This 1994 Land Rover Defender 90 had only 30,000 original miles but was suffering from major rust and corrosion on the frame and body. The bulkhead, frame and axle housings were all badly rotted as well as many other under body components. The Land Rover will get a new galvanized frame, bulkhead repair, full repaint and new interior and top.

The 1994 Land Rover D90 as it arrived in the shop.

There is bad corrosion on many of the aluminum body panels.

The bulkhead is badly rotted.

The axle housings and suspension mounts are also badly rotted.

The gas tank skid plate is completely rotted out as well as is the rear frame.

As the bulkhead is disassembled, more rot is uncovered.

The original differentials are sand blasted and painted and installed in replacement axle housings.

All the suspension bushings are replaced and new springs and shocks are installed on the new galvanized frame.

The body is removed from the frame.

The original steel fuel lines are rusted and would probably start leaking soon.

All new stainless steel fuel lines are installed so rust will never be an issue again.

The drivetrain is installed in the rolling chassis.

The body is completely disassembled and ready to be stripped to bare aluminum then repainted.

The swivels are rebuilt with the correct amount of preload.

All new stainless steel brake lines are installed as well as genuine Land Rover brake hoses.

New genuine Land Rover rubber spring isolators are installed.

The body panels were stripped to bare aluminum and repainted in AA Yellow Glasurit which is an extremely high quality paint.

All the parts were painted individually and are now ready for assembly.

Both sides of the tailgate were repainted to prevent corrosion between the two layers of metal.

All body panels are assembled with genuine Land Rover rivets.

The bulkhead was sand blasted and repaired.

The bulkhead was repainted in AA Yellow Glasurit.

The bulkhead was fully seam sealed to prevent moisture between the two layers of steel.

The under seat boxes were sand blasted and painted.

When the bulkhead is assembled, all new weather stripping and grommets are used.

The bulkhead is assembled on the frame.

1995 and up style door check straps are installed. These keep the doors from slamming shut on an incline.

New genuine Land Rover seat belts are installed.

The rear tub is assembled. New genuine Land Rover fender flares are used; these appear glossy when new but fade to a matte black.

A new "unleaded fuel only" sticker is applied just like it would have had if new.

The rear forward facing seat is replaced with four inward facing jump seats.

When the jump seats are folded, the load bay is fully accessible.

New genuine Land Rover grille lettering is installed.

Here you can see the brilliant sheen of the Glasurit paint.

New door latches are installed.

New style rust-resistant genuine Land Rover door hinges are installed with galvanized hardware.

The fenders are installed.

The seats are re-upholstered and seat heaters are added.

New genuine Land Rover parking lights are installed.

A new windshield is installed in the repainted frame with a new genuine Land Rover gasket.

A new genuine Land Rover retractable antenna is installed.

Genuine Land Rover V8 logos are applied.

The external roll cage is powder coated and installed.

New genuine Land Rover headlight surrounds, grille and grille logo are installed as well as LED headlights.

A new genuine Land Rover bumper is installed.

A new genuine Land Rover rear floor mat is installed.

An NRP stainless steel exhaust is installed. The rear step bumper is powder coated and installed.

The taillight guards are powder coated and new style rust-resistant rear tailgate hinges are installed.

A new genuine Land Rover floor mat is installed. All the carpeting has been replaced with rubber mats.

The heated seat switches are installed in the Tuffy center console.

All cracked or damaged components are replaced with new.

New genuine Land Rover fender top vents are installed.

 

A new genuine Land Rover skid plate is installed.

The finished product.

The rear tire carrier was powder coated and rebuilt.

This side view shows the excellent door gaps.

 

 

A new Badger soft top is installed.

Unlike the original soft top, this one has a full gutter kit around the doors to keep rain and wind out. It also has tinted windows and roll up sides.