Nick's Land Rover - Series III Rebuild

Well, I have completed the interior side panels.

The upper fixing brackets were made of the steel bar, with 25mm long flanges (hole centres 15mm from the bends) and a 16mm rebate.  These brackets were drilled with a slightly oversize hole in the top flange to allow the headlining fixing screws to pass straight through and, a little later, an undersize hole in the bottom flange for the panel securing screws to self-tap into.  They were then sprayed with matt black enamel and fitted loosely in their positions.

The ply sheets needed a lot of trimming after cutting to size.  The height and length were fine, but a lot of notches had to be cut along the top edges (and one in the bottom) to accomodate the bolts and washers securing the hard top panels to the roof and the tub, the fabricated brackets and the bolts holding the seat belt upper anchors.

Once a good fit was achieved, the panels were drilled for their mounting screw holes, temporarily fitted and used as guides for the pilot holes in the brackets and hard top’s horizontal reinforcers.  They were then covered with the vinyl, using spray adhesive.

The mounting screw holes were then pushed through the vinyl with a sharp mandrel.  This gave reference points for securing the net pockets (left panel) and First Aid kit/glowstick mountings (right panel).  Once all the fittings were screwed into their positions, the panels were fitted and all the screws tightened.  I have included a photo of the right side panel with the First Aid kit removed to show the fastenings (velcro straps) and support ledge (1″ aluminium angle).  The First Aid kit had to be mounted at a height which cleared the fold-up seat.

I also fitted some black Tesco’s “boot tideis” - assemblies of three nylon pockets that hang from velcro and poppers - to the galvanised cappings alonside the second row seats, identical on the left and right, for the kids to put their games, boocks, toys and so on in for long trips.  Now I just need to have some paint made up to match the vinyl to paint the Defender rear window surrounds before fitting them.

Interior

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