This 1997 Land Rover Defender 90 had only 30,000 original miles but was suffering from major rust on the frame. The original paint was in good shape but badly faded. There were numerous dings and dents throughout the body. All the rubber weather stripping and seals had dry rotted and cracked. We will replace the frame with a galvanized frame, replace any worn or rusted components and give this Land Rover Defender a cosmetic restoration.
The 1997 Land Rover D90 as it arrived in the shop.
All the rubber seals have badly dry rotted.
The rear cross member is badly rotted.
The interior is in decent shape but needs a refreshing.
The frame has already been repaired once.
The tear down begins.
More rot is uncovered on the frame.
The drivetrain is ready to be removed.
The Marsland frame arrives. Unlike some other replacement Defender frames that are made with a box section like Series frames, Marsland frames are made identical to the original Defender frames.
A new genuine Land Rover gas tank skid plate is installed.
Since the rubber boots on the original tie rod ends are dry rotted, all the tie rod ends are replace with Genuine Land Rover units.
New genuine Land Rover springs are installed.
New genuine Land Rover suspension bushings and hardware are installed.
New galvanized shock towers are installed.
The drivetrain is reinstalled into the rolling chassis.
All new stainless steel fuel lines and brake lines are installed.
A complete new NRP stainless steel exhaust system is installed.
The bulkhead is reinstalled onto the chassis.
The original paint is meticulously buffed out to a nice luster. Now all the dings and dents are being worked out with paintless dent removal.
The doors are disassembled so that the dings and dents can be removed from the inside.
Large dents in the hood were skillfully removed.
The hood is now in nearly perfect condition.
Every part that showed rust or corrosion was replaced.
A new genuine Land Rover bumper is installed.
We use genuine Land Rover trim pieces because aftermarket trim pieces are more likely to fade in a short span of time.
The rear tub is installed.
The original speaker cones had disintegrated. We installed four new JL audio speakers, slightly modified to accept the original speaker grilles.
All the hinges are replaced with new style rust-resistant genuine Land Rover hinges. Unlike the originals, these do not bleed rust from the hinge pivet pins.
The bulkhead is buffed out. New vent flap weather stripping is installed as well as a new bulkhead-to-windshield frame seal.
The original light lenses are buffed out. These original lenses are much nicer than new aftermarket lenses.
The windshield frame is buffed out and a new windshield is installed in a genuine Land Rover windshield gasket.
The roof is stripped and repainted in Alpine White Glasurit.
Four new genuine Land Rover fender flares are installed as well as four new genuine Land Rover side market lights.
The original tires were dismounted, the wheels buffed out, new BF Goodrich all-terrain tires installed and the lug nuts were polished to a chrome-like finish.
The quarter panels are buffed out and a new "unleaded fuel only" decal is installed.
A new genuine Land Rover headliner is installed.
New genuine Land Rover side steps are installed.
The finished project.
The Land Rover looks remarkable for having its original paint.
The rear step bumper is sand blasted and powder coated.
The roof rack and rear ladder are also sand blasted and powder coated.
The external roll cage is sand blasted and powder coated.
The new galvanized hardware.
The mirror like finish of the original paint on the hood.
The original paint hasn't looked this good since the Land Rover was new.
The Alpine window gasket is replaced as well as the roof-to-side panel seal.
New genuine Land Rover rust-resistant door hinges and galvanized hardware.
The roof was seam sealed with self leveling seam sealer and painted in Alpine White Glasurit. New roof rack mounts were fabricated to replace the broken originals.
New Alpine window seals are installed on the freshly painted roof. Self-leveling seam sealer was used to seal the roof gutters because the original seam sealer had shrunk and cracked.
The roof rack and mounting bars were sand blasted and powder coated.
All new stainless steel hardware is used on the rear roof rack support.
The original brush guard is sand blasted and powder coated.
The seat base foam was replaced but the original seat covers retained.
The head liner was replaced with a genuine Land Rover head liner. All door weather stripping was replaced as well.
Here you can see the JL audio speakers installed in the doors with the original speaker grilles.