Sivvy130's 1997 130 Defender 300TDI Extended Cab Resto

[Sivvy130]

Hi All,

Bit new to the forums have finally started to get a bit more involved and subscribed!


Anyways this is my 1997 130 Defender 300TDI extended cab I'm doing a restoration on.
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It's come a fair way since back in October 2015 when I commenced the disassembly. Was hoping to be almost completed by now but due to unexpected hold ups between painting and FUNDS it's still underway.


So far I've completely stripped the car to bare chassis, had it sand blasted and resprayed - gloss black.




Cleaned up both axles and rebuilt differentials.
All new steering linkages and ends
New steering box and drop arm
2" tough dog lift kit fitted
Polyurethane suspension bushes fitted
Re-sealed and painted front and rear brake callipers red.
All new brake pads and drilled and slotted brake rotors
All new wheel bearings all round
A-frame ball joint
285/75R16 Mickey Thompson P3's with sun raisers (when they finally wear out I'd like to go back to alloys with General Grabbers)
New sedimentary filter, cleaned fuel lines and new tank unit.
Cleaned up and repainted brake lines
Swivel hubs rebuilt with all new swivel ball and bearings
Nice new bolts for everything as well!!



Basically gone to town on the rig in a brief description but I wouldn't have it any other way. I hope along the way to keep the thread updated as the project moves along to motivate anyone else interested in a resto or just for eye candy if you like you're defenders!


Currently I'm awaiting the cab back from panel shop after fitting new foot wells, doors, fixing rust at A pillars and roof as well as a nice respray.


With my free time I've been rebuilding my transfer box with all new bearings and Ashcroft ATB Diff and am soon to move on to my R380 gearbox.

More Photos coming soon will keep posted!!![biggrin]
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[VladTepes]

Good stuff mate ! It's great to see an extended can being rescued too. That's how all the 'single cab' utes should have come.

[Sivvy130]

Be good if they all did would of defiantly been a lot easier to find the side window seals!

[Scouse]

The side window seals will be unique to whichever body builder extended the cab. Each one had their own way & some have oval windows while others have rectangular. The seal itself should be relatively easy to find as it would have been sourced locally to the builder.

[Gaz69]

Be good if they all did would of defiantly been a lot easier to find the side window seals!

Not sure if you found the side window seals but this mob may have some in the auto section. I also have a 97 extra cab 130 that im rebuilding.

Keep up the good work!

Rubber Online (http://www.rubberonline.com.au)



Cheers
Garry

[Sivvy130]

Cheers Gary! I'll look into it for the return of the cab

[Sivvy130]

So bit of an update on my absence.

In the last couple of weeks between work and waiting on parts, I’ve stripped down my LT230 transfer box, cleaned up housing and gears, etc.

I ordered an Ashcroft ATB centre Diff and shim kit and began reassembling of the transfer.

Also fitted the modified oil pan.

All endfloats gone and preloaded correctly as per specs.

Very happy with it! Looks good and turns nicely.

I’ll be looking forward to trying this out when she’s finally running again.

Nothing quite like driving the Defender (as much as society disagrees)


Cabs almost finished in the panel shops so hoping to throw up some photos then as well as a few of my rolling chassis with all additional modifications.

Stay tuned :)

https://www.aulro.com/afvb/images/imported/2017/10/392.jpghttps://www.aulro.com/afvb/images/imported/2017/10/393.jpghttps://www.aulro.com/afvb/images/imported/2017/10/394.jpghttps://www.aulro.com/afvb/images/imported/2017/10/395.jpghttps://www.aulro.com/afvb/images/imported/2017/10/396.jpghttps://www.aulro.com/afvb/images/imported/2017/10/397.jpghttps://www.aulro.com/afvb/images/imported/2017/10/398.jpghttps://www.aulro.com/afvb/images/imported/2017/10/399.jpghttps://www.aulro.com/afvb/images/imported/2017/10/400.jpghttps://www.aulro.com/afvb/images/imported/2017/10/401.jpg

[Sivvy130]

Evening all.

Began stripping the R380 manual trans today for a rebuild.

New bearings, synchro rings, seals and a good check over and clean up are on the list.

Hoping to bath the casing and give the main casing a pretty up with a new black coat of paint.


https://www.aulro.com/afvb/images/imported/2017/10/564.jpg

https://www.aulro.com/afvb/images/imported/2017/10/565.jpg

This is the original transmission from factory. Judging by the sealant though someone’s been here before.

Found the filter rather chockers with what appears the inside coating of the casing peeling away.

https://www.aulro.com/afvb/images/imported/2017/10/566.jpg

Synchro rings are defiantly in need of replacement. Rather worn especially 2nd gear.

https://www.aulro.com/afvb/images/imported/2017/10/567.jpg

Everything else so far looks spot on. Will tear down the shafts tomorrow. A nice clean area with a few broom ends will make the rebuild easy. I usually try to place the gears, etc straight off the shafts onto the broom sticks same direction and all. Tends to make the cleaning and rebuild easier.

https://www.aulro.com/afvb/images/imported/2017/10/568.jpg

I’d have to say overall the amazing the handiness of a milk crate when you’re short a bench!!

Holds my vice well!

Building a shed at the moment so my days of limited space, benches and working in the dirt will soon be over :D.


Will update this week on completion.

Regards,

Michael

[Pickles2]

Great thread Sivvy, & great pics.
What are the two covered cars in your initial pics?
Pickles.

[Sivvy130]

Cheers Pickles. Going to town on my rig so hoping to share the process best I can.

Haha those are another project of mine. I picked up 2 R34 skylines for a few hundred dollars. Ones written off the others a repairable write off. Have to repair some bumper damage just drilling spot welds and swapping front ends.

Will hopefully paint myself and drop a turbo engine in. Then she’ll be up for sale to sponsor my Defender mods ;)

[Sivvy130]

Firstly Happy New year and apologies for my absence to all those following my resto.
Ive been rather caught up with work and family vehicles [emoji1304].

With all those sorted, a lots happened with the project in the past couple of months.

Firstly the gear box is finally rebuilt! After a full tear down of the main shaft and all reusable gears and selectors torn down cleaned and lubed. I began reassembling along with new bearings and baulk rings.
https://www.aulro.com/afvb/images/imported/2018/01/39.jpg

I’m rather happy with the outcome if I can say so myself. [emoji1303]

From this:https://www.aulro.com/afvb/images/imported/2018/01/40.jpg

To this:https://www.aulro.com/afvb/images/imported/2018/01/41.jpg

Also on another good note the cab has returned with a fresh coat of paint!

https://www.aulro.com/afvb/images/imported/2018/01/42.jpg

Real eye candy! [emoji16][emoji16][emoji16]

All windows are now fitted, roof lining aswell as heater box, steering column and the dash is currently underway.
I’m stoked at the progress [emoji1303] she’s starting to look more like a Defender finally!

Will update more often now. It’s my New Years resolution [emoji6].

Regards,
Sivvy130

https://www.aulro.com/afvb/images/imported/2018/01/43.jpghttps://www.aulro.com/afvb/images/imported/2018/01/44.jpg
https://www.aulro.com/afvb/images/imported/2018/01/45.jpghttps://www.aulro.com/afvb/images/imported/2018/01/46.jpg

[Toxic_Avenger]

Great work and thanks for the update.

[Gaz69]

Its looking great!

[Sivvy130]

Due to the weather here thanks to the cyclone or should I say tropical low! I wasn’t able to do much to the cab this weekend although it gave me a reason to tear down the 300Tdi engine.
https://www.aulro.com/afvb/images/imported/2018/01/532.jpghttps://www.aulro.com/afvb/images/imported/2018/01/533.jpg

The goals for this engine is a pure strip down to bare block. All welsh plugs removed, oil jets, the works and send it off to Perth for an acid bath to clean any grime in the oil/coolant passages. After, I’ll have all my bores polished and surfaces levelled before rebuild.
https://www.aulro.com/afvb/images/imported/2018/01/534.jpg
I’m going to send the cam and crank down to for a quick polish too.

Once returned she’ll receive new piston rings, big ends and main bearings and the reassembly will begin. https://www.aulro.com/afvb/images/imported/2018/01/535.jpg
https://www.aulro.com/afvb/images/imported/2018/01/536.jpghttps://www.aulro.com/afvb/images/imported/2018/01/537.jpghttps://www.aulro.com/afvb/images/imported/2018/01/538.jpghttps://www.aulro.com/afvb/images/imported/2018/01/539.jpghttps://www.aulro.com/afvb/images/imported/2018/01/540.jpg

As for the cylinder head I’m going to strip it down. Have it crack tested and have the corrosion machined if found to be fine. I believe that will be the case as she’s isn’t warped and looks in reasonable condition. New stem seals and valves to be lapped in.
https://www.aulro.com/afvb/images/imported/2018/01/541.jpg

Now performance wise....

I’ve bought an allisport VGT turbocharger which I’m going to get the exhaust side/manifold and elbows ceramic coated. This coating will keep them not only looking nice [emoji6]
https://www.aulro.com/afvb/images/imported/2018/01/542.jpg but keeps the exhaust gas warmer for longer and encourages a better scavenging effect during the engine cycle. It’s all about those 1% horsepower gains, am I right?! Although in conjunction with the new turbo should provide the engine with a boot full of more power especially in the lower rpm range where I found the girl minimal under load especially.

New injectors will be installed and as I’m going to town I may replace or attempt to rebuild the injection pump.

I plan to also fit a 3” exhaust but keep it clean with muffler. I’ve heard other cars with straight through pipes and it’s brutal.

Any recommendations for shops or sites selling exhausts for the 300???

Other than that I hope this week to assemble in the floor pans and gearbox tunnel cover and have it ready for my new Exmoor trim seats and rubber moulding [emoji1305][emoji1305].

Stay tuned.

Regards,

Sivvy130

[roverrescue]

Sivvy
Love your work
I have 300tdi Conrod bolts and nuts, thrust washers and Conrod bearings
All brand new

I’ll never need them and they have been in the markets for a month with no interest

If you can use them I’ll pay them forward to your great little project

Steve

[Sivvy130]

Hi Steve,
I’ll keep that in mind after I’ve carried out some measurements on the block, etc just to ensure I don’t need oversize.

[emoji1303]

[Kidbeen]

I am full of envy with your mechanical expertise, energy levels and the way work is progressing. I can also imagine the dollars the rebuild it costing. Did you get your Ashcroft parts within Australia or did you order them direct from the UK?

When you are finished I doubt whether you will want to do extreme driving with it and get it all dirty. Haha!

If you have time can you tell us about your mechanical background.

Gary.

[Sivvy130]

Hi Gary,

Abit of a background on me is nothing to out there. I grew up around vehicles and machinery as well as a mechanic for a brother. I like my landies and am a Mechanic by trade.

I tell ya what motivation is key to a lot of what I’ve done especially balancing work, etc. The vehicle actually use to belong to my father but when he passed away it’s been my goal to restore it to its greater glory that we had always planned to do. For me, completion is not only closure but also doing him proud.

Ashcroft bits I bought directly from Ashcroft themselves. I’ve found directly is the best price and knowing what you need/want on you’re first order will help get the job done quicker especially being in AU! Just be weary if you aren’t already that customs will sting hefty import taxes on anything over a $1000. Nothing a few separate orders can’t fix!

Haha it’ll be hard at first but you can’t stop something from doing what it’s made to do ;)

Michael.

[uninformed]

Sivvy
Love your work
I have 300tdi Conrod bolts and nuts, thrust washers and Conrod bearings
All brand new

I’ll never need them and they have been in the markets for a month with no interest

If you can use them I’ll pay them forward to your great little project

Steve

legend :BigThumb:

[Sivvy130]

Been abit of a quiet week in the shed currently!

Defender is down at XW engineering here in Geraldton fabricating me up a new tray.
Once she’s all complete I’ll be taking it down to have it painted to factory paint code like my cab at West Coast Smash Repairs.

Hoping to have a few pics soon!

- Have finished measuring my engine block so I can progress it off to Perth for machining.

Basically cylinder bore taper and ovality was within spec so I’m only going to hone the bores.

Block will be sent for acid bathing, hone, cam bearing replacement and a quick skim over the deck face. After that I’ll prep the block for a touch of paint[emoji1303].

Will also have crank inspected and polished.

Turbo will also be going off for ceramic coating of exhaust components this week.

So plenty going on around the place besides here!

More to come!

Sivvy130

[Wicks89]

This thing will be a wonder to behold when it's done. You need to make sure you take more photos! You want to be able to show the full transformation!