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It’s green, and cost about $200, which I am glad to shell out for an important piece of safety equipment. The first step is to remove the seats and get them to our trim shop for re-covering in a nice grey leather. So our in house wood working department has made up some new seat frame bases that are square and level. Now that the seats are at the trim shop we can continue with the conversion and tear down of the interior. A little further along all the rear stinky carpets have been removed and the interior is starting to be cleaned out and brought down to a blank canvas for us to work with. The headliners were sagging a little so they are out of here as well and we will be replacing them with new factory units for a clean look. In the back of the 90 everything has been cleaned up and a layer of dyna-mat has been installed. Back inside the 90, the in car systems are being installed and that means lots and lots and lots of wires. Another aspect of our work that sets ECR apart is our use of the correct color wires with the correct wiring connectors in all our work. The 90 also needed some upgrades for the rear so we have installed our LED tail light set up that will allow this 90 to stand up to New England winters without the dilemma of tail lights that don't work that is so common in 1995-1997 NAS Defender 90s. Here you can see the new headliners have been installed for a nice clean look to the interior. In the rear the carpets and side trims have been installed and the interior roll cage has been re-installed. Up front the new ROX front bumper, with our new built in recovery points, has been installed and we are running the wiring for the upcoming Warn 9000 winch.
The completed set up looks nearly invisible and doesn't interfere with carrying 4 people in the back of the 90, or carrying any cargo you need to carry. Back up front we have installed the Hella 4000s with their protective covers and mounted and wired the Warn 9000 winch. To make the 90 look even better the owner has sent up some Good Year MTRs and we have mounted them up on the newly powder coated rims.
The new leather seats have now gone into place and are looking great and you can see the new cubby box has been installed.
The power window switches are located in the factory dash system and are all wired correctly with the right connectors and switches so that future repairs will be a snap. The new dash location for the head unit allows for a flip out touch screen system and once it is turned on it controls the normal stuff, like AM, FM and CDs.
If you have music videos or movies on your iPod you can watch those as well through the Alpine head unit. Another important upgrade on this low miles 90, to help keep it from having an engine fire, is to remove the factory oil cooler lines and install our performance ROX oil cooler lines.
One last shot of the upgraded interior now that it is all cleaned up and ready for the customer. Here it is, the low miles beauty, with a ton of service work done to keep it that way, and a huge laundry list of upgrades and tricks that very few other NAS D90 Wagons have. If you have needs for your Defender, from routine service to wild modifications, contact ECR.
The Phi Alpha 9 also features can accommodate a wide variety of engine sizes ranging from 3 to 12 hp giving it lots of speed and fun! It features an optional roll cage which makes it even safer, pair that with durable steel tubing for a frame and you have a super cool and safe go kart! If you are not completely satisfied with the plans, the content or the design, you will get you money back, no questions asked! The rollcage bolts have been removed in the rear, and the cross bar was removed with the sound bar. I pulled the interior yesterday, gave it a good long cleaning and scuffed it up for it’s bi-annual application of herculiner.
These wheels will be fitted with brand-new BF Goodrich tires and mounted on the jeep this saturday. Spent the afternoon wandering around a junkyard off I-25 in 100-degree heat… and found exactly what I needed! It is one of the only 500 5 speed Defender 90 wagons imported to the USA in 1995, and it has less than 10,000 original miles from new. The car was previously owned by a smoker so the entire interior stinks of what smells like a cross between wet cats and cigars. This works fine for some folks, but the new owner wants the dash upgraded to the later spec.


The problem is that this 90 has been sitting somewhere for a long time, and likely in a hot environment because the wood that supports the rear jump seats has warped.
The new dash system will move the radio to the dash and update the vent flap controls and the switch gear. The sheets of dyna-mat combined with the new carpets will make the 90 much more car-like as far as interior noise goes and it all will help make this 90 a great all weather cruiser. We'll be ditching the girly running boards and sills and installing a set of ROX sliders with functional Euro-style side steps. In this image you can see the wires are being roughed in for the upcoming sound system and navigation system.
The image above shows the new wiring for the updated hazard switch and rear wiper systems in the updated dash. We also made a slight modification to tie the 2 interior lamps together, that way both lamps will come on when you open any door. The smell is already gone from the 90 and the new trims are making this 90 look better than it used to and with a layer of dyna-mat hidden under the carpets it will be a quieter ride as well. Next up we will install the jump seats with their new leather covers and the subwoofer boxes. These units blend in behind the jump seats and house a subwoofer on each side of the truck for great sound reproduction without the need for some large goofy sub box inside the truck. To combat the rust bleeds that happen on the stock hinges we have installed a set of upgraded units and attached them to the 90 with stainless steel bolts so that the area will stay clean looking and that is especially important on a white truck.
Once the winch is installed we'll set up the bumper with some Hella 4000 lamps for extra light and a lower skid plate to help protect the steering gear from harm when off roading. The new leather looks great and the new tough wood frames will make sure that the frames will not twist or break like the originals did. Most subwoofer systems mean a compromise of having a huge box in the back of your 90, or even removing one or more of the jump seats.
Under the truck we have added a ROX tie rod guard, heavy duty drag link and a front differential guard for total steering protection when off roading.
As soon as the new ROX sliders go into place the new tires and recoated rims will go back on and give the 90 a great overall look. The new cubby box, shown above, has drink holders built in and has no radio mount for a clean look now that we have moved the radio to the dash. Also notice that the factory 1995 vent flap controls have been replaced with the correct 2004- spec. The controls for the driving lights, power windows, rear wiper, rear washer, rear defrost and hazards are all done with the correct switch gear in the factory locations for a clean and modern look.
If that isn't enough you can load mp3s into the Blackbird unit and listen to them on the AUX. The synthetic winch rope has been added along with the recovery shackles and the lower skid plate. The ROX LED reverse lamps are very bright on their own, but this unit makes daylight when turned on. New dash, all new carpets, new headliners, new leather seats and all the other updates make the interior of this 90 one nice place to be. All those ECR installed upgrades combined with the low original miles makes this limited edition Defender 90 one of the best out there. It has tons of great features that make this one of the coolest, most durable, lowest maintenance and safest go karts available as a do it yourself plan.
Additionally, this go kart frame design can be hooked up to the vertical engine drive system (as all our go kart plans can use this system). It was decided that I would be stripping the inteior and laying down a layer of Herculiner to hopefully subside any eventual rust on the body. Unfortunately four of the front bolts on the rollcage were sized, and stripped out several Torx sockets.
I try to make sure everything is clean and pretty on the cars every year, but last summer was spent building the new Ecto, and I completely neglected the Jeep. When I first got it, I drove it around town all summer long sans rollcage, with the windshield folded down. Now I am debating risking life and limb to drive a wildly unsafe, and amazingly awesome, Jeep around town, putting off replacing all the rollcage parts as long as I can…. Pretty much 98% of these will be covered, but if anyone looks closely at the seams, they’ll see a nice red rollcage.
So we will be tearing out the entire interior in order to ditch the stink and make the 90 better in the process while installing the new owners desired upgrades. Now we will do some upgrades like making the heater opening larger for better in cabin heat and we will install a layer of dyna-mat behind the dash as well to help keep the noise down inside the Rover.


The cheesy front A bar is history as well and will be replaced with a ROX front bumper and skid plate combination.
All the wires we pull are run in correct locations that will not interfere with future repairs. The stock 1995 set up is that the front light comes on when you use the front door and the rear lamp when you use the back, but never the 2 together unless you turn one on manually.
Once installed these units will blend right in with the rear cargo area and they utilize wasted space for something useful. As you can see the boxes use wasted space and turn it into great bass for the trucks sound system. We have also topped off the jump seats with alloy bases instead of the cardboard ones that were original.
This works great for long periods of down time so that you won't come back to a dead battery and also has safety aspects as well.
Up front we also added ROX kick panels for a set up that will stand up to muddy boots, unlike the stock cardboard units. It has a 3 position switch so that it can remain off, can be turned on manually for loading gear or it can come on and off automatically as you select reverse gear.
We run these on our own Defenders, and if we can't bend or break them, we know that customers will be happy with them.
It also features a low maintenance no-fade disk brake system which is easy and quick to install and hookup to the brake pedal.
The Jeep is in such a great shape that we were hoping for the best as far as hidden rust spots were concerned. Once I had the liner on I touched up the paint on the ends of the rollcage, painted my center console forest green (the blue has just gotten too nasty and faded), and retouched the bumpers.
I fell in love with that go-kart, zero-blind spot sensation, and I felt I lost a little bit of it every time I added something to the jeep. The white spars that connect the cage to the windshield are from the Jeeps original rollbars.
Even without the need for the head unit changes the updated dash is ultra cool and something that few NAS Defenders have. We'll top that with 3 Hella 4000 lights a Warn winch and also protect the underbelly with a ROX tie rod guard, diff guard and HD drag link. We see stereo shops that do not know Defenders run wires across the floors, under the carpets and all over the place.
The alloy bases are powder coated black for a stock look, but they are much tougher and they resemble the plastic units as used on the late mode Defenders overseas.
Under the hood the services needed to bring this D90 out of its long hibernation have been done so that when it goes back into service it won't have any issues. In case of any electrical issues you can just reach down and flip the switch thereby cutting power to the entire electrical system.
After the doors and hard top were removed the first step was to remove the carpet and rear seat. Two of the bolts proved to be rather difficult to remove, but came out after some finessing. Normally I would weld in a replacement panel, but I would much rather have this done over the weekend and not push the project back into the next week. Man what a difference a little touch-up work on the dings and scratches make for my perception of this Jeep! I am going to paint everything, and then cover it with tan padding just like the jeep in the movie. If you use all red and black wire like some shops do how do you trace electrical issues that might come up years from now?
First it raises the box a little so that it can be used as an arm rest (the factory units are too low for that) and second, we used that extra space underneath it to house the Alpine digital amplifier. This is a very easy task, its just a lot of fishing carpet around mounts and removing bolts.
With a much larger cross section making contact with the bolt they broke loose easily with a 2 foot breaker bar. All our wires are run where they should be and no new holes are drilled, we use all factory wire runs so that although you are may be adding equipment, you aren't hurting the value of your Defender.
I felt like I was getting boxed in, and that my gloriously-simple topless vehicle was becoming just another ordinary car.



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