Vehicle & Technical > Discovery

Discovery Rebuild Thread

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solihull-mick:
Well time does have a few factors, tools used, and how rotten the disco is your doing, but i can give a rough guide,

Boot floor replacement including cross beams and remove and install trim approx 10 hours, included in that rust treatment and body coating, and paint,

Inner wing replacement one side, including remove and install outer wing and wiring, approx 6 hours, bit more for drivers side if servo has to be removed

Inner and outer cill one side, including remove and install trim and seats, doors etc, approx 8 hours,

These would be a fair bit more if working at home with no air tools, but you get the drift of time invloved,

Once the main strip has been done and rust removed its not that bad a job, make sure everything fits as i should before any weldings done, and if possable make sure the motor is standing on its wheels, as body shells do twist if jacked up while cills and things are removed,last thing you want is to weld a cill in place then find out the door wont shut,  allways if you can cut and remove the rust area and sink in a new piece of steel,this can be done using a joddle tool, makes a great repair which can be double welded, you will find the end jobs looks better and will last a damm site longer with the right coating,

 ive seen to many customers come in with mot fail sheets with rot in the same places as they had patched 12months before,i know cost is a factor in any repair, worth spending a little more to make it last more than 12 months,

Will try and post pics as i go along to show repairs as they happen, good luck to you guys doing this at home, and remember disconect the battery and alternator or any other ecus in the car, they dont like big welding current up them !!!!

Frankie-Boy:

Mine's going in to Mick's soon for the same treatment, It'll be good to see a progress report about it on here.  ;)

lenster:
Why did i choose a disco 1? I searched everywhere for a decent vehicle to become my new ride, but either they were too far gone already or people were asking silly money. I looked at the series II but it has a bigger overhang behing the rear wheels and far too many electrics. My current disco has tide marks right up to the inner door handles, I love the deep water and have a tendency to put the vehicle on its side quite a lot. No amount of sealer can protect wiring that well, so i've gone for an older model. Once Mick has worked his magic I will be assimilating both vehicles. (one for the trekies)

solihull-mick:
Few more pics to add as i go


Rear cross member gone to far, new one been ordered














Santas has come early loads of new steel !!!!

kiteman0:
looking good mick
i need to do the same to my inner wings
cut them completely out  :roll:

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