Details and pictures of the conversion of our Land Rover Defender
Below, we'll try to describe the conversion and illustrate it with pictures. We're happy to answer any questions you may have. It's exciting and interesting for all converting enthusiasts that there are always new developments, even though the Defender hasn't been produced in this form since 2017. The new one is completely different; a true successor in this form isn't currently available from Land Rover. That's a real shame, but there are generally exciting developments on the market.
The description is not chronological; many things have been modified over time, often based on practical experience. We also always tried to strike a balance between budget and what would be "nice." We also deliberately omitted many things because they were too expensive, too heavy, or not absolutely necessary. We're currently learning new things every day; see Improvements for details.
Our focus has always been on a good off-road vehicle that would allow us to get almost anywhere, but with our driving ability in mind.
In the end, it's of little use if we land in one place but destroy our home along the way.
Roof rack and roof tent
The rack is easy to describe. Our requirements were that it should be accessible across the entire roof (i.e., stable), and as lightweight as possible. We were offered a used, unused rack, and we jumped at the chance. The manufacturer is unknown, but it proves its worth every day.
With the roof tent, things became more complex. Today, the selection is much larger. Things were a little different in 2016.
Important to us was the size, the rear opening so the space around the rear door was covered, and a wider covered entrance. We wanted to be able to get from the car into the roof tent dry.
We quickly settled on Howling Moon, the STARGAZER 140. The sleeping area of 220 x 140 cm fits us perfectly. The special feature of this tent is the ability to completely open the roof, meaning we're practically outdoors, protected only by the mosquito nets.
The disadvantage of this tent is its weight and the tarpaulin cover, which is unfortunately always a bit difficult to install.
We replaced the mattress, using different foam and 8cm instead of 6. Furthermore, the crease is sewn, so the foam doesn't buckle.
When folded, we can leave the sleeping bag (a “shared sleeping bag”) and pillow on top.
We use the warm sleeping bags in the vehicle as pillows for the back seat.
Insulation and interior finishing (wood)
There are ready-made kits for the Land Rover in all shapes and sizes. Of course, we looked closely at Ex-Tec, but ultimately decided to go with a custom build. The deciding factor was the availability of an expert in the neighboring town. It was no big deal: we're doing it together with KA Mobile (Werner Kappler). We had already purchased the roof tent from them.
The Land Rover was completely stripped and then insulated with 10cm of Armaflex. In some places, we applied more (e.g., the roof). We also took the opportunity to glue soundproofing mats to the surfaces. Our Land Rover is now quite quiet, which greatly improves the mood while traveling.
Next, the interior was finished. Lightweight, multi-layered panels with a friendly, light wood veneer were used (despite rugged off-road use, nothing rattles so far). The table is built into the sleeping area or backrest. The toilet is installed in a relatively easily accessible box. While this severely limits the emergency sleeping space, easy access, even while driving, is more important. It's also important to us that all storage compartments are accessible from two sides (top and side).
The cushions (8cm, cold foam) are made to measure and the separate cover can be washed.
The side cabinet is accessible from both inside and outside. The hatches inside can also be used as a table (which was used extensively during the coronavirus pandemic for RV dinners).
Storage space – additional storage space
We need additional storage space for the following things:
Warm clothes or a change of summer clothes, extra clothes (e.g. dresses or suits for special occasions), camping equipment, tools and spare parts.
We have three aluminum crates on the roof. A large one for the additional tent and camping equipment (chairs, a small table, cables, and small items). All the additional fastenings for strong winds alone take up a lot of space.
Each of us has our own box for changing clothes. They're completely full!
And then I used the space underneath the vehicle for tools and parts. Everything was very heavy and therefore mounted as low as possible on the vehicle. The Defender has plenty of space, and I'm surprised why so few outfitters offer anything here. Basically, none. I mounted old ammunition boxes on the frame. They're absolutely sturdy, waterproof, and plenty big. And, above all, they're unbeatably cheap when used. They don't restrict ground clearance at all, and the running boards are lower. They're not affected by rock chips at all.
We also mounted the GMB storage box in the rear left side box. This is where the shoes are stored. It's not in the vehicle, but still easily accessible.
We also use the spare tire on the hood as storage space. It fits a lot.
Further expansion outside
The Rhino awning above the side cabinet and kitchen provides additional sheltered space for movement. It protects against rain and strong sun. The tent is completely hand-made, which is a great advantage. The poles are standard and can be purchased as replacements at any hardware store. It's not as attractive or light, but the diameter is suitable.
The TD5's big advantage is its flat hood. This allows the spare tire to be mounted on the front of the hood. This shifts the weight forward. There's room in the back for the bikes. And it looks cool. The downside is that visibility is somewhat limited for short drivers, which can be a disadvantage when driving over potholes. This is where the passenger comes in!
And very importantly, the hood must be additionally secured when open. Never put your head, or even your hand, into the engine compartment without it!
We also added a front guard for the engine, axle, and other parts of the underbody. It's important to ensure that enough air still reaches all the parts. The car gets pretty hot and needs its cooling air.
A bike rack on the former spare tire mount. It's held up very well so far, but the hinges are starting to wear out over time. I'd go with a different approach today; there are plenty of options available.
I also tried putting weight on the bumper. But the Land Rover is temperature-sensitive, so the device is only used for the jack.
Electrics
Our vehicle has two batteries under the driver's seat. It's quite tight in that space, but everything's in one place. With a master switch, we can completely disconnect the starter battery, which has proven itself in the container. We charge the auxiliary battery with solar power. We have foldable solar panels (180W) and 10 meters of cable, which have the great advantage of allowing us to park in the shade and still charge. The converters are from Victron.
With this in mind, we decided not to include a shore power charging function. The converter would just take up space, and we don't need it. We've always had enough power so far. The batteries are monitored with a very simple sensor that transmits the data to our mobile phone (Battery Guard). That's perfectly sufficient for us.
The Engel refrigerator runs on battery power (at least 3 days) or on shore power (110/220V). Thanks to its excellent insulation, it doesn't lose much heat, even in tropical heat.
We have LED lights inside and, very importantly, our closet is illuminated (we would add more LED strips here; searching in the dark is a pain).
We converted the headlights to LEDs. This gives us much better light than the standard Land Rover. The downside is that the bulbs don't heat up, and so snow remains on the headlights. Unfortunately, stopping and manually clearing them is necessary.
We have connected some consumers to the auxiliary battery:
· Navigation
Dashcam
· Additional light outside
This reduces the strain on the starter battery and makes us independent. I wouldn't reattach the auxiliary high beam headlight to the roof rack. In snow or rain, it creates too much glare at eye level.
For navigation, we use the Garmin Overlander. Advantages: Compact and all-in-one; disadvantages: expensive, questionable maps; service could be better.
And we have a dashcam for backup. It gives us a sense of security. But we haven't needed it yet. That's a good thing, too.
Music is very important, just like at home. We have all our music with us and can play it all through our Becker radio. Sound is also important to us, especially since we've already soundproofed the vehicle so well.
Heating
The vehicle had a standard auxiliary heater from the start. We can use it to preheat the engine and immediately make it pleasantly warm. However, this is no substitute for interior heating. Instead, we installed an AUTOTERM (Planar) 2D 12-volt auxiliary heater as a complete kit. The heater is located in a box under the "cubby box" and simultaneously raises it to a comfortable arm height. We have two vents, one directly behind the box and one in the rear footwell. We would like to optimize this in the next conversion. If the table is installed as a bed base, no warm air reaches the rear; everything stays in the footwell and can't be distributed.
So far, we haven't had any problems with the heater. We also have the remote control so we can start the heater from the roof tent.
Water
No water in the vehicle, that was the requirement. The Land Rover isn't watertight as it is, and we didn't want any more moisture. We have two Frontrunner canisters on the roof. One large one (40 liters) in the front for washing and showering, and one (20 liters) for drinking water, also on the roof. So far, we haven't had any problems with subzero temperatures (-12 degrees Celsius was the coldest so far).
In any case, it is more than enough for several days of free standing.
Cook
As with the water, we didn't want to cook in the vehicle. There simply wasn't enough space, so it would be better to move the cooking outside. We have gas and a permanently installed induction hob (when we have shore power).
chassis
Our Land Rover is very heavy, and the design keeps the center of gravity high. Since we don't plan on going into extreme off-road terrain, we can handle this situation.
But this meant that a few extensions and changes were required.
Wheel spacers: Classic solution, we have spacers between the wheel carrier and the rim, the classic width of approx. 60mm.
Stabilizers: Even though they limit axle articulation, they are necessary to reduce vehicle roll. Here, too, we've chosen the standard version.
Springs and shock absorbers: I researched this extensively and spoke with experienced people. There are countless solutions, and you can sink a fortune into this topic. In the end, it took a long conversation with the colleagues at Ex-Tec, and we purchased and installed the second suspension kit. Stronger springs, strong Koni dampers, and the car really handles differently. It was a good yet cost-effective decision. And after about 80,000 km, sometimes on rough roads, it's working.
Steering damper, that was added right away.
Brakes: Opinions differ here. I'm completely sold on the EBC brakes from Britpart. We swapped everything, and it really does brake better, what you'd call better. Driving with foresight is still a must, although the top brakes, reductores, tumoles, or whatever they're called, are always a challenge for man, machine, and especially the brakes. So, here's a clear recommendation: get rid of the stock brakes and replace them with something (e.g., EBC).
fuel
Should we install an additional tank or just take additional canisters? The heavy weight on the far right side of the vehicle and the cost are two arguments against the additional tank. The space requirement, which can almost only be met on the roof (again, the heavy weight outside the low center of gravity), is a disadvantage.
In short, we opted for the GMB auxiliary tank, which simply uses an unused space in the Defender. And it was the right decision. We now have a range of almost 1,200 km, which is perfectly adequate for finding a refueling station. We also have a choice of quality, which is always very important. Installation is straightforward and easy in a workshop, although it's a bit of a fiddle because the rear wheel arch is completely filled. The quality of the GMB parts is very good; everything fits perfectly.
Improvements
What did we notice, what did we change.
We got a new transmission from Ashcroft, not entirely by choice. It happened to us in Calgary; the series gave up the ghost. We took advantage of the situation and, together with Dave Ashcroft and Chad from TRS, configured a new transmission. A longer fifth gear ratio, reinforced bearings, and additional oil cooling. All 100% recommended; I'd like to do it beforehand next time. But long-distance comfort is much better, the car is even quieter, and it doesn't get as hot! Another option would be the overdrive version; this keeps fifth gear as it is, offers better acceleration, but still reduces the revs on flat roads. You have to think carefully.
Clutch, get rid of the stock one and install a reinforced one. Even if your calf hurts a bit, it's worth it. The car is heavy, and just the many tops, stopping and slowly driving over them, puts a strain on the clutch.
We draped the entire roof liner with thin mountaineering rope. Space for hanging things is always needed. We didn't use a rubber band, as it will eventually sag. The same goes for the nets; in our opinion, it doesn't make sense because they restrict the seat height.
We put rubber bands through the inside of all the cupboards so we can clamp things to all the interior walls.
We placed flexible fabric boxes on all free surfaces and secured them with rubber bands, for example for bread, biscuits, coffee, etc. Food that we always need but don't need to be in the fridge.
Basically, we're always coming up with new things; that will probably continue, no matter what vehicle we have. We're constantly learning, and new situations arise.
And I'm sure I forgot to write things down. It's best if you take a look and let yourself be inspired. And feel free to contact me personally.
