1992 200tdi Discovery- gradually improving my daily driver

K2tnt · May 5, 2019

Thanks for the replies- am going to give it a go straightening panel out first.

The Mad Hat Man · May 5, 2019

Easy enough to make a new one ( with improvements)

K2tnt · May 5, 2019

Began stripping more off inner wing (wiring loom, brake pipes, front body mount) in preparation for drilling out spot welds to remove inner wing today. Keep finding bits of Peugeot glass from the rear window of car I hit!

K2tnt · May 6, 2019

Busy day today. Off came the inner wing with much grinding.

You can really see how mangled the old wing was when compared to new one!

Managed to get the upper wing off the old one, won’t put it on new one until it’s fitted to car to get panel gaps right.

Then began chopping rot out of bulkhead to patch it.

Finished by welding in a patch to the upper part of bulkhead- not pretty welding but it’s solid!

Next job will be patching the lower bulkhead before prepping for the new inner wing to go on! Fun!

K2tnt · May 11, 2019

Made plate for lower bulkhead side and welded it on- looking happier. Tomorrow’s job is front of bulkhead, possibly trial fitting inner wing.

K2tnt · May 12, 2019

Busy day today! First of all I made up the plate to go on the lower front bulkhead and welded that on.

Then offered up the inner wing panel to get it tweaked properly to fit...

This shows it with the upper wing panel resting in place.

Then did a load of drilling for the bolts to fix it in place properly.

And another view...

All in all a very productive day! Doesn’t look to bad with bonnet down either.

Getting there now. Upper panel needs going on next- going to tack-weld it to inner wing, although I know I’m going to have to be careful to make sure the outer wing fits properly.
Any tips for checking this?

K2tnt · May 12, 2019

Also has anyone fitted 200tdi headlights to easy-on replacement wings? Looks like some mods will be needed!

Interceptorxj · May 13, 2019

Henry_b said:
Good call keeping it original..

very nice

+ 1

K2tnt · May 17, 2019

Test fitted upper and outer wing today. To get panel gaps right I tried fitting bonnet lock to see fitting when bonnet is shut.
Bonnet was a right pain to get shut properly- guessing this is to do with front slam panel being messed about.
Any ideas on how to get bonnet to shut cleanly? Guessing it’s a combination of adjusting catch, lock and bending panels to get them to fit?

Turboman · May 17, 2019

K2tnt said:
Test fitted upper and outer wing today. To get panel gaps right I tried fitting bonnet lock to see fitting when bonnet is shut.
Bonnet was a right pain to get shut properly- guessing this is to do with front slam panel being messed about.
Any ideas on how to get bonnet to shut cleanly? Guessing it’s a combination of adjusting catch, lock and bending panels to get them to fit?

The fitting on the slam panel is adjustable. It has 2 bolts that you can loosen to move it around until the upper part fits in smoothly.

K2tnt · May 18, 2019

Lots of progress again today- upper panel welded in and primed.

Then cut the headlight mounting panel out the old inner wing and pop-riveted it to new inner wing. Felt wrong cutting brand new metal up but had to trim a few bits to make it fit, made sure I’d fitted the plastic surrounds before finalising everything.

New outer wing fitted temporarily.

Not too bad at all! Panel gaps aren’t quite right, will have to bend inner wing a bit to make it line up with bonnet properly.

Then all that needs doing (all!) is the bonnet catch, wiring to lights/horn and bleeding the brakes. Oh and fitting all the bumf around the front behind the grille the reinforcement bars and plastic panels between bumper and grille.

K2tnt · May 20, 2019

Aaaand she rides! Brakes bled, wheelarch liners back in, fiddly bits by grille back in place!
Drove up and down the road, felt great apart from lack of alternator- this was because I hadn’t reconnected it properly haha! So she’s done.
Bonnet catch not quite right yet, think cable needs replacing but can be released from behind grille with a bit of fiddling. Again panel gaps not perfect but hey ho!

hef19898 · May 24, 2019

Nice job! And the car was a real bargain if you ask me! Over here a guy braking up a RRC wanted 500 bucks for the roof... I'm kind of jealous!

K2tnt · May 24, 2019

Cheers. I’m loving driving it now it’s sorted, so comfortable and characterful to drive and the kids think it’s great! Lots of minor things to keep working through now it works- will keep updates coming!

K2tnt · May 27, 2019

Handbrake adjusted today, but even better fitted original radio, working complete with dash remote buttons! Ace. Need to get a Bluetooth cassette adaptor thing though to listen to music properly...

K2tnt · Aug 23, 2019

Well she did a family holiday brilliantly! Laden with 5 people, 2 dogs and loads of holiday kit up to Filey and back without missing a beat.

Got a friendly wave from one or two fellow owners on trip too. Off to classic car show at Thoresby in Nottinghamshire on Monday.

1992 200tdi Discovery- gradually improving my daily driver

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Attachments

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Mab An Gov

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Similar threads