This 1994 Land Rover Defender 90 was suffering from major frame rot and corrosion on the doors. The Land Rover will get a new galvanized frame, cosmetic restoration, interior work and top.
The 1994 Land Rover D90 as it arrived in the shop.
There is bad corrosion on both doors.
There are many minor cosmetic issues that need to be addressed.
The interior is showing its age.
The axle housings are badly rotted.
The fuel lines are rusted and just starting to leak.
The axle housings will need to be replaced due to major rust.
The tear down begins.
The body is removed from the frame.
Major rot is clearly visible on the gas tank skid plate and frame.
The drivetrain is removed from the frame.
The new frame is being assembled.
New brake hoses and stainless steel brake lines are installed.
The original differentials are installed in replacement axle housings.
New genuine Land Rover springs and Bilstein shocks are installed.
The original M8000 winch was not working and is replaced with a new Warn M8000.
The clutch was badly worn so the flywheel was resurfaced and a new clutch was installed.
Poor wiring harness repairs were discovered during disassembly. All the wiring was correctly repaired.
The radiator fins were badly corroded so the radiator will be replaced.
The drivetrain is installed in the rolling chassis.
A new galvanized steel gas tank skid plate is installed.
Melted insulation is discovered on the battery cables.
The original paint on the bulkhead was buffed out. New vent flap seals and bulkhead-to-winshield seal are installed.
Although the original paint was in decent shape, there were many dings that needed to be removed with paintless dent removal.
Dents on the hood are being removed.
A cut in the fuel pump wire is discovered in the wiring harness.
New stainless steel fuel and brake lines are installed.
A new genuine Land Rover rear mat is installed.
A new genuine Land Rover under seat box is installed.
A new genuine Land Rover rubber floor mat and seat box Hardura trim is installed.
New genuine Land Rover fender flares are installed.
The Warn M8000 winch is mounted in the factory winch mount.
New genuine Land Rover doors are repainted in Conniston Green Glasurit.
The rear tub and roll cage is installed.
The paint formula for the doors was adjusted to match the original paint perfectly.
The doors are painted inside and out.
The seat bases are re-upholstered and new foam added.
A Badger soft top is installed.
The new Warn winch is mounted in the original winch mount.
The finished product.