Build Vision · Restomod

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Muscle.
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A full nut-and-bolt restomod of a 1986 Land Rover One Ten County Station Wagon. The iconic Defender silhouette stays — everything under the skin is transformed. GM LS3 V8 power, ZF 8-speed auto, blacked-out Chelsea Truck Co aesthetic. Built to be driven hard.

PlatformLand Rover Defender 110 SW

Original Year1986 (County spec)

Engine SwapGM LS3 6.2L V8 Crate

Target Power~430 hp

GearboxZF 8HP 8-Speed Auto

Transfer CaseMMX SRT8 High Torque

ExhaustBorla Crate Muffler S-Type

Colour TargetSatin / Matte Black

Wheels18" × 8 CSA Monster Alloy

TyresBFG AT or Falken AT3W

RegoQLD · 433-PNE

Style ReferenceChelsea Truck Co / Nene Overland

Exterior Ref — Chelsea Truck Co

Blacked-out grille, LED circular headlights, integrated front bumper with light bar, side steps, all trim in matte black. No chrome anywhere.

Engine Ref — Nene Overland LS Build

GM LS V8 in Defender bay with all-black dress-up. Corvette LS3 intake, black rocker covers, polished/black accessories. Article in "Lean, Mean Machine" (Land Rover Monthly).

Second Ref — Invision / Dark 110 SW

Gloss deep black full body, chrome-delete mirrors, blacked-out roof, no side steps — cleaner, more premium look.

Original Vehicle

1986 Land Rover One Ten County Station Wagon — Australian market spec, Queensland registered. This is the donor body/chassis.

Engine (LS3)$14,500

Exhaust (Borla)$600

Gearbox (ZF 8HP)$3,000

Transfer (MMX SRT8)$4,500

Wheels ×5 (CSA)$2,000

Running Total$24,600+

Defender 110 · Station Wagon · ECD Automotive Design · Target Build Reference

Exterior Colour

Select Paint

Click a swatch to select your target colour. Matte and satin finishes are the direction based on the Chelsea Truck Co reference. Classic Defender colours shown for comparison.

— Select a colour —

Interior Leather

Select Trim

Interior leather options used across ECD, Chelsea Truck Co, Nene Overland and other top Defender restorers. Full-black or two-tone are most common for dark exterior builds.

— Select a trim —

Interior Options — Restored Defender Reference Builds

ECD Automotive — Nene Overland Style

Brown / hazelnut leather centre panels with black bolsters — the most popular combination for a dark-exterior build. Hand-stitched single vertical diamond pattern. Matching wrapped dash. MOMO Retro steering wheel in black leather.

Reference: ECD Project Kalorado · Nene Overland LS build

Chelsea Truck Co — Full Volcanic Black

Full quilted and perforated black leather throughout — seats, door cards, dash top and instrument cluster surround. Britannia blue or Kahn red piping as accent. Billet aluminium switch pack and foot pedals. Most aggressive/clean look with dark exterior.

Reference: Chelsea Truck Co Concept 001 · CTC Kahn Defender builds

Royal Street Rovers — Saddle Brown

Rolls-Royce grade "Saddle" brown leather — contrasts dramatically with matte black exterior. Full leather including seats, dash, door cards. Teak wood floor detail in cargo area. More premium / classic feel. Used on Project Phoenix ($348K build).

Reference: Royal Street Rovers Project Phoenix

Kahn Heritage — Saddle Tan / Houndstooth

Traditional Saddle Tan leather or Vintage Cloth Houndstooth — more heritage-oriented. Wood-effect steering wheel. Classic English library feel. Better suited to heritage exterior colours than the dark restomod direction of this build.

Reference: Kahn Heritage Remastered Defender

Shoreline / Helderburg — Two-Tone Dark

Dark charcoal or graphite leather with contrast stitching. Often paired with alcantara roof lining. European square weave black carpet. Recaro-style bolstered seats. Modern and refined without being overtly "luxury".

Reference: Shoreline Modern · Helderburg Sandoval

Common Accent / Stitch Colours

Regardless of base leather, accent stitching defines the character:
Gold/Amber stitching — matches exterior amber accents
Red stitching — aggressive, motorsport feel
White stitching — classic, clean contrast
Blue (Britannia) — Chelsea Truck Co signature

Selected Exterior

Not selected

Selected Interior

Not selected

Accent / Stitch

Not selected

Accent Stitch

Exterior Ref — Chelsea Truck Co

Blacked-out grille, LED circular headlights, integrated front bumper with light bar, side steps, all trim in matte black. No chrome anywhere.

Engine Ref — Nene Overland LS Build

GM LS V8 in Defender bay with all-black dress-up. Corvette LS3 intake, black rocker covers, polished/black accessories.

Interior — ECD Hazelnut / Black

Hazelnut leather centres, black bolsters, single vertical diamond stitch. MOMO Retro black steering wheel. Black carpet. Wrapped dash. Most common on LS3 dark builds.

ECD Build Reference

These renders are from ECD Automotive Design — the world's largest Defender restomod builder, using GM LS3 + 6-speed auto as their primary Custom trim powertrain.

PlatformLand Rover Defender 110 SW

Original Year1986 (County spec)

Engine SwapGM LS3 6.2L V8 Crate

Target Power430 hp

GearboxZF 8HP 8-Speed Auto

Transfer CaseMMX SRT8 High Torque

ExhaustBorla Crate Muffler S-Type

Style ReferenceChelsea Truck Co / ECD

Wheels18" × 8 CSA Monster Alloy

TyresBFG AT or Falken AT3W

RegoQLD · 433-PNE

Now LocatedMelbourne VIC

Bodywork & Panels

In Progress

Key finding: Aluminium outer panels are in reasonable shape — no major corrosion (ally doesn't rust). The steel bulkhead has significant perforation in lower sections and must be repaired or replaced before build-up. Tub floor paint heavily degraded — strip and inspect.

Bulkhead

Assess full extent of rust perforationCRITICAL
Source repair panels — footwells & lower sectionsCRITICAL
Weld in repair sections or replace bulkheadCRITICAL
Media blast and treat all bare steelHIGH
Epoxy primer inside all cavitiesHIGH
Modify bulkhead for LS3 engine clearance (if needed)HIGH

Outer Panels (Aluminium)

Inspect all door skins — dress any dentsNORMAL
Remove all chrome trim & badges — deleteHIGH
Fill & smooth former chrome mounting holesHIGH
Bonnet — inspect, clean, prep for paintNORMAL
Replace all door hingesHIGH
Replace all body rubber sealsHIGH
Rear tub — strip paint, inspect floor, treatHIGH

Parts & Suppliers — Where to Source

LRPartShop

lrpartshop.com.au

AU — ships nationally

Defender body panels, bulkhead sections, doors, roof, bonnets, cappings

Landybitz

landybitz.com.au

AU — ships nationally

Body panels, trim, accessories, interior, rollcages, bull bars

KLR Automotive

klrautomotive.com.au

Everything Land Rover & Perentie — panels, mechanicals, accessories

Grant Walker Parts

grantwalker.com.au

VIC — Melbourne

New and second-hand Defender 90/110/130 parts, ships nationally

British Auto Parts

Search: British Auto Parts Victoria

VIC

Classic British car parts — recommended by AULRO community

Paddock Spares

paddockspares.com

Panels, cappings, sills, bulkhead repair sections, body seals

Britpart

britpart.com

OEM and aftermarket panels, trim, seals — huge range

Bearmach

bearmach.com

OEM-quality body panels, doors, bonnets, tubs

John Craddock

johncraddockltd.co.uk

Body panels, mechanical, electrical — comprehensive Defender catalogue

Rovers North

roversnorth.com

Parts for Defender 90/110 — ships internationally

Paint & Finish — Black Restomod

Planned

Aesthetic direction: Satin or matte black as primary finish — Chelsea Truck Co / ECD reference. All trim, mirrors, handles, grille, and bumpers also black. No chrome. No two-tone. Deep-tinted glass throughout. The Defender 110 body is predominantly aluminium panels on a steel bulkhead and chassis — these two metals require completely different primer systems and cannot be treated the same way.

Critical — Aluminium vs Steel: The Defender 110 outer body panels (doors, wings, bonnet, tub sides, roof) are aluminium. The bulkhead, chassis and inner sill sections are steel. Aluminium forms an oxide layer on contact with air that prevents standard primers from adhering. Using the wrong primer on aluminium will cause paint failure within months. Do not use standard automotive primer directly on bare aluminium.

Aluminium Panel Prep Process

Step	Process	Product
1. Strip	Sand to bare aluminium — 80 grit DA sander to remove all old paint. Do not media blast with steel grit (contaminates ally).	DA sander + 80–120 grit discs
2. Clean	Degrease with wax & grease remover — remove all oils including fingerprint oils (moisture and oils from skin cause adhesion failure). Wear gloves once cleaned.	Septone W&G remover / acetone
3. Fine sand	320 grit DA pass over whole panel to create a key. Scotchbrite edges. Blow down and re-clean.	320 grit DA discs
4. Etch prime	Apply acid etch primer — 2 coats. This chemically keys into the bare aluminium surface. MUST go on same session as cleaning. Do not sand etch primer.	U-POL Acid#8 — industry standard for Defender ally
5. Epoxy primer	Apply 2K epoxy primer over etch — seals and provides build base. Can fill light imperfections. PPE mandatory: 2K isocyanates are carcinogenic — use fresh-air fed respirator.	2K epoxy primer (Sikkens / PPG / Spies Hecker)
6. High build	2K high-build polyester primer. Block sand 320 → guide coat → finish 500 dry. Do NOT wet sand primer — moisture trapped under paint causes blistering.	2K surfacer / high-build primer
7. Topcoat	2K satin or matte black basecoat. For matte/satin: do NOT apply clear coat — the topcoat IS the finish. Apply in consistent, even passes.	2K Satin Black (PPG / Dupont / Standox)

Steel Surfaces — Different System

The bulkhead and inner steel panels need a different approach — epoxy primer directly on bare steel (no etch primer needed), then the same build and topcoat system.

Surface	Primer Required
Bare steel (bulkhead, sills)	2K Epoxy primer direct — no etch needed
Bare aluminium (doors, wings, tub)	Acid etch FIRST, then epoxy over top
Galvanised steel (new chassis)	Etch primer — galv is also "special metals"
Previously painted aluminium	Scuff 320 grit + etch any bare spots + sealer coat before topcoat
Chassis / underbody	POR-15 rust converter then Raptor liner or 2K etch + epoxy + Raptor

⚠️ 2K PPE Warning: 2K paints contain isocyanates — highly carcinogenic. Fresh-air fed hood or full-face air-supplied respirator is mandatory, not optional. Standard dust masks provide zero protection. This is not overstated. Have panels sprayed professionally if you don't have the right equipment.

Finish Options — Satin vs Matte vs Gloss

Finish	Look	Maintenance	Notes
Satin Black (recommended)	Low sheen — appears flat in shade, slight glow in sun	Easiest to maintain	Best for a daily-use build. Can be cleaned normally. Small touch-ups blend in. ECD and CTC primary finish.
Matte Black	Completely flat, no sheen at all	Difficult — shows every fingerprint and water mark. Cannot wax. No polishing.	Looks incredible but high maintenance. Better as vinyl wrap so it can be replaced.
Gloss Black	Mirror shine — deep, reflective	Shows swirl marks, must be machine polished	Most dramatic but hardest to keep looking good. Used on reference image 2 (Invision).
Satin/Matte vinyl wrap	Same look as paint	Medium	Cheaper short-term. Protects paint underneath. Can be removed or replaced. Less durable long-term.

Complete Paint Tasks

Decide final finish: satin vs matte vs gloss — get test samples sprayedHIGH
Source 2K PPE — fresh-air fed respirator before painting anythingCRITICAL
Strip all ally panels to bare metal — DA sander 80 gritHIGH
Degrease all panels immediately before primingHIGH
Apply U-POL Acid#8 etch primer — all bare aluminium, 2 coatsCRITICAL
Apply 2K epoxy primer — over etch (ally) and direct (steel)HIGH
High-build 2K primer — block sand, guide coat, 500 grit dryHIGH
Topcoat — 2K satin/matte black, consistent passesHIGH
Powder coat all steel accessories (bull bar, steps, roof rack)NORMAL
Engine bay — satin black all surfacesNORMAL
Chassis / underbody — POR-15 + Raptor linerHIGH

Rivets & Panel Joins — Defender-Specific

The Defender body is assembled with solid and blind rivets throughout — the classic "dots" you see on the exterior are structural rivets, not cosmetic. This creates a challenge for painting. The professional approach (as used by ECD) is to paint panels before assembly, then insert unpainted rivets and touch up — giving a consistent factory-look finish.

Approach	Method	Result
Professional (ECD method)	Paint panels before assembly, insert rivets after, touch-up heads with syringe or brush	Best result — no paint cracking around rivets
Assembled & painted	Mask or fill around rivets, paint assembled panel	Acceptable — some paint cracking around rivet edges over time
Rivet heads unpainted	Mask rivet heads, paint panels only	Historically correct for original Defenders — clean look

Parts & Suppliers — Where to Source

Autobarn

autobarn.com.au

AU — national chain

U-POL Acid#8 etch primer, 2K primers, body fillers, DA sanders

Supercheap Auto

supercheapauto.com.au

AU — national chain

Etch primers, filler, sandpaper, spray guns, PPE

Septone

septone.com.au

W&G wax and grease remover, etch primers, paint accessories

PaintAccess

paintaccess.com.au

2K automotive paints, primers, topcoats — trade quality

Total Tools

totaltools.com.au

AU — national chain

DA sanders, orbital polishers, spray equipment, PPE

U-POL

upol.com

UK — available via AU paint shops

Acid#8 etch primer — gold standard for aluminium. Ask at trade paint suppliers.

Eastwood

eastwood.com

Epoxy primers, panel tools, rust treatments — ships internationally

POR-15

por15.com

US — available AU via Amazon/eBay

Rust treatment for chassis and steel underbody surfaces

Glass & Seals

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Glass — Tinting Plan

Location	Current	Action
Windscreen	Unknown condition	Replace + light tint (legal)
Front side windows	OK	Deep tint (legal limit)
Rear side windows ×4	OK	Max legal tint
Rear door window	Unknown	Max tint / inspect
Roof vent glazing	Cracked	Replace

Seal Replacement

Windscreen surround rubber — full replaceHIGH
All door seals ×4HIGH
Rear door sealHIGH
Window run channelsNORMAL
Roof gutter drain sealsNORMAL
Quarter light sealsNORMAL

Parts & Suppliers — Where to Source

LRPartShop

lrpartshop.com.au

Defender windscreens, window seals, rubber surrounds

O'Brien Glass

obrienautoglass.com.au

AU — national

Windscreen fitting and replacement — check Defender fitment

WFAANZ Members

wfaanz.org.au

Window tinting installers — use a WFAANZ member for VLT-compliant tinting

Paddock Spares

paddockspares.com

Window seals, door rubbers, glass seals — full range

Britpart

britpart.com

Rubber seals, window surrounds, body seals

Accessories — Black Build

Planned

Style rule: Everything that is not painted body colour is matte/satin black. Mirrors, door hinges, light surrounds, step rails, front bumper, grille — all black. Reference: Chelsea Truck Co Defender.

Confirmed Accessories

Item	Action	Finish
Front bumper (existing)	Refab or replace	Matte black powder coat
Side steps (rocker rails)	Side impact rails	Matte black powder coat
Tow ball rear	Replace	Black
Mirrors	Replace — black folding	Matte black
Grille	Blacked-out louvre style	Satin black

Proposed Additions

Circular LED headlights — Chelsea Truck Co styleHIGH
Integrated front bumper with LED light barHIGH
Side impact rocker rails (under doors)HIGH
Snorkel — raised air intake (black)NORMAL
Roof rack — expedition style (black)NORMAL
Recovery points front & rearHIGH
Spare wheel carrier — matching alloy on rear doorNORMAL

Parts & Suppliers — Where to Source

Landybitz

landybitz.com.au

Bull bars, roof racks, sliders, snorkels, accessories

KLR Automotive

klrautomotive.com.au

Accessories, racks, bumpers, external fittings

ARB 4x4

arb.com.au

AU — national

Bull bars, side steps, roof racks, recovery gear — Australian made

Opposite Lock

oppositelock.com.au

AU — national

4WD accessories, bull bars, steps, lighting

Terrafirma

terrafirma4x4.com

Rock sliders, roof racks, accessories designed for Defenders

Chelsea Truck Co

chelseatruckcompany.com

Bespoke accessories, grilles, bumpers, wheel arches — CTC aesthetic reference

Cabin & Trim

Not Started

Direction: Nene Overland-style interior — brown leather centre panels with black bolsters, quality finish without over-complexity. Sound deadening is a must with a V8 — the cabin will need serious insulation to make road trips comfortable.

Seating

Position	Plan
Driver	Retrim — brown leather centre / black bolster
Passenger	Retrim — matching driver seat
Rear bench	Retrim or reuse — match front
Seat belts	Replace ALL — new 3-point

Trim Tasks

Strip all old trim panelsNORMAL
Treat bulkhead interior — anti-rust coatingHIGH
Install heavy-duty sound deadening — floor, walls, roofHIGH
New rubber floor matting — blackNORMAL
Headliner — black alcantara or similarNORMAL
Door cards — retrim in leatherNORMAL
Replace seat belts — full setHIGH
Centre console — custom or Nene-style unitNORMAL

Parts & Suppliers — Where to Source

Landybitz

landybitz.com.au

Interior trim, headlining, carpets, seat covers

LRPartShop

lrpartshop.com.au

Interior panels, trim, door cards

Trim Shops — Melbourne

Search: auto upholstery Melbourne

VIC

Custom leather seat retrim — search for auto upholstery specialists. Specify Defender/restomod brief.

MOMO

momo.com

IT — available AU via Autobarn/Supercheap

Retro steering wheels — MOMO Retro is the ECD standard choice

Exmoor Trim

exmoortrim.co.uk

Defender-specific seat covers, headlinings, carpet sets

Britpart

britpart.com

Interior trim panels, door cards, mats

ECD Automotive

ecdautodesign.com

Bespoke trim reference — interior design inspiration and spec examples

Dashboard & Gauges

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Note: The LS3 conversion means the OEM diesel gauges are redundant. The cluster needs to be rebuilt around the LS3's needs. Oil pressure, water temp and a quality speedometer (may need to interface with ZF 8HP output) are priorities. Consider a Nene Overland-style double-DIN dash with modern infotainment.

Instrument Cluster — LS3 Spec

Remove OEM diesel clusterHIGH
Source LS3-compatible gauges (Autometer, VDO etc)HIGH
Oil pressure gauge — LS3 senderCRITICAL
Water temp gauge — LS3 senderCRITICAL
Speedometer — interface with ZF 8HP outputHIGH
Voltmeter / battery gaugeNORMAL
Fuel level gauge — sender to match tankHIGH
Double-DIN head unit (Nene-style infotainment)NORMAL
Momo or Nardi steering wheelNORMAL

Controls & Switches

ZF 8HP gear selector — centre console or columnHIGH
MMX transfer case selector — Hi/Lo leverHIGH
New switch panel — bespoke for buildNORMAL
Lighting controls — LED headlight switchNORMAL
Engine start/stop button or key — decideNORMAL

Parts & Suppliers — Where to Source

Stack Racing

stackracing.com.au

Aftermarket instrument gauges — oil pressure, temp, boost, volt

Landybitz

landybitz.com.au

Dash panels, switch panels, Puma dash conversions

Smiths Instruments

smiths-instruments.co.uk

Classic-style gauges — period-correct look for Defender interior

Autometer

autometer.com

US — available AU

Performance gauges — used widely in LS swap builds

Dakota Digital

dakotadigital.com

SGI-5 speedometer signal conditioner — required for LS3 VSS to gauge

Wiring & Electrical — Full Rewire

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Most complex part of the entire build. This is not one wiring job — it is three completely separate electrical systems that must all be designed, installed, and integrated. The original Lucas loom (photographed — cracked insulation, multi-generation Narva bodges) is beyond saving and must be removed entirely. Do not patch it. The wiring diagram image in the project files (Defender 3.9 Diesel Circuit Diagram 5) is useful for body loom routing reference only — the engine and transmission systems are completely new.

The Three Wiring Systems — Overview

#	System	What It Does	Source	Complexity
1	Body / Chassis Loom	Lights, indicators, instruments, horn, wipers, switches, fuel sender, rear lights. All the Defender's original electrical functions.	Autosparks UK (new loom) or custom build	Moderate — well documented
2	LS3 Engine Management Loom	ECM (E38 or aftermarket), injectors, coils, sensors, throttle body, fuel pump, fans, alternator, O2 sensors. Makes the engine run.	Standalone harness (Wiring Specialties / SIKKY / Haltech) or Commodore donor loom stripped down	High — must be correct for the specific ECM
3	ZF 8HP TCU / CAN Bus	Transmission Control Unit, gear selector signal, CAN bus communication between ECM and TCU, reverse light trigger, speedo output.	CANTCU standalone harness (House of Torque) or TurboLamik / MaxxECU	High — needs specialist setup and road tuning

System 1 — Body & Chassis Loom (Autosparks)

Autosparks (UK) produce new-manufacture body looms for the Defender 90/110. For a 1986 110 Station Wagon, you need multiple harness sections — not a single loom. Note long lead times (they build to order). Contact Autosparks with your VIN / serial number to confirm exact harness set.

Section	Autosparks SKU	Purpose
Main harness	LR404	Dash, fuses, switches, primary feeds (2.5NA spec — matches 1986)
Chassis / rear loom	LR432	Rear lights, rear heater, wash/wipe to rear
Instrument panel	LR461	Small dash harness — gauges and warning lights
Fuel tank lead	LR475	Fuel sender to dash gauge
Wiper harness	LR480	Intermittent wiper system
Washer pump lead	LR472	Washer pump to switch

Note: The engine harness from Autosparks covers the original diesel — do NOT order it. The LS3 engine loom is covered by System 2 separately. Order body/chassis/dash looms only.

System 2 — LS3 Standalone Engine Loom

A standalone engine harness strips the factory Commodore/Corvette loom down to only what the LS3 needs to run — removes ABS, traction control, theft deterrent, HVAC etc. If sourcing a VF Commodore LS3 conversion pack, the engine loom and ECU come with it and can be used with minimal modification.

Option	Pros	Est. Cost
VF Commodore conversion pack loom + ECU	Already paired to engine, Australian-spec tune, complete. Best value.	Included with donor engine
Wiring Specialties standalone LS3 harness	Clean purpose-built harness, RHD option available, pre-wired relays/fuses	~USD $450–600
SIKKY standalone LS3 harness	High temp TXL wire, fireproof fiberglass on hot runs, fans/fuel pump relays included	~USD $400–550
Haltech Elite 2500 + terminated harness	Aftermarket ECU — more tuning flexibility, standalone from GM ECM	~AUD $3,000–4,500
MaxxECU + LS harness	Can control ZF 8HP natively via expansion — one ECU for both engine and trans	~USD $1,500–2,500

Speedo signal: The LS3 ECM outputs a VSS signal that is incompatible with the Defender's mechanical speedo. A Dakota Digital SGI-5 signal conditioner is needed to translate the ECM vehicle speed signal to drive an aftermarket speedometer. Budget ~USD $150.

System 3 — ZF 8HP TCU & CAN Bus

The ZF 8HP cannot be driven without a TCU (Transmission Control Unit). It is NOT plug-and-play — it requires a standalone controller, its own wiring harness, and professional calibration (similar to tuning an engine ECU). This is one of the most critical and most commonly underestimated parts of the ZF 8HP swap.

Controller Option	Notes	Est. Cost
TurboLamik (recommended by Street Machine AU)	Most popular in Australia for LS + ZF builds. Road-tunable. Base maps available for common LS/ZF combos. Proven in AU market.	~AUD $1,200–1,800
CANTCU (House of Torque)	Specialist standalone ZF8HP controller with dedicated harness kit. Includes time-delay relay + OBD port. Good documentation.	~USD $600–900 + harness
MaxxECU (with ZF expansion harness)	Controls both LS3 and ZF 8HP from one ECU — elegant solution but higher cost and complexity. Motorsport grade.	~USD $1,500+ for full system
Syvecs	High-end motorsport ECU — overkill for a street build but very capable.	~USD $3,000+

Critical: The TCU must be road-tuned to the specific vehicle weight, engine torque output, and driving behaviour. Base maps from TurboLamik are a starting point — professional road tuning is still required. Budget ~$1,000–1,500 for a full TCU tune session.

Power, Earth & Fusing Strategy

The LS3 V8 draws far more current than the original diesel. The charging system, battery, main feeds and earth bonding all need to be sized for a petrol V8 — not the original 2.5L diesel electrical design.

Component	Spec Required
Alternator	LS3-driven, minimum 160A — source with engine from Commodore
Battery	AGM type, minimum 600 CCA — size for V8 cold crank
Main battery cable	2 AWG or 0 AWG from battery to fuse box and starter
Main fuse box	Modern blade-type — Blue Sea Systems or equivalent. Size: 150–200A main fuse
Earth bonding	Dedicated earth straps: engine block to chassis, chassis to body, body to battery negative. Poor earths cause endless gremlins on LS swaps.
Aux fuse block	Separate PDM or fused relay board for accessories (lights, compressor, USB etc.)
Relay board	Minimum 6 relays — headlights, fans ×2, fuel pump, horn, aux

Wiring Checklist — Body & Chassis Loom

Remove ALL existing wiring — complete clean slate before new loom installCRITICAL
Contact Autosparks UK — confirm correct harness set for 1986 110 SW VINHIGH
Order Autosparks body loom: LR404 main + LR432 chassis + LR461 dash + LR475 fuel + LR480 wiper + LR472 washerHIGH
Install modern blade-type fuse box (Blue Sea or equivalent) — 150A mainHIGH
Install relay board — headlights, twin fans, fuel pump, horn, auxHIGH
Install earth bonding kit — block→chassis, chassis→body, body→battery negCRITICAL
Source AGM battery — minimum 600 CCA, sized for V8HIGH
Run 0 AWG main cable — battery to fuse box and starterHIGH
Install auxiliary fuse block for accessoriesNORMAL

Wiring Checklist — Engine & Transmission

Decide engine loom: VF donor loom vs Wiring Specialties standaloneCRITICAL
Source/install LS3 standalone engine management harnessCRITICAL
LS3 ECM mounted and connected — confirm tune for engine specCRITICAL
Choose ZF 8HP TCU controller — TurboLamik recommendedCRITICAL
Install TCU with CANTCU or TurboLamik standalone harnessCRITICAL
CAN bus wiring between ECM and TCUCRITICAL
Dakota Digital SGI-5 speedo signal conditioner — ECM VSS to aftermarket gaugeHIGH
OBD port installed in cabin — for diagnostics accessHIGH
LS3 engine dyno tuneCRITICAL
ZF 8HP TCU road tune — professional sessionCRITICAL

Lighting — All LED

Circular LED headlights — 7" units, black housingHIGH
LED front indicators — in bumperHIGH
LED light bar — bumper-mounted, wired via relayNORMAL
LED tail / brake / reverse lightsHIGH
Number plate LED stripNORMAL
Interior LED dome / map lightsNORMAL
Aux driving lights — wired via relay + switchNORMAL
Check all LED circuits for correct load — LED indicators may need resistorsHIGH

Parts & Suppliers — Where to Source

Narva

narva.com.au

Wiring, connectors, relays, fuse holders, LED lighting — Australian brand

Repco / Autobarn

repco.com.au

AU — national chain

General electrical — terminals, connectors, heat shrink, wire by the metre

Haltech

haltech.com

AU — Campbellfield VIC

Aftermarket ECU option (Elite 2500) — Australian company, local support

Autosparks

autosparks.co.uk

UK — ships to AU

Complete new body looms for Defender 90/110 — LR404, LR432, LR461, LR475, LR480

House of Torque

house-of-torque.com

CANTCU ZF8HP standalone controller and harness kit — with OBD port

TurboLamik

turbolamik.com

EU — used widely in AU

ZF 8HP TCU controller — most popular in Australian LS+ZF builds

Wiring Specialties

wiringspecialties.com

Standalone LS3 engine harnesses — RHD option available. Pro Series recommended.

SIKKY Manufacturing

sikky.com

Standalone LS3/L99 wiring harnesses — high temp TXL wire throughout

Blue Sea Systems

bluesea.com

US — available AU marine/auto

Marine-grade fuse blocks, relay panels, bus bars — best in class

Dakota Digital

dakotadigital.com

SGI-5 speed signal conditioner — VSS translation for aftermarket speedo

GM LS3 6.2L V8 Crate Engine

Planned — $14,500

Engine choice: GM LS3 crate engine — the same 6.2L unit fitted to C6 Corvette and late Camaro SS. Referenced in both the Nene Overland article and the build notes. Proven Defender swap engine with good Australian support. The Nene article also shows the 5.3L L83 as an alternative at lower cost — decision to be confirmed.

ConfigurationV8, OHV Pushrod, 16v

Displacement6,162 cc / 376 CID

Bore × Stroke103.25 mm × 92.0 mm

Compression10.7 : 1

Peak Power430 hp @ 5,900 rpm

Peak Torque575 Nm @ 4,600 rpm

Redline6,600 rpm

Cam Lift0.551" intake / 0.522" exh

Cam Duration204° int / 211° exh @ 0.050"

BlockCast aluminium, 6-bolt mains

HeadsAluminium L92/LS3 rect port

CrankNodular iron

RodsPowdered metal steel

PistonsHypereutectic aluminium

Fuel (AU)95 RON minimum (98 RON preferred)

Reluctor58X crankshaft encoder

TC Stall (GM rec)2,400 – 2,800 rpm

Warranty (crate)GM 2yr / 50,000 mile

Second-Hand Engine Options — Save $6,000+

Key insight: A used LS3 from a wrecked VE or VF Commodore SS/HSV is mechanically identical to the GM crate engine — same block, heads, and internals. With Holden production ending in 2017, there is now a strong supply of low-km Commodore LS3 engines in Australia at significant savings. A complete engine conversion (engine + loom + ECU) from a VF Commodore is the smartest buy — it includes everything you need to make it run.

Source	What You Get	Price (AUD)	Pros / Cons
GM Crate Engine (new)	Bare long block + basics. No loom/ECU	~$14,500	Brand new, warranty. Need separate ECU/loom kit ~$1,500 extra
VF LS3 engine only (used wrecker)	Dressed engine, no loom/ECU	~$4,000–6,000	Low risk if low km. Need to source ECU/loom separately
VF LS3 complete conversion	Engine + ECU + loom + gearbox + shifter	~$8,000–14,000	Best value — everything to make it run. Wreckers like Salvage Auto Sales QLD stock these regularly
HSV LS3 Clubsport/GTS	Often tuned/upgraded. May have cam package	~$6,000–10,000	Higher spec but verify tune history and condition
Camaro SS LS3 (US import)	Same engine but different accessories	~$5,000–8,000	Accessory drive different — extra work to adapt

Recommendation: Source a complete VF SSV Redline or SS conversion pack from a specialist wrecking company (Salvage Auto Sales Nerang QLD has regular stock with 3-month warranty and videos of engines running). Target under 100,000 km. Save ~$6,000–10,000 vs new crate. The ECU and loom are already tuned for the engine — fewer headaches.

Engine Installation Tasks

Source LS3 crate engine — confirm supplierCRITICAL
Design / source custom engine mounts for 110 chassisCRITICAL
Check bulkhead clearance — may need modificationCRITICAL
Source GM E38 ECM tune for crate specHIGH
Engine dress-up — all-black rocker covers etcNORMAL
Source LS3-specific oil pan — may need low-profileHIGH
Power steering pump — source LS3-driven unitHIGH
Alternator — high-output (at least 160A)HIGH
Air intake / cold air systemNORMAL

LS3 vs L83 Comparison

Spec	LS3 (preferred)	L83 (alternative)
Displacement	6.2L	5.3L
Power	~430 hp	~360 hp
Torque	~575 Nm	~500 Nm
Cost (crate)	~$14,500	Lower (used)
AFM cylinder deact	No — simpler	Yes — can disable
Gen	Gen IV (LS)	Gen V (LT)
Nene Overland use	Yes — 430/525 hp	Yes — 360 hp

Recommendation: LS3 is cleaner for a Defender swap — simpler wiring, no cylinder deactivation system, massive parts and tune support in Australia. Commodore VE/VF LS3 is a cost-effective alternative to a fresh crate unit.

Key Torque Specs — LS3

Fastener	Torque	Notes
Cylinder head bolts (outer)	68 Nm + 60° + 60°	TTY — angle method
Main cap bolts (inner)	45 Nm + 80°	TTY
Main cap bolts (outer)	15 Nm + 53°	TTY
Rod bearing bolts	20 Nm + 75°	TTY — do not reuse
Flywheel / flexplate bolts	105 Nm	Apply Loctite 262
Spark plugs	15 Nm	Dry
Oil pan drain plug	25 Nm
Harmonic balancer bolt	240 Nm	Use holding tool
Engine mount bolts	65 Nm (custom mounts)	TBC per mount design

Parts & Suppliers — Where to Source

Holmart

holmart.com.au

VIC — Melbourne

New LS3 crate engines, genuine Holden GM parts — Victorian stock

Eagle Auto Parts

eagleautoparts.com.au

LS3 crate engines, BluePrint builds, performance packages

Total Performance

totalperformance.net.au

VIC — Thomastown

LS engine parts, cams, heads, torque converters. Showroom open.

Malex Motorsports

malexmotorsports.com

Genuine GM LS3 parts — water pumps, balancers, sensors

Performance Wholesale

performancewholesale.com.au

LS cam kits, lifters, oil pumps, gaskets

Salvage Auto Sales

Search: Salvage Auto Sales Nerang QLD

QLD — Nerang

VE/VF LS3 complete engine conversions — videos of running engines, 3 month warranty

Australia Speed

australiaspeed.com.au

AU — Melbourne

LS3 engine parts, cam packages, headers, exhaust

Walkinshaw Racing Engines

walkinshawracingengines.com.au

VIC — Clayton South

Professional LS engine builds, dyno tuning — Walkinshaw heritage

Proflow Performance

proflow.com.au

VIC — Epping

LS conversion engine mounts, brackets, fabrication parts

PPE (Pacific Performance)

ppeindustries.com

US — ships AU

LS swap ancillaries, coolant reroute kits, oil pans

Exhaust System — Borla

Planned — $600

Specified: Borla Crate Muffler S-Type — the aggressive-sounding stainless unit designed for crate engine builds. Will need custom headers/extractors and mid-pipe fabricated to suit the 110 chassis and Borla muffler mounting position.

Exhaust System Plan

Design exhaust routing — headers to rearHIGH
Source / fabricate LS3 shorty headersHIGH
Confirm mid-pipe routing through chassisHIGH
Mount Borla S-Type mufflerNORMAL
Decide exit — rear or side exitNORMAL
Heat wrap headers where near body / bulkheadHIGH
Stainless tip — black coated preferredNORMAL

Exhaust Specs

Component	Spec
Muffler	Borla Crate S-Type
Material	Stainless steel
Headers	Custom LS3 shorty — TBD
Primary pipe dia.	~1¾" – 1⅞" (headers)
Mid-pipe dia.	~2½" – 3" TBD
Muffler cost	~$600

Parts & Suppliers — Where to Source

Australia Speed

australiaspeed.com.au

Exhaust systems, VE headers, LS-specific exhaust components

Pacemaker Headers

pacemakerheaders.com.au

Australian-made headers — check LS fitment for Defender application

Repco

repco.com.au

AU — national

Exhaust clamps, flanges, flexi sections, heat wrap

Supercheap Auto

supercheapauto.com.au

AU — national

Exhaust heat shield, wrap, clamps, hangers

Borla

borla.com

US — order via AU performance shops

Borla S-Type Crate Muffler — the specified unit for this build

DEI (Design Engineering)

dei-online.com

US — available AU

Titanium exhaust wrap, heat sleeves, heat barriers — best quality

ZF 8HP 8-Speed Automatic

Planned — $3,000

Why ZF 8HP: The ZF 8HP is the gold standard automatic for LS swaps. Used in BMW, Dodge, Jeep (SRT8) and Jaguar applications. The MMX SRT8 transfer case is designed to bolt directly to the ZF 8HP output. This makes the gearbox-to-transfer adaptor a known, engineered solution rather than a fabrication exercise.

Type8-Speed Torque Conv. Auto

1st Gear4.714 : 1

2nd Gear3.143 : 1

3rd Gear2.106 : 1

4th Gear1.667 : 1

5th Gear1.285 : 1

6th Gear (direct)1.000 : 1

7th Gear0.839 : 1

8th Gear (OD)0.667 : 1

Reverse3.317 : 1

Ratio Spread7.07 : 1 (1st ÷ 8th)

8HP70 Max Torque700 Nm input

Weight~87 kg (inc. fluid)

FluidZF Lifeguard 8 (ATF)

Shift methodElectronic (TCU) — needs tune

Controller optionsTurboLamik / MME / Syvecs / ZackTuned

Second-Hand ZF 8HP70 — Sourcing Guide

Street Machine AU (confirmed): The 8HP70 is the go-to choice for LS swaps — confirmed by Australian transmission specialist Andrew (Street Machine Feb 2025). The SRT8-spec 8HP70 from a Dodge Charger, Jeep Grand Cherokee SRT8, or Chrysler 300 SRT8 is ideal — these are RWD applications already paired with V8s. The Torqueflite 8 (Stellantis-built 8HP70 under licence) is the same transmission with a different badge.

Source Vehicle	Variant	Est. Price (AU)	Notes
Jeep Grand Cherokee SRT8	8HP70 (Torqueflite 8)	~$1,500–2,500	Ideal — V8, RWD-biased, pairs with MMX transfer. Source from US-spec wreckers
Dodge Charger / Challenger SRT8	8HP70 (Torqueflite 8)	~$1,500–2,500	Same unit as Grand Cherokee SRT. US-spec, RWD — perfect donor
BMW 5 Series F10 / X5 F15	8HP70	~$1,200–2,000	Same gearbox — but RHD BMW wreckers are easier to find in AU. Needs adapter to LS3
Range Rover Sport L494	8HP70 (4WD variant)	~$1,500–2,500	4WD version — different output flanges. More complex adaptation
ZF 8HP70 rebuild (specialist)	Any core + Sunset Speed / Pure upgrade	~$3,000–5,000	Sunset Speed AU does 8HP70 Stage 2 rebuilds to 1,400hp rating

Note: The 8HP needs professional TCU setup — similar to tuning an engine ECU. Budget ~$1,000–1,500 for a TurboLamik or equivalent controller and mapping. Do not attempt to drive it without proper TCU calibration.

Gearbox Installation Tasks

Source ZF 8HP unit — confirm variant (8HP45 or 70)CRITICAL
LS3-to-ZF 8HP bell housing adaptor plateCRITICAL
Torque converter — confirm LS3 compatible unitCRITICAL
TCU tune / wiring for ZF 8HPCRITICAL
Gear selector — paddle shift or console leverHIGH
Gearbox crossmember / mount fabricationHIGH
Transmission cooler lines and coolerHIGH
Fill with ZF Lifeguard 8 fluidNORMAL

ZF 8HP Variant Guide

Variant	Torque Rating	Common Source
8HP45	450 Nm input	BMW 3/5-series
8HP50	500 Nm input	BMW X5 / Jaguar
8HP70	700 Nm+ input	Dodge Charger SRT8 / RAM — BEST fit for LS3
8HP75	750 Nm input	Range Rover Sport

Recommended: Source the 8HP70 from a Dodge Charger or Jeep Grand Cherokee SRT8 — it's already paired to the Hemi V8 and is the same unit the MMX transfer case is designed around. Gives plenty of headroom over the LS3's 575 Nm.

Parts & Suppliers — Where to Source

Salvage Auto Sales

Search: Salvage Auto Sales Nerang QLD

QLD — Nerang

ZF 6L80/8HP units from VF Commodore conversions — with warranty

Sunset Speed

sunsetspeed.com.au

ZF 8HP70 Stage 2 rebuild kits — up to 1,400hp rating

Goleby's Parts

golebysparts.com.au

ZF 8HP swap kits, DomiWorks adapters, performance transmission parts

GRT Transmission Specialists

Search: GRT Transmission Specialists AU

ZF 8HP professional rebuild specialists — mentioned in Street Machine feature

Total Performance

totalperformance.net.au

VIC — Thomastown

GM transmission controllers, torque converters, trans parts

House of Torque

house-of-torque.com

CANTCU ZF8HP controller and standalone harness kit

TurboLamik

turbolamik.com

ZF 8HP TCU controller — most used in AU LS+ZF builds

ZackTuned

zacktuned.com

ZF 8HP adapter plates, CAN bus TCU, 4WD transfer adapters

MMX SRT8 High Torque Transfer Case

Planned — $4,500

Why MMX SRT8: The Mopar Performance MMX unit is a heavy-duty transfer case designed to bolt directly to the ZF 8HP. It was used in Jeep Grand Cherokee SRT8 applications — so the ZF 8HP → MMX SRT8 combination is an engineered, proven drivetrain stack. This replaces the OEM LT230 entirely.

Transfer Case Tasks

Confirm MMX SRT8 source and specCRITICAL
Verify ZF 8HP → MMX output shaft compatibilityCRITICAL
Front and rear output shaft flange compatibility with Defender axlesCRITICAL
Fabricate or source transfer case crossmemberHIGH
Hi/Lo selector linkage to cabinHIGH
New front propshaft to match MMX outputHIGH
New rear propshaft to match MMX outputHIGH
Fill with correct fluid (confirm spec)NORMAL

Drivetrain Stack Summary

Component	Unit	$
Engine	GM LS3 6.2L Crate	$14,500
Adaptor plate	LS3 → ZF 8HP bell	~$500–800
Gearbox	ZF 8HP70 (SRT8 source)	$3,000
Transfer case	MMX SRT8 Hi-Torque	$4,500
Front propshaft	Custom — new	TBD
Rear propshaft	Custom — new	TBD
Exhaust (Borla)	Borla S-Type crate	$600
Drivetrain subtotal		~$23,400+

Parts & Suppliers — Where to Source

Gearbox Express

Search: Gearbox Express Australia

Transfer cases, gearboxes — second-hand and rebuilt units

Ashcroft Transmissions

ashcroft-transmissions.co.uk

Defender transfer case upgrades, differentials, heavy duty drivetrain

MMX

Search: MMX SRT8 High Torque Transfer Case

MMX SRT8 High Torque Transfer Case — specified unit for this build

Driveshafts, Axles & Propshafts

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Important: The MMX SRT8 transfer case output flanges are likely different to the OEM LT230 — both propshafts will need to be either rebuilt or replaced to mate the MMX outputs to the Defender axle flanges. Get the MMX output flange spec confirmed before ordering props.

Propshafts

Confirm MMX front output flange specCRITICAL
Confirm MMX rear output flange specCRITICAL
Measure front propshaft length (MMX to front axle)HIGH
Measure rear propshaft length (MMX to rear axle)HIGH
Order/fabricate front prop — heavy duty UJsHIGH
Order/fabricate rear prop — heavy duty UJsHIGH

Front Axle Half-Shafts

Inspect front half-shafts — replace if wornHIGH
Check CV joints — replace both sidesHIGH
Swivel housings — full reseal both sidesHIGH
Swivel pre-load check and adjustNORMAL
Consider heavy-duty half-shafts for V8 power levelsHIGH

Parts & Suppliers — Where to Source

KLR Automotive

klrautomotive.com.au

Defender driveshafts, axle parts, CV joints

LRPartShop

lrpartshop.com.au

Propshafts, half-shafts, universal joints, flanges

Ashcroft Transmissions

ashcroft-transmissions.co.uk

Heavy duty half-shafts, driveshafts, CV joints for Defender

Britpart

britpart.com

Driveshaft components, UJ kits, flange bolts

Tom Woods Driveshafts

tomwoodsdriveshafts.com

US — ships AU

Double-cardan front propshaft — mandatory with 50mm lift. Custom to your measurements.

Cooling, Fuel & Ancillaries

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Critical consideration: The LS3 puts out significantly more heat than the original diesel. A purpose-built radiator and high-flow cooling system is mandatory. The fuel system needs a complete rebuild for petrol EFI — the original diesel tank, pump and lines are not compatible.

Cooling System

Source high-capacity alloy radiator — LS3 specCRITICAL
Determine radiator mounting position in 110 bayCRITICAL
Electric fan(s) — dual pusher/puller setupHIGH
Thermostat — LS3 spec 82°CHIGH
Overflow / coolant reservoirNORMAL
Transmission oil cooler — ZF 8HPHIGH
Fill with correct LS3 coolant (Dex-Cool)NORMAL

Fuel System — Petrol EFI

Remove old diesel tank — inspect or replace tankCRITICAL
In-tank high-pressure EFI pump (43 psi min)CRITICAL
Fuel pressure regulator — LS3 spec (58 psi)CRITICAL
New fuel lines — returnless or return styleHIGH
Fuel filter — in-line high-flowHIGH
Fuel sender unit for gaugeNORMAL

Parts & Suppliers — Where to Source

Natrad

natrad.com.au

AU — national chain

Custom radiator fabrication for LS3 fitment — Natrad can build to spec

PWR Performance

pwrperformance.com

AU — QLD

Custom aluminium radiators and intercoolers — Australian manufacturer

Davies Craig

daviescraig.com.au

AU — VIC

Electric water pump kits, cooling controllers — Australian brand

Repco

repco.com.au

AU — national

Hoses, clamps, thermostats, coolant, overflow tanks

Total Performance

totalperformance.net.au

VIC

LS3 thermostat housings, water pump gaskets, cooling ancillaries

Meziere

meziere.com

Electric water pumps for LS3 — eliminates belt-driven pump, saves space

Chassis

In Progress — Bare & Assessed

Critical decision point: The bare chassis is sitting on stands showing heavy surface rust throughout. Given the LS3 V8 power output (~430 hp / 575 Nm), a heavily corroded original chassis is a significant structural risk. Strongly recommend a new galvanised chassis — this also makes LS3 engine mount design much cleaner on known geometry.

Chassis Decision

Probe all sections — establish true structural conditionCRITICAL
Decision: repair original vs new galvanised chassisCRITICAL
If new chassis: order Richards 4WD galvanised 110CRITICAL
If repair: media blast, weld new outriggers, POR-15CRITICAL
Design LS3 engine mount positions on chassisCRITICAL
Design ZF 8HP + MMX crossmember positionsHIGH
Check / modify front spring turrets for lift (if planned)NORMAL

Chassis Supplier Options (AU)

Supplier	Product	Notes
Richards 4WD (AU)	Galvanised 110 chassis	Best local option — known fitment
Marsland (UK)	Hot-dip galvanised	Import freight applies
Original (repair)	Blast + weld + POR-15	Lower cost, more labour

Parts & Suppliers — Where to Source

Richards 4WD

richards4wd.com.au

Galvanised Defender 110 replacement chassis — best AU option

LRPartShop

lrpartshop.com.au

Chassis sections, bulkhead panels, outriggers

Raptor Liner

raptorproducts.com

AU — via Supercheap

Textured polyurethane underbody coating — Raptor Liner on chassis

Marsland Engineering

marsland.co.uk

Hot-dip galvanised Defender chassis — freight to AU

Paddock Spares

paddockspares.com

Chassis crossmembers, outriggers, repair sections

POR-15

por15.com

US — available AU

Rust treatment for chassis prep if repairing original

Front Axle & Steering

Rods Purchased ✓

✓ Purchased: Defender 90/110/130 Steering Rods — Reinforced Heavy Duty set. This is the correct upgrade for a V8 build — the OEM steering rods are a known weak point under increased power and wheel size. Heavy-duty rods eliminate the risk of bending under off-road stress or hard cornering with larger tyres.

Steering Rods — Purchased

Item	Spec
Description	Reinforced Heavy Duty Steering Rods
Fitment	Defender 90 / 110 / 130
Status	✓ PURCHASED
Why uprated	OEM mild steel rods can bend under heavy off-road use or with larger tyres and increased V8 torque loads through the steering. Reinforced rods are a direct replacement — no fabrication needed.
Components	Drag link (steering box to swivel housing), track rod (swivel to swivel across axle)
Install timing	During front axle rebuild — fit with new ball joints

Why Heavy Duty Steering Rods for This Build

With 18" wheels, 50mm suspension lift, and LS3 V8 torque, three things put increased stress on the OEM steering rods: larger tyre leverage on the rod ends, suspension geometry changes at lift height, and the extra front axle articulation that comes with the Bilstein 50mm kit. Heavy-duty rods are a sensible proactive upgrade.

OEM Rod Issue	HD Rod Solution
Mild steel tube — bends under impact	Heavier wall or solid section — resists bending
Designed for 16" wheels and stock geometry	Built for lifted, larger-tyred applications
Age-related wear at rod ends	New rod ends supplied with HD rods
Can buckle in a serious off-road impact	Substantially stronger — maintains steering control

Steering System — Full Tasks

Purchase reinforced heavy duty steering rods (drag link + track rod)HIGH
Inspect steering relay / relay rod — check for play and wearHIGH
Replace steering relay if any play detectedHIGH
Replace all steering ball joints — drag link and track rod endsHIGH
Install HD drag link and track rod with new ball jointsHIGH
Steering column UJ — inspect and replace if wornNORMAL
Power steering pump — source LS3-driven unit (separate from engine section)HIGH
Power steering reservoir and lines — newHIGH
Set toe / steering geometry — 4-wheel alignment after full buildCRITICAL
Check steering lock-to-lock clearance with 18" wheels at full liftHIGH

Front Swivel Housings

The swivel housings (birfield joints) are the critical service item on the Defender front axle. At 40 years old these have almost certainly never been rebuilt. With V8 power and the LS3's torque, the front driveshaft CVs and swivel seals must be in top condition.

Remove swivel housings — both sidesHIGH
Inspect swivel balls for pitting and wearHIGH
Replace swivel seals — both sidesHIGH
Set swivel bearing pre-load with correct shimsHIGH
Pack swivel balls with EP90 or correct greaseHIGH
Replace hub oil seals — both sidesHIGH
Replace front wheel bearings — taper rollerHIGH
Front diff — drain oil, check, replace pinion seal, refill EP90HIGH

Parts & Suppliers — Where to Source

KLR Automotive

klrautomotive.com.au

Steering rods, ball joints, relay assemblies, swivel kits

LRPartShop

lrpartshop.com.au

Steering components, ball joints, drag link ends, track rod ends

SuperPro

superpro.com.au

Polyurethane steering and suspension bushes — Australian brand

Britpart

britpart.com

Steering rods, ball joints, relay rod — comprehensive Defender catalogue

Paddock Spares

paddockspares.com

Steering components, swivel housings, swivel kits, bearings

Bearmach

bearmach.com

OEM-quality steering parts, swivel seal kits, hub bearings

Suspension — Lift Kit & Uprate

Kit Purchased ✓

✓ Purchased: PPD Performance 50mm Premium Kit with Bilstein B6 Shock Absorbers — Part #LANDROVER 001 B. This is the correct kit for a 1986 Defender 110. The Bilstein B6 is designed specifically for the Australian market and provides 50mm lift front and rear. Spring rate must be confirmed as heavy-duty to accommodate the LS3 V8 nose weight — contact PPD if standard rate was ordered.

Still required with this kit: (1) A double-cardan front propshaft is mandatory with 50mm lift — the standard U-joint front prop will bind and vibrate at full droop. Source a Tom Woods or similar unit before the suspension goes on. (2) The Terrafirma TF642GD extended brake hoses (3-line, 2" extended stainless) must be fitted — standard hoses will be too short at 50mm lift and will be under tension. (3) Full 4-wheel alignment required after installation.

Kit Purchased — Bilstein B6 50mm Premium

Item	Spec
Part number	#LANDROVER 001 B
Supplier	PPD Performance (AU)
Lift — Front	50mm
Lift — Rear	50mm
Shocks	Bilstein B6 — monotube, Australian market spec
Spring type	Coil — confirm rate (heavy-duty recommended for V8)
Status	✓ PURCHASED
Total Vic legal lift (with 50mm tyre dia. increase)	75mm — at self-cert limit

Confirm with PPD: Spring rate selection matters significantly with the LS3 V8 in the nose. If the kit was ordered with standard-rate front springs, contact PPD Performance to confirm whether the heavy-duty front springs are recommended for your accessory weight (V8 engine, bull bar, winch if fitted). They can advise.

Spring Rate — V8 Nose Weight

The LS3 V8 (~210kg) + ZF 8HP gearbox (~90kg) places approximately 60–80kg more over the front axle than the original diesel. Without the correct spring rate, the vehicle will sit nose-down despite the 50mm lift springs.

Position	Spring Rate Required	Why
Front	Heavy duty — check with PPD for V8 + any bull bar weight	LS3 + ZF + steel bull bar = significant front load
Rear	Medium duty	No major weight change at rear — match for level stance

PPD Performance AU: ppdperformance.com.au — they offer spring rate selection guides specifically for Defenders fitted with non-standard engines. Ask them directly.

Bushes, Arms & Links

Replace all 8 radius arm bushes — SuperPro polyurethaneHIGH
Replace front Panhard rod bushesHIGH
Replace rear Panhard rod bushesHIGH
Anti-roll bar links and drop links — frontNORMAL
Anti-roll bar bushes — frontNORMAL
Consider heavy-duty radius arms (V8 torque loading)HIGH
Caster correction check after lift installNORMAL

Installation & Related Tasks

Choose kit — Bilstein B6 50mm Premium #LANDROVER 001 BCRITICAL
Purchase kit — PPD Performance confirmedCRITICAL
Confirm front spring rate suitable for V8 nose weight — call PPDCRITICAL
Order double-cardan front propshaft — Tom Woods or equivalentCRITICAL
Order Terrafirma TF642GD extended brake hoses (3-line, 2" extended)CRITICAL
Remove inner helper coils if currently fittedHIGH
Install springs and shocks — all 4 cornersHIGH
Full 4-wheel alignment after install — mandatoryCRITICAL
Check tyre clearance at full lock + full compressionHIGH
Victoria self-cert check — confirm total lift ≤75mm with tyresHIGH

Parts & Suppliers — Where to Source

PPD Performance

ppdperformance.com.au

Bilstein B6 50mm kit supplier — your purchased kit. Spring rate advice available.

ARB / Old Man Emu

arb.com.au

AU — national

OME suspension kits — Nitrocharger Sport and BP-51 for Defenders

SuperPro

superpro.com.au

Polyurethane suspension bushes — radius arm, Panhard, anti-roll bar

Dobinsons

dobinsons.com

AU — QLD

Alternative suspension — multiple spring rates available for custom weight

Opposite Lock

oppositelock.com.au

4WD suspension, lift kits, accessories — national chain

Terrafirma

terrafirma4x4.com

TF642GD extended brake hoses (mandatory with 50mm lift) — stainless 3-line kit

Tom Woods Driveshafts

tomwoodsdriveshafts.com

Double-cardan front prop — mandatory with 50mm lift

Brakes — Uprated for V8

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Safety critical + V8 uprate mandatory: At 430 hp / 575 Nm, the stock Defender 110 braking setup is completely inadequate. The OEM front discs are ~280mm — specifically designed for a 2.5L diesel. A 6.2L V8 weighing 200kg more at the nose needs a serious big-brake kit. Lucari's 6-pot kit is explicitly designed for LS3 V8 Defenders. All flexible hoses will be perished after 40 years — replacement is a VASS requirement for 30+ year old vehicles.

Recommended Big Brake Kits — V8 Spec

Kit	Spec	Est. Price	Notes
Lucari 6-Pot Front Kit	6-piston caliper — requires 18"+ wheels	~£2,394 (~$5,500 AUD)	Specifically designed for LS3 V8 Defenders. Explicitly listed for high-power builds. Suits 18" CSA wheels. Ships from UK.
Alcon Front + Rear Kit	Alcon 4-piston front caliper, larger disc	~$3,000–4,000 AUD	Premium motorsport brand. Used by ECD Automotive as standard brake upgrade on V8 builds. Grey or red caliper options.
IRB Developments (AP Racing)	AP Racing 4- or 6-piston calipers, AP discs	~£800–2,000 (~$2,000–5,000 AUD)	Three kit levels. Bolt-on — no mods required. All seals, gaskets, mounts included. Available in red, black, silver.
LOF POWERspec	Dimpled & grooved discs, high-friction organic pads	~£300–600 (~$700–1,500 AUD)	Budget upgrade — better than OEM for a loaded/towing vehicle. Not designed for V8 power levels but improves on stock significantly.
Terrafirma Extended Hoses	3-line 2" extended stainless hose kit	~£80 (~$200 AUD)	TF642GD — mandatory with 50mm suspension lift. Replaces all 3 flexible hoses. Defender 110/130 to 1999.

Full Brake System Rebuild Tasks

Choose and order front big-brake kit (Lucari 6-pot recommended for V8)CRITICAL
Confirm caliper clearance with 18" CSA Monster wheels before orderingCRITICAL
Replace all 4 flexible brake hoses — stainless braidedCRITICAL
Order Terrafirma TF642GD extended hoses (for 50mm lift)CRITICAL
Replace all hard lines — copper-nickel (Cunifer) throughoutHIGH
Replace master cylinder — new unitCRITICAL
Inspect brake servo — replace if any doubtHIGH
Rear drums — new drums, new wheel cylinders, new shoesHIGH
Replace handbrake cableHIGH
Bleed complete system — fresh DOT 4 fluidHIGH
Full brake test / VASS inspection confirmationCRITICAL

Brake Spec Summary — V8 Build

Item	OEM Spec	V8 Build Spec
Front caliper	Brembo 2-piston sliding	6-piston (Lucari) or 4-piston (Alcon/AP)
Front disc diameter	~280mm vented	330–355mm+ vented
Rear brakes	254mm drum, twin cylinder	New drums + cylinders minimum — disc conversion optional
Flexible hoses	Rubber — 40 years old	Stainless braided, 2" extended for lift
Hard lines	Original mild steel	Copper-nickel (Cunifer) throughout
Brake fluid	DOT 3/4 (ancient)	Fresh DOT 4 — full bleed after build
Caliper finish	OEM black	Black (matching build aesthetic)

Parts & Suppliers — Where to Source

Repco

repco.com.au

AU — national

Brake lines, master cylinder, wheel cylinders, DOT 4 fluid

Pirtek

pirtek.com.au

AU — national

Custom copper-nickel (Cunifer) brake line fabrication — national franchise

KLR Automotive

klrautomotive.com.au

Defender brake parts — calipers, master cylinders, drums, shoes

Lucari Solutions

lucari-solutions.co.uk

6-pot big brake kit — explicitly designed for LS3 V8 Defenders. Requires 18"+ wheels.

Terrafirma

terrafirma4x4.com

TF642GD extended stainless brake hoses — required with 50mm lift

LOF Clutches

lofclutches.com

POWERspec brake kit — dimpled/grooved discs, high-friction pads for loaded Defenders

IRB Developments

irbdevelopments.com

AP Racing 4-pot and 6-pot big brake packages — bolt-on, multiple caliper colours

Alcon

alconcomponents.com

UK — used by ECD

Alcon front+rear brake upgrade — ECD standard V8 brake spec

Wheels & Tyres

Planned — $2,000 wheels

Specified: 18" × 8" CSA Monster alloy wheels — $400 each × 5 (including spare) = $2,000. BFGoodrich All-Terrain or Falken Wildpeak AT3W tyres. The 18" wheels are larger than OEM and will require checking for clearance with the brake uprate and suspension lift.

Wheel & Tyre Spec

Item	Spec
Rim	18" × 8 CSA Monster Alloy
Cost per wheel	$400 × 5 = $2,000
PCD	5 × 165.1mm (Defender spec)
Offset	TBC — check clearance
Tyre option A	BFGoodrich All-Terrain T/A KO2
Tyre option B	Falken Wildpeak AT3W
Target tyre size	265/70R18 or 285/60R18
Qty	5 (inc. spare)

Wheel & Tyre Tasks

Confirm CSA Monster fitment (PCD, offset, centre bore)HIGH
Check wheel clearance with brake uprateHIGH
Check wheel clearance with suspension liftNORMAL
Order 5 × CSA Monster wheelsNORMAL
Decide final tyre — BFG AT KO2 vs Falken AT3WNORMAL
Order 5 × tyres, mount and balanceNORMAL
Wheel colour — confirm satin black or gunmetalNORMAL

Parts & Suppliers — Where to Source

CSA Wheels

Search: CSA Monster wheel Australia

CSA Monster alloy — your specified 18"×8 wheel. $400 per wheel.

Bob Jane T-Marts

bobjane.com.au

AU — national

BFGoodrich AT KO2 and Falken Wildpeak tyres — fitting and balancing

JAX Tyres

jaxtyres.com.au

AU — national

Tyre fitting, 4WD specialist — BFG AT and Wildpeak stocked

4WD Supacentre

4wdsupacentre.com.au

AU — national

Alloy wheels, 4WD tyres, accessories

Tyre Power

tyrepower.com.au

AU — national

BFGoodrich AT KO2 supplier — competitive pricing

Build Budget Tracker

In Progress

Note: All costs in AUD. Many items are estimates — confirm with suppliers. Labour not yet included. This is a complex restomod; professional fabrication (engine mounts, exhaust, wiring) will add significantly to totals.

Confirmed / Specified Costs

Item	Estimate (AUD)
GM LS3 Crate Engine	$14,500
Borla Crate Muffler S-Type	$600
ZF 8HP Gearbox	$3,000
MMX SRT8 Transfer Case	$4,500
CSA Monster 18" Wheels ×5	$2,000

Confirmed subtotal	$24,600

Estimated Additional Costs

Item	Estimate (AUD)
New galvanised chassis (Richards)	~$6,000–8,000
Bulkhead repair / replacement	~$2,000–4,000
Wiring — full rewire	~$3,000–5,000
Engine mounts (custom fab)	~$1,500–2,500
Exhaust headers + mid-pipe (custom)	~$2,000–3,500
Cooling system (alloy rad + fans)	~$1,500–2,500
Fuel system (tank, pump, lines)	~$1,000–2,000
Brakes — uprated kit front	~$1,500–2,500
Suspension — springs + shocks + bushes	~$2,000–3,500
Axle seals, bearings, swivels	~$1,000–2,000
Propshafts (custom ×2)	~$1,500–2,500
Tyres (BFG / Falken ×5)	~$2,000–2,500
Paint — matte/satin black full	~$5,000–10,000
Interior — leather retrim + sound dead.	~$4,000–8,000
Accessories (lights, bumper, steps)	~$3,000–5,000
ECU tune (LS3 + ZF 8HP)	~$1,500–2,500
Misc. hardware, seals, fluids	~$2,000–3,000

Estimated additional	~$41,000–65,000

Total Build Estimate

Conservative Estimate

~$65,000 AUD

Realistic / Mid Estimate

~$80,000–90,000 AUD

High / Pro Build Estimate

~$100,000+ AUD

Note: These are parts-only estimates. Professional labour for engine mounts, exhaust fabrication, wiring, and painting can add $20,000–40,000 on top. A Chelsea Truck Co or Nene Overland completed build sells for £80,000–£200,000 in the UK — this DIY build has significant value upside.

VASS Certification — Engine Swap

Action Required

Critical: Swapping a GM LS3 V8 into a Land Rover Defender is a significant modification — the LS3 is not an OEM option for this vehicle. In Victoria, this requires a VASS (Vehicle Assessment Signatory Scheme) Approval Certificate before the vehicle can be re-registered. Talk to a VASS engineer BEFORE you start the build — they can flag issues early and save expensive rework.

The VASS Process — Step by Step

Contact a VASS-accredited engineer BEFORE starting any workCRITICAL
Initial inspection / consultation — engineer advises on what's requiredCRITICAL
Keep receipt for purchase of LS3 engine (required by VicRoads)HIGH
Engineer inspects completed buildHIGH
Engineer issues VASS Approval CertificateHIGH
Complete "Change of Vehicle Description" form (VicRoads)HIGH
Attend VicRoads Customer Service Centre with VASS cert + engine receiptHIGH
VicRoads inspection and registration updateNORMAL
Roadworthy Certificate (RWC) — required separatelyHIGH

What the VASS Engineer Will Check

Area	What's Assessed
Engine mounts	Must be sound — fabricated mounts must be engineered
Power-to-weight ratio	LS3 is a large jump — engineer uses VSB14 Table LA1 assessment
Brakes	Old vehicles (30+ yrs): ALL brake lines must be replaced as a VASS requirement regardless of condition
Cooling system	Must be adequate for new engine spec
Fuel system	Must be appropriate for petrol EFI — not diesel
Exhaust	Must meet ADR noise requirements
Safety systems	Seatbelts, wipers, demisters (required for 30+ year old vehicles)
Engine number	Registered operator must notify VicRoads of change

VASS Engineers — Melbourne

Find the full current list at vicroads.vic.gov.au — search "VASS signatory list". The list is updated regularly. Always confirm the engineer handles engine conversions specifically before booking.

Engineer / Firm	Area	Notes
VASS1089	Thomastown VIC	Specalises in engine mods, imports. Issues mod plate on the spot
BTT Engineering	VIC / TAS	Light and heavy vehicles, VASS + AVE
Search VicRoads list	Various Melbourne	vicroads.vic.gov.au — filter by "engine modifications"

Tip from AULRO community: Ring before emailing — many engineers don't respond to email reliably. Ask specifically if they handle V8 conversions in 4WDs.

Estimated VASS & Compliance Costs

Item	Estimate (AUD)
Initial VASS consultation	~$150–300
Final inspection + VASS cert	~$300–600
VicRoads inspection fee	~$50–100
Roadworthy Certificate (RWC)	~$150–250
Registration update / plates	~$100–200
Total VASS + rego compliance
Realistic total	~$800–1,500 AUD

Note: Complex or non-compliant builds can require rework and multiple engineer visits. Budget $2,000–$3,000 to be safe. The VASS cert is valid for only 30 days — timing matters.

Key VSB14 / ADR Requirements for This Build

Regulation	Requirement	Status
VSB14 Section LA — Engine	Replacement engine must be assessed for power-to-weight, emissions, and structural compatibility. Non-OEM engine = complex modification = VASS cert mandatory.	Required — not optional
Brake lines (30+ year vehicle)	All brake lines must be replaced as part of VASS process for vehicles over 30 years old — regardless of condition.	Mandatory replacement
Seat belts (30+ year vehicle)	Must have retractable seat belts and compliant mountings.	Must verify / replace
Demisters / wipers	Must be functional 2-speed wipers and front demister.	Check and confirm
ADR noise / exhaust	Exhaust must not exceed ADR 83/00 noise limits (~74 dB(A) drive-by). Borla S-Type is designed to comply with US street standards — confirm AU compliance.	Confirm with engineer
Engine receipt	Must have original purchase receipt for new engine as proof of ownership for VicRoads.	Keep all receipts

Parts & Suppliers — Where to Source

VASS1089

vass1089.com.au

VIC — Thomastown

VASS certified engineer — engine swaps, modifications, imports. Issues mod plate on the spot.

BTT Engineering

bttengineering.com.au

VIC / TAS

VASS and AVE certifications for light and heavy vehicles

VicRoads / Transport Victoria

transport.vic.gov.au

VIC

VASS signatory list, VSI 8 modification guide, Change of Description forms

Australian Land Rover Owners (AULRO)

aulro.com

AU community

Forum — search for Victoria VASS engineer recommendations from other Defender owners

Suspension Lift — Victoria Rules

Plan Accordingly

Good news: The 1986 Defender 110 has NO Electronic Stability Control (ESC) — this means it falls under the simpler, more permissive lift rules. Victoria (VSI 8 / VSB14) allows up to 75mm total lift without engineering certification for qualifying off-road 4WDs. The Defender qualifies as ADR Category NA/NB which is eligible.

Victoria Lift Limits — No ESC Vehicle

Lift Amount	Requirement
Up to 75mm total	Self-certification only — no engineer cert required
Up to 50mm suspension lift	Allowed within the 75mm total
Up to 50mm tyre diameter increase	= 25mm ride height — allowed within the 75mm total
76mm – 125mm total	Requires VASS certification + testing
Above 125mm	Not permitted under VSB14

Lift Rules — Conditions

Condition	Detail
Suspension travel	Must retain at least 1/3 of original travel in both directions
Suspension kits	Must be commercially available kits — no homemade spacers
Kit certification	Kit must be designed and tested for this make/model/variant
Wheel track	Must not increase by more than 50mm (beam axle vehicles)
Tyre clearance	Tyres must be fully contained within mudguards (straight ahead)
Tyre standards	Must have load rating ≥ tyre placard; minimum speed rating N (140 km/h)

Build Recommendation

Recommended setup: 50mm suspension lift + 50mm tyre diameter increase (= 25mm height). This gives the desired stance from the reference photos and stays within the 75mm self-cert limit — no VASS needed for the suspension. Given the LS3 engine weight in the front (heavier than the diesel), uprated front coil springs may naturally sit lower than expected — factor this into spring selection.

Component	Recommended Spec	Note
Front springs	50mm lift, uprated rate for V8 weight	LS3 ~60kg heavier than diesel — stiffer springs needed
Rear springs	50mm lift, medium duty	Match front stance
Shocks	Bilstein B6 or Fox 2.0	Must be commercial kit for Defender
Tyre diameter increase	+50mm diameter max (= 25mm height)	e.g. 7.50R16 → 285/75R16 or 18" equivalent
Total lift	~75mm	At limit — self-cert, no engineer needed

Window Tinting — Victoria Legal Limits

Plan Accordingly

Victoria tinting law (from Transport Victoria / VSI 8): The Defender 110 is a 4WD wagon — it fits category that allows 20% VLT on all windows behind the driver, provided dual external mirrors are fitted each side. The build spec (blacked-out mirrors fitted each side) enables the darkest legal tint on all rear glass. No aftermarket film on windscreen.

Victoria VLT Limits — This Vehicle

Window Location	Legal Limit (VLT%)	Build Spec
Windscreen	No tint film permitted (only factory glass)	New windscreen — no film
Top 10% of windscreen	Tint strip permitted above wiper arc	Optional visor strip
Front side windows	Minimum 35% VLT	35% — darkest legal for front
Rear side windows	Minimum 20% VLT (if dual mirrors fitted)	20% — very dark tint
Rear door window	Minimum 20% VLT (if dual mirrors fitted)	20% — matches sides
Reflectance	Max 10% — applies to all windows	Standard quality tint film meets this

Tinting Rules to Know

Fit dual external mirrors both sides (enables 20% VLT rear)HIGH
No aftermarket film on windscreen (except top visor strip)CRITICAL
If factory privacy glass: combined glass + film must still meet VLT limitsHIGH
Use WFAANZ-member installer — they carry VLT meters and certify complianceNORMAL
No mirror or reflective film anywhereNORMAL
No bubbling or distortion — grounds for defect noticeNORMAL

Defender advantage: 4WDs, SUVs and vans with dual side mirrors are allowed 20% VLT on all glass behind the driver — darker than standard passenger cars (35%). The Chelsea Truck Co dark glass look is achievable legally in Victoria.

Exhaust & Noise Regulations

Confirm with Engineer

ADR 83/00 — Exterior Noise: Australian Design Rules set exterior noise limits. The relevant standard is ADR 83/00 which covers stationary noise (max ~96 dB(A)) and drive-by noise (~74 dB(A) for light vehicles). Modified exhausts must not exceed these limits. The Borla S-Type is a street-legal muffler but a V8 with open headers and no cats will need careful setup.

Exhaust Compliance Rules

Requirement	Detail
ADR 83/00 noise limit	~74 dB(A) drive-by, ~96 dB(A) stationary (engine speed based)
Modification Code LA (VSB14)	Modified exhaust permitted if it satisfies noise and emissions requirements
Catalytic converters	1986 Defender predates cat requirements — LS3 swap complicates this. Check with VASS engineer on whether cats are required.
Borla S-Type	Street-legal in US — engineer must confirm ADR compliance for AU
Owner certification	Exhaust mods can be owner-certified under VSB14 if ADR noise limits are met

Exhaust Checklist

Confirm with VASS engineer: are catalytic converters required on this build?CRITICAL
Confirm Borla S-Type meets ADR 83/00 noise limitsHIGH
No exhaust outlet directly in front of rear wheelNORMAL
Exhaust exit must not direct gases towards occupantsNORMAL
Heat shielding wherever exhaust runs near body, wiring or fuel linesHIGH

Registration & Club Permit Options

Decide Early

Important decision: Given the 1986 Defender is over 25 years old and the build is significant, a Club Permit (H-plate) may be the most practical path during build and initial testing — then full registration once the build is completed and VASS certified. Club Permit allows 90 days/year of road use.

Full Registration Path

Step	Requirement
Engine swap compliance	VASS Approval Certificate (mandatory)
Roadworthy Certificate	Required before re-registration
VicRoads inspection	Vehicle inspection at VicRoads CSC
Change of description	Change of Vehicle Description form (engine number change)
Annual registration	Normal rego process once approved

Club Permit (H-Plate) Path

Item	Detail
Eligibility	Vehicle 25+ years old — Defender 1986 qualifies easily
Annual road use	45 or 90 days per year (choose at registration)
Modifications allowed	More lenient for historic/modified vehicles per VSI 33
VASS still required?	Yes — if significantly modified, VASS still required even for club permit
Club membership	Must be member of an approved car club
Cost advantage	Significantly cheaper annual rego fees

Recommended clubs: Land Rover Club of Victoria, RACV, or similar recognised car clubs with VicRoads approval.

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Select Paint

Select Trim

Bodywork & Panels

Bulkhead

Outer Panels (Aluminium)

Paint & Finish — Black Restomod

Aluminium Panel Prep Process

Steel Surfaces — Different System

Finish Options — Satin vs Matte vs Gloss

Complete Paint Tasks

Rivets & Panel Joins — Defender-Specific

Glass & Seals

Glass — Tinting Plan

Seal Replacement

Accessories — Black Build

Confirmed Accessories

Proposed Additions

Cabin & Trim

Seating

Trim Tasks

Dashboard & Gauges

Instrument Cluster — LS3 Spec

Controls & Switches

Wiring & Electrical — Full Rewire

The Three Wiring Systems — Overview

System 1 — Body & Chassis Loom (Autosparks)

System 2 — LS3 Standalone Engine Loom

System 3 — ZF 8HP TCU & CAN Bus

Power, Earth & Fusing Strategy

Wiring Checklist — Body & Chassis Loom

Wiring Checklist — Engine & Transmission

Lighting — All LED

GM LS3 6.2L V8 Crate Engine

Second-Hand Engine Options — Save $6,000+

Engine Installation Tasks

LS3 vs L83 Comparison

Key Torque Specs — LS3

Exhaust System — Borla

Exhaust System Plan

Exhaust Specs

ZF 8HP 8-Speed Automatic

Second-Hand ZF 8HP70 — Sourcing Guide

Gearbox Installation Tasks

ZF 8HP Variant Guide

MMX SRT8 High Torque Transfer Case

Transfer Case Tasks

Drivetrain Stack Summary

Driveshafts, Axles & Propshafts

Propshafts

Front Axle Half-Shafts

Cooling, Fuel & Ancillaries

Cooling System

Fuel System — Petrol EFI

Chassis

Chassis Decision

Chassis Supplier Options (AU)

Front Axle & Steering

Steering Rods — Purchased

Why Heavy Duty Steering Rods for This Build

Steering System — Full Tasks

Front Swivel Housings

Suspension — Lift Kit & Uprate

Kit Purchased — Bilstein B6 50mm Premium

Spring Rate — V8 Nose Weight

Bushes, Arms & Links

Installation & Related Tasks

Brakes — Uprated for V8

Recommended Big Brake Kits — V8 Spec

Full Brake System Rebuild Tasks

Brake Spec Summary — V8 Build

Wheels & Tyres

Wheel & Tyre Spec

Wheel & Tyre Tasks

Build Budget Tracker

Confirmed / Specified Costs

Estimated Additional Costs

Total Build Estimate

VASS Certification — Engine Swap

The VASS Process — Step by Step

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