Tom1809 Posted July 31, 2014 Share Posted July 31, 2014 Hi guys, I'm in the process of stripping my defender down for a rebuild and I have some alignment issues. The body work is a combination of a td5 rear tub and seat box. 200tdi bulkhead & screen, I assume defender side panels and roof as they are smooth and has the anti drumming rib. The problem I have is with the the td5 tub and seat box and floor all in properly, the sides don't seem to match the tub and then don't align with the roof. As I've been un bolting it the bolts have been snapping or starting to pull out at a angle, is the roofs and sides different lengths on a td5 compared to a 90? Or early 200tdi's. My bulkhead has gone past the point of repair so I have a decent td5 one to fit but want to make sure that there's nothing wrong before I send it to paint as I don't want to do it twice. I'm wondering if the chassis is my issue for it not aligning properly as it's the rotten the axles stand went the the bottom rail and up through the top. Cheers Tom Quote Link to comment Share on other sites More sharing options...
Scotts90 Posted July 31, 2014 Share Posted July 31, 2014 If your chassis is that rotten then it certainly won't help! I have a td5 bulkhead, td screen, YRM seat box battery and toolbox replacements on either side, I've fitted NAS quarters, new floor and supports to the rear tub as well as new rear light panels. I've just fitted rear later spec side panels and have an older ribbed roof...and td5 doors...and it all bolts together without any "major" issues. All the doors shut with ease, panel gaps are per factory tolerances, assembling things loosely first to allow for tweaking was a good help. By the sounds of things the body is under a degree of stress due to the rot and if you have the chassis sitting on stands then it makes things worse. Quote Link to comment Share on other sites More sharing options...
Maverik Posted August 1, 2014 Share Posted August 1, 2014 The only thing I found when doing my rebuild was that Td5 era doors aren't a straight forward fit to an 1986 era bulkhead using 1986 era door hinges... my theory was that for some reason the Td5 era door mounting holes where 5mm closer to the edge of the door than the pre Td5 types... I could be talking twollop, but I had a really strangely fitting door at one point. now I have a Td5 bulkhead and tdci doors, all fits relatively well... Quote Link to comment Share on other sites More sharing options...
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