the people I meet along the way.

stay tuned...

[Presto]

Hi Brett, any idea what's gone in the gearbox?

I recently rebuilt my R380 with a complete new main shaft (worn output splines), which although wasn't easy, is certainly do-able for someone mechanically minded. Some special tools help too.

The LT230 is fairly easy, and I highly recommend you do the intermediate gear bush mod while you have it apart.

I machined a bush and housing myself, but got the rest of the parts from Ashcrofts. The rebuild kits were fairly reasonable, so depending on what's gone bang, you should be able to do it for way less than $4k!

[landy]

Hi Brett,

Its probably a good thing its gone now. Much better than on the road!

have you looked into an Ashcroft replacement? even with the import costs it would be why less than 4K plus parts. Or like mentioned above, rebuild it yourself. You can down load all the workshop manuals from Legion Land rover. follow the links to the manuals page.

Cheers

Nino.

[Bushman83]

Hi Brett, any idea what's gone in the gearbox?

I recently rebuilt my R380 with a complete new main shaft (worn output splines), which although wasn't easy, is certainly do-able for someone mechanically minded. Some special tools help too.

The LT230 is fairly easy, and I highly recommend you do the intermediate gear bush mod while you have it apart.

I machined a bush and housing myself, but got the rest of the parts from Ashcrofts. The rebuild kits were fairly reasonable, so depending on what's gone bang, you should be able to do it for way less than $4k!

No idea. Still had drive to the wheels but didn't sound good. Problem is its my daily driver.. I'm lucky I have a work car this fortnight. Need it back on the road asap and feeling 100% confident that it's been done right. Don't really have the time to play with it myself, let alone take it off my car safely. It would be nice to get some of the Ashcroft mods but will have to wait till next time.. hopefully not again for another 21 years. Will know next week once they've pulled them apart the final $ damage.

[Bushman83]

Hi Brett,

Its probably a good thing its gone now. Much better than on the road!

have you looked into an Ashcroft replacement? even with the import costs it would be why less than 4K plus parts. Or like mentioned above, rebuild it yourself. You can down load all the workshop manuals from Legion Land rover. follow the links to the manuals page.

Cheers

Nino.

hey Nino.. yes I'm at least glad it went bang now. Still have 3 months before departure to get everything A1. Yes have looked at the Ashcroft gear though from my calculations of the taxes/duties with the transfer box at least it worked out about the same price except without fitment included. Should know next week the actual quote then can decide. Thanks for the manuals tip.

[Bushman83]

ok.. so the boxes were stripped and I've been told there is major damage to the gears in both the gearbox and transfer boxes. Teeth have been stripped. Due to the great difficulty in sourcing the parts I've been quoted around $8000 to rebuild!!:eek:... so the gearbox mob I'm using are recommending finding other boxes. Looks like I will be importing a nice new LT77s and LT230 from Ashcrofts! ;)

Anyone know of a good import broker they can recommend?

[landy]

Hi Brett.. I've not ordered any large items from Ashcrofts so can't offer an opinion on importing. But I have been following several threads with intrest as I'd like to get the HD R380 box should I ever need one. I gather that it's possible to do it all yourself (almost) and save a lot of money or in some cases cost you a lot more than nessasary. For instance. I noted in one thread that it's best to refuse to use DHL as they add a lot of extra hidden charges. But TNT is reasonably good. And think about breaking the shipment up. Import costs may be higher than freight costs.
I'll follow this thread with intrest. Please post up how you go. At a quoted $8k you would be better to buy a spares car and just salvage it as needed!

Cheers
Nino

[Presto]

Hi Brett,

$8k sounds crazy to me, but at anything close to that, I would definitely go down the route of new boxes from Ashcrofts! Give them a call, they export all over the world and should be able to offer their experience. Although I've never purchased an item from them as large as a complete box, I have had them send me numerous LT/R380/diff rebuild kits, and their shipping costs and efficiency have always impressed.

[Bushman83]

I'm thinking while everything is stripped to replace my clutch plate. It's only done 50000km in 5 years but it might be worth doing now.

I'm trying to decide on the Valeo standard or HD clutch kit.. I'm leaning towards the HD kit. Anyone have any real world experience? I've searched around the forums and some say it makes the clutch pedal heavier others say no difference. Opinions?

[Presto]

When I had the R380 out of mine, I put in a HD clutch and new rear main seal. Peddle feels the same to me.

[Bushman83]

When I had the R380 out of mine, I put in a HD clutch and new rear main seal. Peddle feels the same to me.
Thanks mate. I'll give the HD clutch a go then.

[steane]

I run the valeo 130 clutch in my 110. Clutch pedal is light although I did replace master, slave, hose, throw-out bearing, clutch fork ie the whole lot.

[Wicks89]

Yeah I personally don't see the point in a 'HD' clutch in a defender unless you're having problems and towing.
The way I see it your clutch has done the last few hundred thousand fine, no point throwing even MORE cash down.

Just my opinion.

[DiscoMick]

Can't comment on your particular gearbox and its rebuild costs, although $8k sounds very exxy, but I can confirm it recently cost me $4k to have my Disco's ZF auto rebuilt.
Surely there would be wreckers with good used gearboxes for your Defender around somewhere. I would be calling the major Land Rover businesses in SE Qld such as MR Automotive and British Offroad to see what they had 'out the back' if I were you.
A good used box given a thorough service would have to be an option, surely?

[Timj]

Yeah I personally don't see the point in a 'HD' clutch in a defender unless you're having problems and towing.
The way I see it your clutch has done the last few hundred thousand fine, no point throwing even MORE cash down.

Just my opinion.

Hi Wicks,

The reason why is that a clutch is a wear item. The clutch plate is friction material and the pressure plate has springs. These all wear and need replacing eventually. Might be worth while replacing this before a round Australia trip as you then know for sure that you have a lot of wear left. If your comment is just about the HD item rather than a standard one then ignore my comment :). However it would be fair to assume a fairly well loaded vehicle in this case and therefore heavier than a standard truck so HD might be worth it, again to ensure the happy completion of the whole trip without having to worry about it at all.

Cheers,

TimJ.

[slug_burner]

Unless you have been trying to smoke the tyres up off the line your driven clutch plate will have very little ware. Diesels have good torque down at low revs so you don't have to slip the clutch very much at all. I'd be surprised if your clutch was worn after the km you speak of after your last clutch change.

The weakness in the defender clutch system is in the arm that interfaces with the slave cylinder rod, the rod wears through the face of the arm.

[Bushman83]

Thanks for all your feedback guys. I decided to just replace the clutch so I know "for sure" that everything is up to standard. I bought the HD clutch kit and a new HD reinforced clutch release arm. Should keep me going!

The LT77s and LT230 have been ordered from Ashcroft's in the UK. I got the upgraded sleeved casing and HD crosspin options for the LT230. They should have them built for me early this week.

On another note here is a quick video review of my Goodyear Duratracs.
Goodyear Duratrac Tyre Review - YouTube

[Bushman83]

Defender Dislocated Spring @ Sundown NP - YouTube
A short video from my Sundown National Park trip a few months back where my rear spring unseated. I've since installed some APT rear dislocation cones to stop it happening again.

[Robmacca]

I love Sundown NP. Great spot to get away and explore. Still keen to return there to find out where or how far the track follows the river past rats castle

[komaterpillar]

Sundown is an awesome spot, I was down there again just a fortnight ago. Might be time for another weekender with a few forum members?

[Bushman83]

http://youtu.be/QkvGxvq07tI
Installed a pair of Mulgo side rails.

Also a quick update video of my upcoming trip.
http://youtu.be/QU1qYzcEc9E

[Bushman83]

The final video on my Defender Expedition camper upgrade.
http://youtu.be/WbI1DIcdy1c

:)

[komaterpillar]

Great work mate, good luck with the trip. i'm sure a Lot of people including myself would trade places with you in a heart beat :D

[lux201]

Love the work, you are an inspiration to us all. Hope to see you out off the tracks one day.

[Bushman83]

Thanks guys..

Another update! Waiting on my brake rotors to arrive. Seems to be taking a while.

http://youtu.be/VTACCS9Kheo

[Bushman83]

Finally got my car back together today. New bearings and disc rotors all round. Just need to shim up the cv.

Here's a video of my test trip in August last year to Sundown National Park.
Enjoy.

http://youtu.be/vgY6i3D-Wr4

[John H]

Just found this thread whilst looking at ideas for my Perentie.AWESOME.Keep us informed of your progress etc.When in SA say g'day.Cheers.

[steane]

Are you on the road yet Bushman?

[Robmacca]

Are you on the road yet Bushman?
Yes, apparently he is...... Left in January I think

[steane]

Yes, apparently he is...... Left in January I think

He needs to stop and do another instalment for us then! What does he think he is on, a holiday? :p

Seriously though, it would be good to find out where things are at on the trip, in-particular how the old Deefer is doing ;)

[Bushman83]

YES!!! I'm on the road! :D Day 1 started on Monday 9 February 2015. 3 years of preparation of my Defender has thus far payed off. Currently travelling south through NSW.

For those interested you can follow me on my blog at www.roamingtheoutback.com (http://www.roamingtheoutback.com)

From there you can access my youtube channel and facebook page to keep up to date.

Internet access is rare it seems so will be a while in between posts.
:)


He needs to stop and do another instalment for us then! What does he think he is on, a holiday? :p

Seriously though, it would be good to find out where things are at on the trip, in-particular how the old Deefer is doing ;)

[Toxic_Avenger]

Could have sworn I saw your vehicle around tamworth Monday morning around 10am. I was in the work car, saw the plates def093 or similar which rang a Bell. Details are hazy at 100kmh approaching each other.

[Bushman83]

Could have sworn I saw your vehicle around tamworth Monday morning around 10am. I was in the work car, saw the plates def093 or similar which rang a Bell. Details are hazy at 100kmh approaching each other.

Yes that was me heading out on my way to Oxley wild rivers NP. Camped at Youdales hut for a few days. Will probably be back out that way in a week or 2 while I do a loop back up the coast then out to Mt Kaputar NP.

[alexturner]

Hey Brett!

Awesome build - stop by for a coffee when you're in Sydney! Drop me a line!

I was wondering, are you having any issues with you HF radio? Having the autotune antenna so close to the body my induce a fair amount of capacitance with the ground plane (roof) and mightn't tune properly (or get signal at all) - has is been working for you?

Also, where did that dual battery switch selector come from? Looks great!

Alex

[Bushman83]

Thanks Alex. Should actually be in Sydney within the next week or so. There are a few members on here keen to catch up so might try to organise something.

This far HF performs fine. Have used it a few times. Can contact Swan Hill pretty clearly from the eastern coastline. Guess I'll find out later when I hit SA and begin to use it more. No problems tuning at all.

The battery switch is from the Blue sea systems automatic charging relay set up. https://www.bluesea.com/products/7622/ML-ACR_Automatic_Charging_Relay_with_Manual_Control_-_12V_DC_500A
Thanks


Hey Brett!

Awesome build - stop by for a coffee when you're in Sydney! Drop me a line!

I was wondering, are you having any issues with you HF radio? Having the autotune antenna so close to the body my induce a fair amount of capacitance with the ground plane (roof) and mightn't tune properly (or get signal at all) - has is been working for you?

Also, where did that dual battery switch selector come from? Looks great!

Alex

[peter_yqm]

Hmmm, I don't know what you mean by 'close'. I had a Codan auto tune that was mounted close to the vehicle side and the antenna failed (wouldn't tune), whether it was the proximity to the metal is moot but I was strongly advised by an HF radio expert that it was much too close.
I currently have a Barrett and the manual specifies a minimum distance of 160mm if mounted near the body. Picture from the Barrett 950 installation manual.
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thought this might help,
..........peter

[steane]

When do you expect to reach Adelaide Brett?

If it's when I'm at home (heading to Alice and across the Simpson in late June - July) then you are welcome to stop by for a coffee. You are also welcome to use my place if you need to do any mechanical work/servicing.

Our Defenders are quite similar and my nephew has been following the build of both of them:lol2:

[110 mac]

Fantastic thread Brett. Good luck with the trip mate.:D

[Bushman83]

Not sure mate.. Currently working my way towards Melbourne. It's getting pretty cold now so i'm thinking about escaping back north to some warmth!


When do you expect to reach Adelaide Brett?

If it's when I'm at home (heading to Alice and across the Simpson in late June - July) then you are welcome to stop by for a coffee. You are also welcome to use my place if you need to do any mechanical work/servicing.

Our Defenders are quite similar and my nephew has been following the build of both of them:lol2:

[Bushman83]

My trip around Australia was completed after 304 days on the road. I had to skip Western Australia due to lack of time. Everything performed really well. Unfortunately all the photos of this thread were deleted when I changed ISP's but I will reupload them if the moderators can give me access to edit my posts again.

For a detailed look at my trip and Defender visit my website at Home - Roaming The Outback (http://www.roamingtheoutback.com)

Here are a few detailed videos reviewing my set up and modifications after travelling for 10 months.

Enjoy the videos.
https://www.youtube.com/watch?v=puaPceLTnPY
https://www.youtube.com/watch?v=0zP_9SVeDEk
https://www.youtube.com/watch?v=7WViv7IgCOE