Modern Muscle in a Classic Shell

Sometimes the brief isn’t about electrification — it’s about raw power and seamless integration. Our V8 Defender project swapped diesel for a Chevrolet LT1 V8 and a 10-speed automatic gearbox. To make it work, we engineered a full custom loom, designed new ECU/TCU integration, and even 3D-scanned and 3D-printed bespoke interior parts. The result is a Defender that’s not only powerful, but also a showcase of modern engineering meeting classic design.

Dmitrijs G.

9/2/20252 min read

Modern Muscle in a Classic Shell – The V8 Defender Project

Not every Defender we work on goes electric. Some customers want a different kind of performance upgrade — and that’s where our V8 Defender project comes in. This build demonstrates not just power, but the full range of engineering and integration expertise that VASS delivers.

The Heart of the Build

The original diesel powertrain was removed in favour of a Chevrolet LT1 V8 engine, paired with a 10-speed automatic gearbox. To make this work seamlessly, we had to design a full custom wiring loom, integrating modern electronics with the Defender’s systems. This loom connects the new ECU and TCU with the vehicle’s dashboard, air conditioning system, and other electronics, ensuring everything communicates reliably.

Engineering Beyond Wiring

But this project wasn’t just about the loom. We also tackled the interior design and integration:

A bespoke centre console designed in Autodesk CAD, then brought to life via 3D printing.
Custom dashboard components designed and produced in-house.
Smart packaging of new controls, making everything feel cohesive and OEM-quality.

Scanning and Mounting the Impossible

One of the biggest challenges was joining components that were never designed to work together. To achieve this, we 3D scanned the relevant parts, then designed and printed mounts and brackets that allowed us to connect modern systems into the Defender’s original structure. This process not only ensured precision but also reduced trial-and-error, saving both time and cost.

More Than Just One Car

The most exciting part? Every design we created for this Defender now exists in 3D. That means these components can be:

Adjusted and reused for future builds.
3D printed on demand for replacements.
Scaled for production if needed.

This makes the project more than just a one-off — it’s part of a growing library of VASS-engineered solutions that can be applied to future vehicles.

The Result

The finished Defender is more than a powerful machine — it’s an emotional vehicle, blending raw V8 performance with precision engineering and modern comfort. From wiring to CAD, from scanning to 3D printing, this project shows how far we go to make impossible combinations work flawlessly.

👉 “Classic strength, engineered with modern precision.”