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This 1991 Land Rover Defender 90 has undergone a full and complete restoration/rebuild and is ready for years of off road excursions. The Defender came limped into our shop on its last legs after years of abuse. There was no way a simple respray and bolting on a few new parts would bring this up to our standards. It had to be brought back to Better-Than Factory condition. Unlike most Defender restorations out there, nothing was left untouched in this process. Every rusted or worn part was replaced with new and most hardware was replaced with stainless.
Significant NEW parts include: Galvanized chassis, all new Land Rover doors, Land Rover wiring loom, fully rebuilt 200Tdi engine (new pistons/rings, bearings, Bosch fuel injectors and cam shaft), Enhanced Uprated Turbo Charger, 4 wheel disc brakes, Ashcrofts rebuilt R380 gearbox and LT230 transfer box (with uprated 1.2 ratio for better highway performance), HD clutch/pressure plate, and much more. The partial list of new parts (mostly genuine Land Rover, “LR”) is below.
Chassis/Bulkhead
The body-off restoration/rebuild process included:
- New Richards galvanized chassis coated in SPI black epoxy,
- New galvanized sill panels coated in SPI black epoxy,
- Bulkhead completely refurbished in UK and SPI epoxy coated, and
- Every bolt/nut/washer/screw replaced with stainless steel (few exceptions where hardened steel is required).
Engine
The 200Tdi engine was stripped to bare block and performance increased to above factory specs. Overhaul includes:
- Tested/reconditioned head by Turner Engineering in UK including new valves/guides and ports were gas-flowed for added performance,
- New enhanced uprated turbo charger,
- New LR crank bearings,
- New pistons/rings,
- New LR oil jets,
- New Bosch fuel injectors,
- New camshaft and bearings,
- Crankshaft was micrometer tested to be within factory specs,
- Exhaust is heat wrapped from manifold through downpipe for increased flow and performance.
Other engine upgrades include:
- LR wiring loom,
- LR timing belt,
- LR motor mounts,
- LR thermostat,
- Allisport uprated radiator, intercooler and cyclone breather,
- LR HD clutch/pressure plate/release bearing,
- Vortex filter raised air intake (Camel Trophy version),
- New injector pipes,
- LR core plugs,
- New lift pump,
- New alternator,
- New power steering pump,
- Stainless steel fuel lines,
- Rebuilt oil pump,
- New water pump,
- LR fuel tank and sender,
- New high capacity heater core,
- Complete stainless exhaust without center silencer,
- DEI titanium exhaust wrap to boost engine performance and control temps,
- New high capacity electric radiator fan, and
- New high grade silicon water/turbo hoses.
Suspension/Steering
Suspension is completely new with:
- Old Man Emu shocks/springs with 1.5” lift,
- All new bushings,
- HD steering/panhard/track rods,
- All new ball joints and bushings, shock towers,
- All hardware on suspension and axles was replaced with new stainless or hardened hardware,
- SPI epoxy coated radius arms, trailing arms and rear upper link,
- Steering box has been overhauled with LR parts, and
- Front steering is protected by Front Runner steering guard.
Axles/Diffs/Wheels
Axles were completely rebuilt with LR parts including:
- LR OEM Timken differential/pinion bearings and new seals,
- All new hubs,
- HD drive flanges,
- Challenger steel wheels with offset,
- BF Goodrich A/T 265/75 off-road tyres,
- SPI Epoxy coated axle housings/hubs,
- New LR swivel balls,
- HD drive flanges, and
- New OEM Timkin bearings.
Brakes
Brake system is completely new with new calipers/pads/rotors. Rear drum brakes were replaced with all new disc brake system. Hydraulics have all been replaced with new master cylinder and new cunifer pipes/fittings.
Gearbox
The gearbox has been upgraded to the newer/stronger R380 5-speed manual gearbox. It has been completely rebuilt by Ashcrofts (the premier Land Rover Gearbox shop in the UK). Also installed is a Slickshift shifter for easier shifting.
Transfer Box
The LT230 transfer box is a complete rebuild unit from Ashcroft Transmissions in UK. The new box includes major upgrades: HD ATB centre diff (provides increased traction), sleeved casing for strength and a 1.22 high range gear ratio (boosts 5th gear by 10mph at 2,500RPM) and cross-drilled input gear for added lubrication to prevent spline wear (common on these Land Rovers).
Body/Exterior
The body/exterior was completely disassembled for repair/cleaning/painting which included:
- Body panels that were significantly dented were replaced, NOT body filled,
- Body has been finished with a base SPI epoxy primer,
- Land Rover Limestone main color in PPG paint,
- Land Rover Beluga Black for roof and accents in PPG paint,
- Closed-cell foam/rubber separates steel from aluminium to prevent galvanic corrosion,
- New 5-bar chequer plate on wings, bonnet, sills and rear corners,
- New complete LR front doors from 2016 production line (new take-offs from Israeli military),
- New LR rear door 2007 model,
- New LR door/window seals,
- New rear sliding tinted windows,
- Tinted rear door/rear quarter/alpine/front door glass,
- New HD door hinges,
- New stainless steel rear door hinges,
- Stainless steel rear and front thresholds,
- New front bumper/A-bar,
- New LED headlamps, and
- LED exterior lighting all around.
Interior
Interior is completely refurbished and upgraded including:
- LR wiring loom,
- Completely soundproofed on all exterior and floor surfaces,
- LR power windows,
- New LR air conditioning system,
- Genuine leather covered upper/lower dash,
- Leather door cards with aluminium hardware,
- Leather seating with new cushions, seat heaters and seat extensions,
- Premium leather cubby box,
- Premium carpets,
- 4 leather rear jump seats,
- Padded cargo area,
- New Exmoor Trim Nimbus 15” steering wheel,
- LED interior lighting,
- All new VDO dash gauges (rev counter, water temp, speedo and volts),
- Custom aluminium center console plate,
- Premium suede style headlining and trim,
- New LR seatbelts front/rear, and
- Single LR key for all doors and ignition.
Upgrades
Upgrades and extras include:
- Alpine 9” screen w/Apple CarPlay, 4 Polk Audio speaker and subwoofer,
- Front Runner roof rack with expedition rails,
- Front Runner metal headlight/taillight guards,
- Front Runner spare wheel carrier,
- Light bar with 4 Rugged Ridge LED lights,
- 2 Rugged Ridge LED flood lights on bumper,
- LED work light above rear door, and
- NAS rear step bumper.
