Back to the Defender 90 Section
Back to the Tdi Conversion Section
1994 Defender 90 Soft Top
300 Tdi conversion, galvanized frame and accident repair
This 1994 Defender 90 has come to us from Oregon for some accident repairs and a conversion from 3.9 EFI V8 to 300 Tdi (turbo diesel). We'll also be adding an ECR hybrid galvanized chassis that will allow the direct bolt in of the Tdi engine and still retain all the NAS (North America Spec) body mounts and rear fuel tank, with no modifications.
In most cases we would just lift the body in our frame swap system to be able to drop it down on a new galv. frame and Tdi running gear, but due to the need to repair the accident damage we'll do this one the old fashion way, we'll take it apart into large sections and get it ready for the repairs and a new paint job.
Here you can see we have removed the front clip and are getting ready to remove the bulkhead. We'll rework the bulkhead to get it straight again, but some of the front sheet-metal is toast and will be replaced with new panels. Next step is to get it stripped down to the rolling chassis so that we can remove the axles and get them set up on the new galv. frame.
This image shows the 90 taken down to the large pieces that we can work with. The tub will now be cleaned up of all the dirt and dust and we will start to prep it for new exterior paint.
Speaking of dirt, the top of the fuel tank is one area that takes it pretty hard when a 90 is used off road. Here you can see the accumulation of dirt and debris. In a west coast car luckily this doesn't immediately turn to corrosion problems like they do here in the Eastern US, but to make sure there are no future issues we will be installing new stainless steel fuel lines so that rust will never be a factor in this Defenders fuel lines.
Here you can see the 90 reduced to the old damaged chassis. The nose of this one is swayed badly, but the axles check out as being straight so that is good news.
This image shows the new back bone for this D90, its new galvanized hybrid frame. This frame has all the mounts and needed points for the special NAS parts, like the fuel tank cradle, etc., but it has engine mounts and a crossmember for the 300 Tdi so that the drive-train is a direct bolt in without goofy custom mounts, making everything bolt together without issue, thus making replacement parts down the road a breeze because everything, expect the frame itself will be a factory part.
Here you can see the 90 a little further along. The ARB lockers have been added to the diffs and the suspension has been installed. The new, not rebuilt, 300 Tdi has been installed in the frame and the rear body is now back on the body so that it can get stripped down and ready for paint.
The new, not rebuilt, R380 gearbox is now installed as well with the correct 1.4 ratio transfer case. Along with the galvanized frame we are also doing all the other rust resistant items on the chassis, adding our stainless steel brake and fuel lines, with dummy ss filter, to make sure this 90 won't have any rust issues any time soon.
Stay tuned as the Tdi powered NAS 90 comes together.
If you have dreams for your Defender, contact ECR. We'll be happy to make your Defender world class... just like this one.
East Coast Rover Co.
Contact info