LATE APRIL – MID-MAY 2026
After months of disassembly and mechanical restoration, attention turned to the bodywork.
The Defender’s doors, load bin, bulkhead, and numerous smaller aluminum parts moved through a painstaking process of sanding, inspection, fine sanding, priming and then more sanding and priming to remove any imperfections. Much of this work would ultimately disappear beneath paint, but it would determine the quality and longevity of the finished vehicle.
This phase of the build was less about adding new components and more about refining every surface before reassembly could begin.
Preparing the Panels
Before any paint could be applied, each panel required extensive preparation. Surfaces were repaired, imperfections identified and corrected, and primer repeatedly applied and sanded until the panels met the standards required for final finishing.
Like much of the restoration process, progress during this stage was measured less by dramatic visual changes and more by attention to detail.
News Doors and Bulkhead
Earlier inspections had revealed corrosion severe enough to require replacement of all five doors and the bulkhead. With the new components now on hand, preparation work could begin alongside the restoration of the original aluminum panels.
Replacing these major structural components addressed issues that would have been difficult—or impossible—to correct once the vehicle had been reassembled.
Paint & Protection
Once preparation was complete, the panels entered the paint process. Multiple coats were applied before being finished with clear coat protection.
At the same time, corrosion protection measures were applied throughout the vehicle, helping ensure the Defender would be protected against the elements for years to come.
The Details
Many of the smallest components required as much attention as the larger panels. Hinges, brackets, and other hardware were individually prepared, coated, and refinished before being set aside for installation.
While these pieces represent only a small part of the overall project, collectively they contribute to the finished appearance and durability of the vehicle.
By the end of this phase, many of the Defender’s exterior components had completed their journey through the body shop. Doors, panels, and structural components that had once shown the effects of age and corrosion were now prepared for reassembly.
The next stage of the build would finally bring these restored components back together as the Defender began to take shape once again.
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Images courtesy of LR Defender SA