Build Journal #2: Rebuilding the Foundations

APRIL 2026 – EARLY MAY 2026

After months of teardown, inspection, and refurbishment, the first restored components began returning to the workshop in April.

The powder-coated chassis arrived back alongside rebuilt axles and suspension components, while the engine overhaul continued at engineering. This phase focused on rebuilding the mechanical foundations of the Defender.

From Bare Metal to Powder Coat

The chassis and associated black parts returned from sandblasting and powder coating finished in satin black and sealed with a protective clear coat.

After months of disassembly and inspection, seeing the restored chassis back in the workshop marked a turning point in the project. Elevated on trestles while reassembly began, it would remain there for the next several months before eventually returning to its wheels.

Rebuilding the Axles and Suspension

Both front and rear axles were completely stripped down into individual components before being cleaned, inspected, and rebuilt with new bearings, seals, hardware, and brake components.

At the same time, upgraded suspension components were installed, including Koni shock absorbers and Terrafirma coils. New brake rotors and overhauled calipers completed the process before the rebuilt axles were mounted back onto the chassis.

Rebuilding the TD5

While work continued on the chassis and suspension, the 18P TD5 engine remained at engineering for inspection and overhaul.

The engine was completely stripped down, cleaned, and measured before new pistons, rings, bearings, seals, and a replacement cylinder head were fitted. Every major internal component was either replaced or confirmed within specification before reassembly began.

With the chassis, suspension, and drivetrain components progressing through restoration, attention now turned to the bodywork.

All images courtesy of LR Defender SA