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Project "SPOT" D-90 Restoration

LATEAPEX

By LATEAPEX
in Show us your Rover!

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LATEAPEX

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As some of you know I had acquired a RHD 90 with a 19J, Clean CA title.

 

Looking over the rig at purchase. I knew immediately that it had spent most of its life in the UK. Bill and I decided to do a complete frame up.

You can see in the initial pictures that with the frame “repair” that was performed and the body rust that we definitely had a project on our hands.

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0487.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0492-1.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0503.jpg

 

TEARDOWN

Got it over to our shop and started tinkering with ideas on what will be needed to complete the project.

To make the teardown brief, attached is a summary of pictures of the teardown to the frame. Removed the front clip, which will be put away until paint as will the windscreen and roof assembly. The doors and front bulkhead are a loss unfortunately as they have already once been “repaired”

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/shop6.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/downsized_0601081725.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/downsized_0615081435.jpg

 

The one item I was expecting to not suffer the same fate was the rear Tub assembly. Boy were we wrong! Its going to take some work to bring this back to life. Still debating on if its worth it.

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/downsized_0615081803b.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/0615081803.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/downsized_0615081803a.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/downsized_0615081802.jpg

 

I am currently categorizing parts as well as stripping, plating (Zink, Anodizing , GALVI) and Powder-coating while we wait for our brand new Galvi frame which is hopefully expected for the end of this month, as well as a BUNCH of other goodies which will arrive in the same road trip ;)

I will try my best to keep this thread currently being updated with our progress. Things are kinda slow right now as we wait for parts.

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  • 1 month later...
LATEAPEX Newbie

LATEAPEX

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UPDATE!

 

Bill and I flew out to denver on friday to meet with Jim Pendy(Pendy Imports) We met Jim at his buddys shop, Keith with Rover Tracks. He had a loading dock to get my Galvi roller frame with Bills 2.8TD with the custom tranny and T/C mounted on it, into the back of the moving van. We rented a 16" Penske moving van to get em all in there.

 

The trip home, 1,290 Miles, 20ish hours straight :eek: no sleep, just stoping enough for snacks and Gas. We got back into town yesterday afternoon..

 

This is what our goodies looked like when we arrived.

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5547.jpg

 

My new Galvi frame, attached is bills brand spankin new power stroke 2.8TD

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5548.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5579.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5581.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5582.jpg

 

 

We where able to fit it in there well once we drilled a few holes through the steel beams of the moving vans floor to hook the straps in...:D oops :rolleyes:

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5555.jpg

 

Was able so snap a shot of Keith's Awesome 110!

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5553.jpg

 

We got everything unloaded today and into our shop. We got some doors from Pendy in better condition than the current ones. He also brought along a bulkhead for us to see if we wanted to try to make work... i think i have decided on getting one of pendys Brand new Galvi Bulkheads he has laying around, so that is on its way on a pallet. :D

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5592.jpg

 

Hopefully work will commence this week on getting the 300TDI out of bill CT110 and throwing this Awesome 2.8 in! the 300 will shortly be on my frame. Next on the list is building a custom exhaust system for both of these rigs.. then to get the reserve fuel tank on mine, and start routing some fuel line and changeover valves to kill time untill the suspension and lockers arrive.

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LATEAPEX Newbie

LATEAPEX

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It was quite an interesting weekend. Was able to get the CT110 torn down enough to get access to the motor. The plan was to be able to remove the motor,tranny,T/C,overdrive unit, as a whole.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5608.jpg

 

After about 2 hours of disconnecting wires, fuel, coolant, cross members. It was time to see if our cherry picker was up to the task of lifting this very heavy setup.

 

So far so good

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5612.jpg

 

It was quite a task with how high we starting off with bills rig, combination of the lift and the “37s. We ended up needing to get the motor up about 6.5-7 feet to clear the front frame cross member once the weight was off the frame.

 

Well that was….”easy”

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5613.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5614.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5615.jpg

 

The motor mounts come off the 300 as it gets put aside for now… we gotz ourselves a 2.8 to stab in! Bill worked on cleaning up the wiring and put some dynomat on the bulkhead to help a little with the noise..

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_5626.jpg

 

VOILA! Like magic…. Little fight with getting the right link on the chain for the balance, but other than that it was relatively easy. Now time for a nice custom 3.0” custom exhaust and figure out the cooling system!

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LATEAPEX Newbie

LATEAPEX

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Ya... alot of work ahead of us.. for mine at least.

 

The 110 should be running as soon as i get the exhaust made. We have a custom Rad and front mount Intercooler on its way for it as well. should be a couple weeks :cool:

 

Getting Bills 110 completed is my first priority.

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  • 1 year later...
LATEAPEX Newbie

LATEAPEX

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WOW Has the time flown By!

 

I could of sworn I was just on here yesterday posting about the steps remaining on Bill’s Rig! And now here I am almost two years later! :o

Well I can safely say that Bill’s Rig is done and has been for a long while now. Ended up building a stainless 3†turbo back system for it and the cooling system ended up being efficient enough after fabbing up a E-Fan with in-line temp sensor. Bill Ended up ditching the 37â€s with bead locks and went with more “proper†34â€s with nato wheels setup. Leaving him with the need to change from the 4:11’s to 3:80 somethings.. The Shake down runs to Hollister, Pismo, and Salt Lake City have proven that I haven’t left anything loose under there! :D

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_3685-1.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_3743.jpg

 

NOW….Back to my………..Project!

A lot has happened with moving from our small San Jose shop, to a nice 3,800sqFt shop in Gilroy.

 

Starting off with the rear tub/bed repair.. After 4 months of cutting,grinding,Tig welding the Bed is officially done. I decided to run dual tanks leaving me with the need to make another Diesel fill box.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0271.jpg

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0301.jpg

 

I had taken measurements from Bill’s 110 and made my own box to connect up to a standard NAS rear tank. Adding the Diesel sending unit and pickup. With this rear additional tank, which now will serve as the main, I will have a total of 36 gallons capacity. That combined with the 300TDI, im hoping for some decent range between fill ups.

All of the rott from the affected areas where cut out and new panels where welded in place.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0299.jpg

 

Also the door striker plates where not able to be repaired. Luckily I sourced a pair of striker plates and was able to successfully replace them. Seen in green

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0300.jpg

 

Since my rover is/was a RHD ROW, the tub has a bulkhead directly behing the seats, leaving me at 6’3†with no leg room. Luckily Mudd UK has a bulkhead removal/lowering Bar. That in combination with their seat frame extenders, should leave me with room to breathe/stretch :D

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0325.jpg

 

The floor of the rear tub was rotted beyond repair. I sourced a floor pan from a 1965 Series rover(think it was a 100â€). Amazingly enough the pieces are identical in shape and fit in a 1990 tub perfectly! About what felt like a million, maybe two million solid aircraft Rivets later the bed was completed and sent off to paint!

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0437.jpg

 

All steel pieces that where removed where powder coated or Galvi Dipped like the bed capping pieces which are going to be kept unpainted

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0456.jpg

 

The entire interior, Tub,seat box,floor pans are being treated with spray in bedliner

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0553.jpg

 

The hood frame was installed after the under side of the hood was shot but prior to the topcoat allowing me to make sure my rivets where painted.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0529.jpg

 

Also hood protection is fitted

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0526.jpg

 

Fenders also have the wing protection treatment

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0552.jpg

 

Tomorrow night, hopefully I will get some time to continue with where I am with suspension, fuel, Brake lines ETC.

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LATEAPEX Newbie

LATEAPEX

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nice work Sean, say I'm in Gilroy quite often now for the next month or so and would like to drop by and see this up close

l

 

Thanks Will!

 

Sure thing! I work in Morgan Hill M-F and usually swing by the shop after work. I also try to make it there one day on the weekends..

 

ill PM you my number

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LATEAPEX Newbie

LATEAPEX

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Update

I decided to give Rovertym “engineering” a try on their 3” Lift setup with the drop radius arm’s, trailing arms, front and rear upper and lower shock mounts, drop panhard bar, and Bilstein 7100 series resi shocks.

Unfortunately there where unnecessary hurdles to tackle in the installation process for it to be sold as a kit, mainly the front radius arms being longer than stock creating a near clearance issue with the shock and the spring perch on the frame.

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0205.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0206.jpg

What is more frustrating to me is that EVERY bolt that was provided in this kit was NOT the correct Length or Diameter AND had the Incorrect grip range for the application it was given.

And even more frustrating than that little issue was that there where no shock mount spacers provided to center the shocks in their mounts. This meant I had to machine myself shock spacers for all of the mounts which by the way all had a different spacing gap.

Ten minuets on the phone with these guys summed up my assumptions on why I received the “kit” in this order. Three words…. “Not A Clue”

 

The condition of these parts provided proof that just because you can cut metal and weld it, doesn’t make you an engineer. I am just confused that I have not seen or heard anybody else that have had any fit finish/quality concerns regarding rovertym parts. Too many issues here for this to be an isolated case

But on the brighter side the trailing arms look pretty and Bilstein did their job right on these shocks!

OK I am no officially done with my rant

 

Luckily other pieces have gone much smoother. Since I am converting to LHD during this project a new heater box was in order to make things proper.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0276.jpg

 

Also I liked the compact design and functionality of the Brake master cyl used on the newer D110, as they have eliminated the need to use any proportioning valve. With it being for a 110 I assume I will add a adjustable bias valve for when the rig is not loaded/towing a chaser. I found after the fact that for me to use this master, the 110 booster and brake pedal box assembly would also need to be updated.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0252.jpg

 

here is a quick shot of the roller (kinda old pic but kinda looks the same)

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0259.jpg

 

Since I have decided to run dual tanks, and don’t feel like spending $1,200 on all of the Land Rover linkages and fuel changeover valves, I have come up with a nice cheap solution. A couple of hours researching Diesel Yacht fuel systems, I found a 6 Port changeover valve with OFF position for pennies in comparison.

Here is a quick mockup pic

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0444.jpg

 

Pic of the valve lever on the seat box

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0406.jpg

 

Another really cool piece that I just received is this battery master switch that I found on Hellamarine’s website. It is the exact switch that Land Rover Special Vehicles used on Bill’s CT110

http://www.hellamarine.com/?a=3&t=3&View=FullStory&productID=213&pcid=37

 

All of the diesel line being used is synthetic so its bio-diesel/veg safe if I ever decide to go that route.

I had bent up some 5/16” hard line for routing over the tighter areas of the frame, keeping them attached using the plethora of BMW plastic clip retainers that I have at my disposal.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0419.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0416.jpg

 

Also a 2 micron Racor fuel filter/water seperator used on commercial vehicles will be used as a post tank/pre factory filter. It’s a cool piece because if I accidently run a tank dry, I can pump/prime the system back up using this filter since the 300TDi is a siphon feed system (no in tank pumps)

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0446.jpg

 

I decided to use a Copper/Nickel brake line kit found on LRseries.com. (BTW they are awesome! Have everything always, and are lightyears cheaper than any US source as long as you bulk order for shipping costs) This copper kit was nice because they are easy to form by hand not really needing my line tools except for the tighter turns that where needed. They are still in mock up phase, as I still have to “pretty” them up a bit. Some can be seen in the above picture.

 

I have a million other things in the mix as well, Exhaust, Large front intercooler mounting, Interior, finishing body panels for paint, ETC. Hoping to keep this writeup more up to date in the future

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LATEAPEX Newbie

LATEAPEX

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we can find a better bolt for the upper shock mount

 

I ended up using Dash # bolts used in aerospace applications and Jet nuts. super precise sizes, grade 10+ strength and very customizable in application/size/grip range/pitch. We use them alot at work, so i had some good souces although they are waaaaay overkill for application. :D unfortunately the shock mounts where no where close spacing wise to allow me to use any normal (off the shelf) grip range bolt without using 1" worth of washers stacked up

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TigerDan Newbie

TigerDan

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Lookin' good...and seems to be taking you about as long as some of my projects take me...!

 

A question: What did you do with the nasty old bulkhead that you took off? Is it still around? If so I'd be interested in it, even as rough as it is.

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TigerDan Newbie

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Yeah, I could tell that from the photos...however, I don't mind having a go at repairing it if the price is right. I sure haven't been able to find a decent one I can afford, and I have more time than money right now. If you're interested in selling it, shoot me a PM with price.
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  • 4 weeks later...
TigerDan Newbie

TigerDan

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So you did make some progress! Definitely looks better than when I saw it on Sat. I didn't know if I'd wasted too much of your time and kept you from achieving your goal of getting the tub mounted, but it looks like you managed!
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LATEAPEX Newbie

LATEAPEX

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So you did make some progress! Definitely looks better than when I saw it on Sat. I didn't know if I'd wasted too much of your time and kept you from achieving your goal of getting the tub mounted, but it looks like you managed!

 

Things went well on Sat. My main goal was to check clearances on the rear tank, lines, and wiring harness. hoping to get the floor pan beams and seat box mounted up this week. Nice meeting you!

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TigerDan Newbie

TigerDan

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You too!

 

Now I'm getting more and more inspired to make some progress on my own D90 project. I've been eying that bulkhead sitting out in the driveway and hopefully I'll have a little time tomorrow to tear into it. At least the weather was a little cooler today, hopefully it will be tomorrow as well.

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LATEAPEX

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You too!

 

Now I'm getting more and more inspired to make some progress on my own D90 project. I've been eying that bulkhead sitting out in the driveway and hopefully I'll have a little time tomorrow to tear into it. At least the weather was a little cooler today, hopefully it will be tomorrow as well.

 

Well get on it! :cool: we can race to completion!

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  • 3 months later...
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LATEAPEX

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Just wanted to chime in with a quick small update.

 

Finally had a chance to finish up the exhaust. Decided to Tig a 2.75" Stainless Downpipe meeting a 3" back half (had alot of 3" pipe laying around)

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0011.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0012.jpg

 

Then got slightly distracted with a trip to Shaver Lake trip a couple weekends ago with Bill and his CT110 and my GF in her newly acquired 4Runner Limited. Our goal was to hit the Brewer lake Trail and camp at the lake. Unfortunately the trail was closed for the season the night before we arrived due to snow.. luckily Bald Mountain is open all year!

 

[http://i10.photobucket.com/albums/a135/lateapexsti/Shaver%20Lake%20Nov%202010/IMG_0085.jpg

 

The goal for the trip was to get my GF behind the wheel so she could get acquainted with off road driving and to try out her new toy.. She was lovin every min of the experience (which is good news for me ;) ) The Rig did well also with its highway tires and CDL and Rear Diff Lock.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Shaver%20Lake%20Nov%202010/IMG_8160.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Shaver%20Lake%20Nov%202010/IMG_0093.jpg

 

Eventually we camped off of the feeder road to Bald Mtn Trail. Luckily we found a spot where there was patchy snow. Unfortunatley the temps got down to the 18-20 degree mark on the second night.

 

http://i10.photobucket.com/albums/a135/lateapexsti/Shaver%20Lake%20Nov%202010/IMG_0086.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Shaver%20Lake%20Nov%202010/IMG_0087.jpg

 

Back to business.... Finally!.... More parts back from paint!

 

I was able to get the Van sides, windshield frame, and roof mounted up this last weekend

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0100.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0101.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0102.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0103.jpg

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  • 1 year later...
LATEAPEX Newbie

LATEAPEX

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Well a lot has happened since my last update. Shortly after I had posted I started working at Tesla Motors which has consumed just about every spare moment that I have. Luckily I have escaped a few times to make the trek down to the shop to attempt some sort of "progress":rolleyes: but I have found it difficult to keep the ball rolling when there are months between visits. With this in mind, Bill and I have just recently decided to pack up shop and move back to San Jose which will allow me to actually make progress after work.

 

To spare you from the boredom of the details I thought I would just post some pictures from now to completion which will hopefully be soon. I can almost taste it now :cool:

 

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0629.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0629.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0630.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0630.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0631.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0631.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0632.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0632.jpg

On-Board Air and Sub hides behind this enclosure

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_04192.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_04192.jpg

 

Freshly painted Man cave 3.0 :D

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_06142.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_06142.jpg

http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0633.jpg[/img]"]http://i10.photobucket.com/albums/a135/lateapexsti/Project-Spot/IMG_0633.jpg

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