Land Rover Ninety rebuild

Ninety 1987

Land Rover Ninety

This Land Rover was bought in the UK very cheap. The dealer I bought it from was really friendly, and he offered his help in sending It to the ferry at Harwich so I could come and pick it up at the ferry in Esbjerg (Denmark). Later on we drove home to Aarhus where I live, and without any problems.

It’s unbelievable to think that the Land Rover looks like new after only 3 months..

My Land Rover’s data: SALLDVAB7AA288078

SAL	Manufacturer code: Land Rover
LD	Model: Defender (for early models: Ninety, or One Ten)
V	Wheel base: 92.9 inch, but designated 90
A	Body type: 2-door: Pickup, hood cab, truck cab, or soft/hard top
B	Engine type: 2.5 litre diesel turbo (model 19J)
7	Steering and transmission: Right-hand drive (RHD), 5-speed manual (LT85, LT77, LT77S, R380 or other)
A	Model year: 1983, 1984
A	Assembly location: Solihull, UK
288078	Serial number

The plan is to add new pistons, valves, valve-guides and so on. .

Then I plan to galvanise the chassis and bulkhead and mount two new front doors from a Series 3. These doors can be separated in to two, which is nice to then drive topless!

The whole braking system will be renewed also because of converting from Right Hand Drive to Left Hand Drive.

Before I started the project here in May 2007 I thought I could predict which spares I was going to need, so I went out buying a lot of parts from UK dealers.

	The Land Rover as I saw it on the internet. The picture was taken at the dealers shop at Leeds in England
Description from seller 4/12-06: The chassis is solid....the bulkhead is in really good condition although I do suspect it has been repaired on the passenger side. it does run very very well. the interior is in good condition which is to be suspected for a vehicle of that age and it has new polybushes all round. there is also a ‘swing away’ spare wheel carrier which is worth around £100 there is no road tax but I can assist with taking it to the ferry...I can have it delivered to the docks in Harwich. There are no faults with 90. All the panels are straight and I’m sure you will not be disappointed. Although there is a man coming to see it sometime this afternoon - if you feel that you would like to have some more pictures i will gladly send you some more. The paintwork is really good in some areas, but it has been strangely brush painted in some areas. If you were to buy this vehicle in no time at all and very cheaply you would have a nice car. If you need any help in the future please don’t hesitate to call me, I’m getting some good contacts in Europe and would love to keep in touch...may I also add that this is not purely for profit....thanks again Claus have a good Christmas and I look forward to hearing from you sometime. Maybe send me a picture of the 90 in the restoration process?? Regards John
	£1450
A similar Ninety would cost more than £4500 here in Denmark. So that’s why I bought it in the UK.

	The Pick up in Esbjerg harbour 09/12-06 only 5 days after I first saw i ton the internet.
Quite funny driving in the opposite side.
	Nice ride
It all works as it should.

	It is not nice, but it was very cheap. The most important thing is the fact that there is no rust in the cassis. Polybushed all over! New diesel tank! It’s even painted with a brush!!
All the parts I needed to convert it from RHD to LHD. I also found a used steering box. Got it all for £60 at the scrap yard.	Januar 07.

Engine rebuild: 4th day.

	New pistons with rings.
Various parts to go in the cylinder head. .
	New valves.
New valve guides


This is the tool to be used to grind the old valve seats up to fit the new valves.

Cleaned up for inspection.

	Special tool made to fit the new valve guides.
Turbo pistons in the newly honed cylinders.

Cylinder head ready to be installed.

Then the Fuel injection pump was leaking.

All cleaned up ready to install timing belt.

This is my small modification to my LT77. It is well known that the oil flow to the

Mainshaft splines is very poor, resulting in premature wear – I used a bit of 3/4" pipe, welded on to the back plate. Hopefully the oil will now reach the splines on the mainshaft.

	These are my homemade "Rock sliders" made of 80x30x3 mm RHS box. Afterwards they will be galvanized.

	First I welded a U-profile on to the cross member and drilled three holes and then fitted the slider. I think this is the strongest way to mount them.

	I designed them so they would fit under the wheel arch.
The front mounting at the outrigger. There is a back plate with tapped holes on the other side of the outrigger.

Day 8


Bad corrosion on the rear corner.

Messy wiring


I The upholstery has seen better days.



	120cm from the rear outrigger and up to the top bulkhead. This is important to remember this measurement when it shall come together again.



Day 9


	Rear cross member needs attention.


	Ready to be shot blasted

	Ready to be shot blasted

Day 10
New brackets on the rear axle will need to be re-fabricated.

Day 4

On its way to shot blasting.
	Bulkhead ready for galvanizing

	Chassis must be emptied for sand blasting

Zinc coated
	Epoxy primed

New seat covers:

Good old brown seats

Cleaned and painted


	That’s it

Land Rover rear tub ready for painting

	Look at how many layers of old paint


Always remember to test fit parts that have been shot blasted - due to the fact that they may deform a bit.

	My tiny mobile blaster.
Ready for galvanizing

New brake cylinder


	Galvanized bulkhead for my Land Rover



The ‘clean’ stage of my rebuild




The motor goes in



My little precious dog called Andy. He is a Nova Scotia Duck Tolling Retriever.

	The new rims have not yet arrived.

The new rims



The bodywork has now been painted in "Chawton white" The chassis is mounted with a new set of silver modular rims with BF/AT 285/35-16. Painting is a real nightmare. It took me 50 hours to finish the parts ready for painting. Then it took me about 30 hours to paint it.



New panels in aluminium for the seat box.

Ready for primer
	Remember to use the correct primer for aluminium.
Topcoat is the Chawton white




	Spaghetti




	At first it looked quit messy, but I got it sorted out. It took me about one day to reassembly the Bulkhead.

Nice


	Yes. It all fits. Don’t forget that the RHD heater won’t fit in the LHD bulkhead.



Yes... it starts just fine

It took some time to get the door openings right. They can be rather difficult to line up with the bulkhead and the rear tub.

All the hinges are Zinc coated as well.

Does the door fit? Yes but not the first time.

Rear door shortened down and then the frame went off to be galvanized

Front doors were galvanised as well.



Licence plates. Note the fabricated rear door. I made it from the old rear door.

Cant wait to get it finished now

Seatbelt retainer from a Series 3

New soundproof and floor covering system from Exmoor Trim

Snorkel from Rebel 4x4 in the UK.


Insulation in the door frame before the panel is fitted.
	The homemade panel

First drive



	I’m quit satisfied with it.


Test drive:
Would you believe this Land Rover to be 20 years old? As you can see I’ve re-trimmed the seats wit a re-trim kit from Paddock Spares. I reckon it’s a decent quality. The hood was ordered from Exmoor-trim and I think it’s a really great quality.

Me and my Dog.

The used steering box is leaking oil.

The test drive went all right except from the leaking steering box otherwise I can only say that I’m satisfied.

Next on this project I’ll be installing a 200tdi from a Discovery. I found the engine on E-bay and I paid £250 for it. It’s a 1993 with 98,000 K on the clock. Can’t wait to get the extra power.

Thanks to Nigel Barker UK for the help translating this site.