i want to make a jig/spit

[BrokenBiker]

has anyone got any tips for making a roll over jig that will be strong enough so that I can work on the floor, sills and chassis rails of a defender 90 without it losing its shape?

obviously I would leave one sill in place while the other is being replaced, and would do the floor in sections as not all of it needs doing, would do chassis rails one at a time

but would like a jig so I wouldn't have to brace between the door pillars to do the sills

 

[Robotstar5]

There is little structural strength in a Defender body, it relies on the chassis. Usual method is to remove the body (lots of bits bolted together) sort out the chassis then bolt the body back on. To line it all up, fit the rear tub first and use the doors to set the bulkhead position.

 

[BrokenBiker]

does all of the body come off to just leave the floor and chassis or does the floor come off too?

ive not done a full landy before, just a few body panel repairs on a Rangie classic 3dr

 

[Robotstar5]

Everything unbolts to leave a rolling chassis

Time lapse rebuild of a Defender here will give you an idea

 

[BrokenBiker]

thanks robotstar, I have just been looking for a time lapse strip down, but the build will serve just as informative

 

[BrokenBiker]

very good video, makes me more confident about buying this 90 and being able to restore it.

 

[madkayaker]

and one more thing the body isn't square to start with! so don't be suppressed when its a pig to fit back together proper. i used a pair of trestles so sit the rear body on when i replaced the floor in my lightweight with a length of unistrut bolted across back to keep it where is should be two people can happily lift and flip a rear over as needed. the rot will also be worse that expected once you have everything open for viewing as ali rots when in contact with steel

 

[BrokenBiker]

yeah I was aware that they aren't square anyway lol and also about the rot.

have a few mates that have played with 110's and they usually just buy them cheap, strip them out and hoon around the farm in them then sell them off as parts.