Defender Rust Repair

[MacFamily]

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

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

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

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

https://www.aulro.com/afvb/images/imported/2009/07/1007.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1008.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1009.jpg

[MacFamily]

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

https://www.aulro.com/afvb/images/imported/2009/07/1001.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1002.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1003.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1004.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1005.jpg

[MacFamily]

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

A few pics of the welding and preparing for painting.

https://www.aulro.com/afvb/images/imported/2009/07/989.jpg

https://www.aulro.com/afvb/images/imported/2009/07/990.jpg

https://www.aulro.com/afvb/images/imported/2009/07/991.jpg

https://www.aulro.com/afvb/images/imported/2009/07/992.jpg

https://www.aulro.com/afvb/images/imported/2009/07/993.jpg

https://www.aulro.com/afvb/images/imported/2009/07/994.jpg

https://www.aulro.com/afvb/images/imported/2009/07/995.jpg

https://www.aulro.com/afvb/images/imported/2009/07/996.jpg

https://www.aulro.com/afvb/images/imported/2009/07/997.jpg

https://www.aulro.com/afvb/images/imported/2009/07/998.jpg

https://www.aulro.com/afvb/images/imported/2009/07/999.jpg

https://www.aulro.com/afvb/images/imported/2009/07/1000.jpg

[MacFamily]

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

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

Here are some before pics

https://www.aulro.com/afvb/images/imported/2009/07/892.jpg

https://www.aulro.com/afvb/images/imported/2009/07/893.jpg

https://www.aulro.com/afvb/images/imported/2009/07/894.jpg

https://www.aulro.com/afvb/images/imported/2009/07/895.jpg

After herculiner from firewall to the rear door

https://www.aulro.com/afvb/images/imported/2010/01/1059.jpg

https://www.aulro.com/afvb/images/imported/2010/01/1060.jpg

https://www.aulro.com/afvb/images/imported/2010/01/1063.jpg

https://www.aulro.com/afvb/images/imported/2010/01/1061.jpg

https://www.aulro.com/afvb/images/imported/2009/07/896.jpg

https://www.aulro.com/afvb/images/imported/2009/07/897.jpg

[MacFamily]

Just some other Random pics..

I also used herculiner on the rear crossmember

https://www.aulro.com/afvb/images/imported/2009/07/889.jpg

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

Behind aircon

https://www.aulro.com/afvb/images/imported/2010/01/1057.jpg

Driver side

https://www.aulro.com/afvb/images/imported/2010/01/1058.jpg

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

https://www.aulro.com/afvb/images/imported/2010/01/1064.jpg

https://www.aulro.com/afvb/images/imported/2010/01/1065.jpg

Front of firewall

https://www.aulro.com/afvb/images/imported/2009/07/890.jpg

https://www.aulro.com/afvb/images/imported/2009/07/891.jpg

[flagg]

Nice one Aaron :)

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

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

dec

[DeeJay]

Nice one Aaron :)

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

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

dec

I was interested too:D

Herculiner Retailers Australia UTE LINER tub liner BED LINER rhino liner SPEEDLINER DIY (http://www.herculinersales.com.au/order_form.html)


We could look at a 4 buddies pack, I must ask my mates what a buddy is....

[catfishman]

that looks pretty impressive Aaron - i think i know what i will be doing in a few weeks time - job well done

[aki]

impressive job! I like it, well done. axel

[cal415]

Nice work, i bought a tin of herculiner to do the back of my 110 too, i wasn't sure if i would have enough to do the seat box etc as well, did you use only 1 tin?

[MacFamily]

Nice work, i bought a tin of herculiner to do the back of my 110 too, i wasn't sure if i would have enough to do the seat box etc as well, did you use only 1 tin?

I bought the kit came with a tin of black Herculiner 2xroller brushs 1xbrush.

I think the tin is 1 US gallon = 3.78541178 liters, but I was able to do 2 coats from the fiewall to the back door.

This is where I purchased my kit Lynx Corporation - Online Shopping (http://www.lynxcorp.com.au/shopping/default.asp?Category=313)

another link Herculiner Retailers Australia UTE LINER tub liner BED LINER rhino liner SPEEDLINER DIY (http://www.herculinersales.com.au/)

[cal415]

Excellent i got the same kit, but i wasnt sure if i would have enough to do the seat box and upright sections of the tub in the rear, but now i know :)

[Awfamily]

hello to all but I noticed Cal415 you have a V8 County, can you tell me what you think of it and any ideas on engine and fuel consumption. we have just bought a V8 county to do up and first question is do we keep the V8 and rebuild it or replace it with a turbo Diesel. Any suggestions would be greatly appreciated from anybody.
Kind Regards