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Seat Box OUT
With all the panels replaced its time to take out the seatbox so that all the joins can be sealed and a layer of heat/sound insulation put in place.
Floor panels and gearbox tunnel were quickly removed by undoing all the visible screws.
Front edge of the seatbox had a bolt to chassis in each footwell - easily undone with floor panels out.
Rear edge of the seatbox has a line of bolts to undo.
Seatbox bolts to sill and pillar removed.
Detached the handbrake cable (chocked wheels :eek:).
The box can then be easily lifted/flipped out. Given the amount of sound that comes through the seatbox , it is unsurprisingly light!
http://www.aulro.com/afvb/attachment...1&d=1414989694
The underside has got little more than a layer of dust for insulation!
http://www.aulro.com/afvb/attachment...1&d=1414990247
After a trip to the red centre I've jet washed the old girl at least three times, but some areas are clearly unreachable:
http://www.aulro.com/afvb/attachment...1&d=1414990323
I need to change the fuel level sender, do some wiring and plumbing so a little clean up needed. With the vehicle immobilised inside the garage I had to use a stiff brush, a hoover, a spray bottle of water and a rag!
http://www.aulro.com/afvb/attachment...1&d=1414990732
http://www.aulro.com/afvb/attachment...1&d=1414990869
And that's that for now.
Next up: clean, seal, insulate and re-install the seatbox the way it should be done.
Might be a while till I get around to it though, I have a second fuel tank to install first!
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Clean n Seal
Bit of rainy weekend, so not a lot of seat box action to report.
I've got the underside of the seat box nice and clean. I took off the nuts/plates that the seats bolt onto as I will not tolerate any steel on aluminium. They were tacked in place with a small rivet, I will tack them back on after I lay down a bitumen barrier.
Seams all sealed up with Sikaflex.
http://www.aulro.com/afvb/attachment...1&d=1416110527
Next up - a layer of foil faced bitumen stuff, aka dynamat.
:spudniksnore:
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I should probably stop ending posts with 'next up....'
Some progress over the weekend:
Repair the corroded section of pillar (also notice the bracket in the background, more work to be revealed!).
http://www.aulro.com/afvb/attachment...1&d=1416821515
For replacement aluminium, might as well use the old seat box panels.
http://www.aulro.com/afvb/attachment...1&d=1416821661
One for driver side and one for passenger
http://www.aulro.com/afvb/attachment...1&d=1416821746
Started to clean up the passenger side pillar of all surface corrosion, ready for the replacement panel..... but curiosity sent me on a tangent.... I removed the bracket in the background holding the tub to the chassis - and found this fella:
http://www.aulro.com/afvb/attachment...1&d=1416821811
Completely munched! Checked the mounting bracket in the center but fortunately ok - just a bit surface corrosion
http://www.aulro.com/afvb/attachment...1&d=1416822132
So that's what happens when you bolt steel to aluminium and let them go at it for 25 years! Without removing the seatbox or anything, the brackets are fairly easy to get at and remove. Seeing as Landrover consider a coat of paint to be enough separation, you may want to check and isolate your chassis to body brackets sooner rather than later.
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The scream
Whilst trying to ignore the screaming fella in the background, I got back on with the pillar fix. Bit of sikaflex:
http://www.aulro.com/afvb/attachment...1&d=1416824241
The repair section then stuck and riveted into place:
http://www.aulro.com/afvb/attachment...1&d=1416824351
Screaming fella gagged with some bitumen tape:
http://www.aulro.com/afvb/attachment...1&d=1416824420
Blindfolded with some neoprene foam
http://www.aulro.com/afvb/attachment...1&d=1416824500
Locked away for good:
http://www.aulro.com/afvb/attachment...1&d=1416824582
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fine, back to brackets.
Bitumen taped (ooohhh yea :))
http://www.aulro.com/afvb/attachment...1&d=1416825362
Brackets back on, uglier, but better than new. No more aluminium munching!
http://www.aulro.com/afvb/attachment...1&d=1416825649
http://www.aulro.com/afvb/attachment...1&d=1416825799
What I like about using bitumen as a gasket is that it coats the bolts as you push them through, separating them from contact with the panel and locking your nuts. For steel washers, I'm having a go with neoprene gaskets.
http://www.aulro.com/afvb/attachment...1&d=1416826105
Well that's that, up next .... :spudniksnore:
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I went with dynamat for a base layer. There are cheaper options but seeing as it will be suspended underneath the seatbox with foam attached - better not skimp.
Unfortunately dynamat have changed from a heat reflecting silver skin to a black one. This new stuff is thinner and sticks to the wax paper when even slightly warm. I used the old stuff on a 30 degree day and had no issues.
Anyway:
http://www.aulro.com/afvb/attachment...1&d=1416903179
Decided to cover only the panels that separate from the cabin, with exception of the inner side of the battery box which I've covered to reflect transmission/exhaust heat away from the batteries.
The seat box took 3 sheets so a Dynamat 'Trunk Kit' (5 sheets) should be enough to cover the seat box, floor panels and transmission tunnel.
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Shiny side up
Got hold of some heavy weight 25mm thick insulation -> Foil | Foam | Vinyl | Foam | Stickyness
http://www.aulro.com/afvb/attachment...1&d=1417080043
Slits in first foam and vinyl layer so it rolls flat over the extrusions.
http://www.aulro.com/afvb/attachment...1&d=1417080302
With backing still on, openings marked out with a Stanley knife.
http://www.aulro.com/afvb/attachment...1&d=1417080405
Roll it on, peel n stick, section at a time.
http://www.aulro.com/afvb/attachment...1&d=1417080172
Shiny side up:
http://www.aulro.com/afvb/attachment...1&d=1417080599
The access panels were cut in at 45 degrees to prevent gaps.
This box is going to be a lot heavier going back on! :)
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Manic, Thanks for the post. I'm planning to do the same as you have done to the seatbox on a Series 3 I am rebuilding.
Do you have any feedback on how successful the soundproofing was?
Thanks
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It reduced the annoying transmission whine considerably which I was very happy about, but overall not a huge difference in cabin noise because of all the wind/engine and other noise a `defender` generates.
On the 90 there is a strip along the floor behind the front seats where the rear tub meets the seatbox and the rear wheel arches. I ran out of foam, time and energy so I did not cover those areas. The noise that is still noticeable now comes up from behind my seat, which is much more agreeable but it could be further reduced if I continued to insulate the entire floor/underside all the way to the back.
For now I'm happy enough with the way things sound to leave it.
Good luck with yours, let us know how you get on.
