Vehicle & Technical > Discovery
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!!!! :shock:
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 :shock:
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 :D
Body clear of chassis, Oh and some silly bloke who forgot the head light washer pipe :oops: and got soaked!!!!!
Time to burn off a few stupid side steps!!!!
Put spare chassis back under rotten body shell
Me dancing well trying!!! :oops:
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, :D
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 !!!! :lol:
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