Full Disco Rebuild (with pics)

[solihull-mick]

Ok not sure where to start on this, but here goes, Good friend of mine and fellow mud-clubber has a metal challenged 300 disco with a slight chassis twist, so having a large workshop at my disposal and a weath of landrover experience under my belt we came up with a plan,

1, Buy scrap disco for chassis
2, Carry out all welding as needed,Cills,boot floor,inner wings,A Pillars,B Pillars, Floor Pans,Seat belt Fixing Points,
3, Rewire the vehicle including all add on goodies
4, Replace the worn out 300tdi with a fresh 200tdi
5, Replace the worn out syncros in the gearbox
6 Add a whole host of off road goodies while the body was off
7,Fully repaint the chassis,

Oh and all these to be done in a week!!!!

Ok a disco was had from Mr Porny  at a great price,(top guy buy the way)
Back to the workshop for action, Pics say a hundred word so heres a few

DAY ONE

As we started just removing the body



Cills Very crunchy

 

Slowly parting the body from the chassis



Slght problem the cills collapsed under the weight of the shell!!!!
After a little swearing and running for timber we had it sorted



There she blows



Body clear of chassis, Oh and some silly bloke who forgot the head light washer pipe   and got soaked!!!!!



Time to burn off a few stupid side steps!!!!



Put spare chassis back under rotten body shell



Me dancing well trying!!!



Removed engine from doner chassis to check clutch, was sweet so did clutch fork trick and welded a stiffner across it, Refitted engine to chassis,

[solihull-mick]

Ok time to strip the next disco that needs the welding and chassis,




Body lifted clear from old twisded chassis






What a happy chappy!!!!


New chassis get presure washed, attaked by me with a needle scaller, any welded repairs done, axles swoped,and full chassis repaint readdy to go back under the body



Checking the state of the boot floor with the body off, not good!!!


Starting to remove all the badness from the boot area


Due to the corrosion decided to fit fill in panels as well as the boot floor and x members



More rot!!



Fitted the body and chassis back together, to try and keep the body im line, amazing how much a disco flexys with no boot floor and chassis!!!
Also removed both wings to check the inner wings and bulkhead,

[solihull-mick]

Ok time to get some steel back in the boot































Boot floor done, primed and stone chipped, sealed, time for the rest!!











More pics to follow,  

[Range Rover Blues]

So was the green one really that rotten compared to the purple one?

[solihull-mick]

Oh Yes, we did take a good hard look at both shells and the purple one was better, just !!!!

[Jake]

Looks like you've got your work cut out there!!
Coming on nice though.
Nice and neat.
 

[fish]

Keep the pictures coming, I wll be interested to see how the inner wing repairs go.

[lenster]

what a satchel!!!!!!!!!!!!!!

i saw j's 110 through the doorway. is that done?

[muddydisco]

About time you did abit of work for a living . Guess who i'm working with at vision vauxhall @ stafford MR HOWE. So i think lee's time as just about run out  

[solihull-mick]

what a satchel!!!!!!!!!!!!!!

i saw j's 110 through the doorway. is that done?

yo len, yes jamies double cab is nearly done, been doing that in between this one, came out really good, will post a few pics before i paint it

[sub4x4]

nice job good to see the pics if only i could weld lol

[Ja1983]

blimey, seeing all that work is enough to put a person off buying a disco!!

looking great so far tho!  

[solihull-mick]

Got on to the driver cill enjoy











Drivers side done, lot worst the other side







Removed the lower part of the "A" pillar to gain access to the corroded inner cill and foot well, not a fan of plates over rust!!!!!











Just as well it came off, can fix a small rot hole

[J B]

looks a fine job,

when can you start on mine  

[solihull-mick]

got on with the passenger sill today













got the"A" pillar back in place









more pics as i get them

[chris9119]

Just as a note, it would be better to put the pictures in your gallery to save us all waiting a week for the post to open......

The pictures are also being counted as part of your forum up-load limit which must be getting near its limit.

[pux]

great write up and good pics as for upload space they look like there hosted somewhere else i.e photobucket  so keep em coming

[Guardian.]

doing an ace job on that lads, glad im not getting the bill for it!
keep it up.

[solihull-mick]

Thanks for your kind words guys, and i will keep the pics coming soon as i get them        

[lenster]

i think it's pants, you used to go out and play in the mud. now you just want to spend your time welding. i've had to spend the last few weekends playing by myself (i'm nearly blind).

i wonder what colour it will be ?        

[BrumLee]

i think it's pants, you used to go out and play in the mud. now you just want to spend your time welding. i've had to spend the last few weekends playing by myself (i'm nearly blind).

i wonder what colour it will be ?        

You won't be able to see what colour if you don't stop playing with yourself      

[solihull-mick]

Len will give you a clue!  its the same colour as the over spray in the workshop from jamies 110 double cab  

[solihull-mick]

Finished the passenger side sill, not had much time on her this week as the workshops been full,



rebuilt the "A" pillar, replace the wing rib and rail





Started to rebuild the bulkhead today,



Inner wing panel going in place, great fit, real nice panel








Welded top and bottom,


small patch to fit in the morning then its the other side











Then the body will come off, seal and gravitex all the under side of the shell, then a good coat off 2pack,

[solihull-mick]

Ok drivers side now



Bad repairs prior get cut of















awaiting battery tray and inner wing,

[Chris Putt]

Your front end rebuilding looks Mega!

Got to faff about with mine see how much is completely wasted tomorrow. Really dreading it at the moment, I can see me ending up replacing most of it to tell you the truth, much like yours! Unfortunately my welding skills arent up to much, but luckily a mate of mine is pretty hot with a MIG so all should be ok..

Didi you get repair panels made up and delivered or make all of your own?

Chris

[solihull-mick]

Hi there the owner of the disco got the panels, good price i think, will get the number for you, i think hes on the mud-club anyway, as in the wanted section,

[Staffy]

Hi, looking good.

One question. I have been away from car maintenance and restoring for a few years due to health reasons.

The bug has bitten for Land Rovers now and was wondering what the black paint is that you have used to seal the joints.

Looking forward to the next set of photos

Cheers
Phil

[solihull-mick]

Hi staffy, its a seam sealer called tiger seal, once its on the joint simply brush over it with thinners and you get a smooth factory look seam, and you can paint over it to, so there you go

[solihull-mick]

made new head light tray



body off chassis again to repair front body mounts and rear body mounts







repaired front one other side to do





all welded up







oh battery tray and inner wing done



ok all the welding done, time to seal and prime the under side of the shell



nice new boot floor



painted and sealed



Back on chassis and running, new brake pipes every where, time to prep for paint











bonnet primed ready for colour



will update as i get the pics

[solihull-mick]

primer going on









colour going on 2 pack metalic black









disco and 110 crew cab both fresh rebuilds and fresh paint jobs nice