200tdi 3 door Disco's (& other ramblings...) also '86 Ninety 200tdi hybrid...

Zed. · Apr 25, 2022

sorted the rad hight issue, a mate visited with his 300tdi 90 csw so out with the box-of-inches & chassis to rad top (@ side by wing) of ~19 1/2" and the Disco 200tdi radpack in my Ninety was ~20" so time to remove the spacer from the lower rad-frame..

call for the anglegrinder again...

removed the peg from the riser & drilled the frame 10mm to suit (iirc ~35mm from front edge & in same centres as previously)

test-fit.

it fits, can see the pencil-mark for the centre...

stitch-welded on upper / rad side & re-assembled (4 short M8 bolts).

test-fit again.

looks better

issue with the Ninety's 2.5d rad steady brackets not fitting so.....

I've bought replica steadies - the ones that bolt to the front-panel / rad grille thing

Buggerit...

now to await postage

Rich. (impatient!!!!!)

Zed. · May 2, 2022

had a fiddle with the Offender today...

the 200tdi engine loom was scruffy and had bare wires with hardly any insulation tape coverage so...

some time & tape later

the power connections on the startermotor were a fiddle to access - I need quadruple-jointed arms

I wanted to secure the pas pipework across the front crossmember and there are a pair of suitable holes already awaiting some rivnuts...

fitted.

need to make some clamps now - tomorrow's job in work

how I've decided to route the pas pipework....

I'd ordered the metric compression-fittings (pack of 2, one needed

) so the (expensive genuine LR) 200tdi fuel return pipe could be fitted

engine end

and back to the electronic speedo conversion, comparing the VDO 100mm diameter E-speedo with the origonal 1986 item.

Spaghetti!

VDO speedo fits

and the important bit

never going back in (hopefully anyway

)

the VDO speedo is simple to wire, ignition power / earth, trigger signal and illumination (live & earth to bulbholders).

as to a sender to generate the speed-signal, I've bought a Discovery electronic sender & hopefully it'll fit the transferbox? this takes an ignition-live feed and returns it's signal to the speedometer.

calibration is simple with either pulse-count or driven distance (2 miles?) - I'll use distance to calibrate.

hopefully the Nnety will actually have an honest speedometer now

Rich.

Knappster · May 3, 2022

Looking good! That belt is due for replacement though…

Zed. · May 3, 2022

Knappster said:
That belt is due for replacement though…

this is at dummy-build stage, have pas, waterpump and cambelt kit waitig in the rear (loadspace

)

I've still got to decide on how the exhaust downpipe will be threadded in (thinking of removing the chassis's undergearbox crossmember

) and the rad needs removing to refit the front-panel & it's steadying 'A' frame

plus all the other jobs

think wiring the new speedo is possibly the easiest task

Rich.

Zed. · May 7, 2022

today I battled with the evil that is a 1986 Ninety's under-gearbox crossmember

something that was an annoying task I could have avoided IF I'd known to fit the exhaust downpipe on the Defender 200tdi engine BEFORE slotting it into the Ninety's enginebay

done now

tomorrow I'll modify a Oneten 200tdi mid silencer by shortening to fit the Ninety & hopefully connect to the 2.5nad's rear silencer to exit as origonal.

also intending to fit the X-Eng disc handbrake setup and while the drum assembly is off I'll have access to fit the electronic speedometer's sender onto the transfer box.

if I've time then maybe I can swap some yellow Bilstein dampers on to match the steering damper

Rich.

Knappster · May 8, 2022

Looking forward to your thoughts on the x-eng handbrake as I’m looking at one for my 90…

Zed. · May 8, 2022

Knappster said:
Looking forward to your thoughts on the x-eng handbrake as I’m looking at one for my 90…

there Seems to be devided opinions, if you're offroading then it should be good kit, if you're road-driving then will it be an improvement over LR's huge drumbrake?

a lot of my thinking is based around it being cheap in Newbury autojumble

^^BUT...

why was it removed from a vehicle

also, the kit I have seems to be for a Disco / RR so the caliper is positioned on the exhaust side (@21.00 from the clock looking from the rear) - will this be an issue in a Ninety

if so I'll just re-drill the bracket

distructions below....

https://foundry4x4.co.uk/pdf/X Eng at Foundry 4x4 X-Brake Defender Instructions.pdf

Rich.

Zed. · May 8, 2022

another days fiddlin, nothing much to show for it though

modified the oneten 200tdi mid exhaust silencer to fit (chop&weld) so now need to find a suitable flange to weld onto the rear section I already have from the 2.5nad...

removed the speedo cable from the transferbox & it's not going back hopefully, the 300tdi electronic speedo sender I bought seems to not want to fit the transferbox so I'll investigate further when the handbrake drum setup is removed for the disc swap...

decided it was time to add a reversing light switch to the gearbox, I'd bought a genuine LR reversing light switch box & hopefully it's contents were also genuine LR

theres a bolt int the gearbox / selector housing that needs removing to fit the switch, hopefully it'll fit

and I tried degreasing the transferbox, don't think it worked though

Rich.

Zed. · May 9, 2022

had a play with a spare Disco transferbox (1.2:1 ratio) that lives in my garage earlier, after I dug it up first

tried the X-eng. disc handbrake setup on it to decide if it'll fit the Ninety (it's a Disco / RR kit I believe

)

the Defender kit positions the caliper @ top (ish) whereas the Disco kit has the caliper @ '9'Oclock (looking from rear) with slight differences in the position of the calipers cable linkages.

another view of the lonkage, this wouldn't be an issue in a D1 but might be problematic in a Landee

side view because I can

I've included this image as it shows the bracket & disc offset, sorta found it interesting

the bracket has a 'skid' / deflector that should be @ 6 O'clock (as I've turned the bracket from Disco to Defender it's @ 9 O'clock

)

and the Ninety's current handbrake setup, I'll assemble as D1 and if theres clearance around the exhaust / silencer AND if the (new 200tdi Defender) handbrake cable fits nicely build / adjust& hopefully forget

also.....

X-eng sell handbrake pads @£LOTS, I've traced these to JCB items @£8 posted so bought a set to try (maybe wasted £8 on pads that dont fit

)

Rich.

Zed. · May 10, 2022

more ~~Junk~~ new parts delivered today, hope they were worth the investment

Genuine LR 'puma' type vss, better Bloody work

BOX says Made in UK, Sensor says....

time to replace the 'old' fyses & fuseboxes with newer 'modern' types

hopefully an easy install

going to try to remove the 'old' drum hangbrake setup & fit the 'new' disc setup. hpefully worth the time & effort

Rich.

Zed. · May 10, 2022

AND........

decided to 'test' the vss against a 'spare' VDO Electronic speedo (80mm dia. so smaller than the 100mm dia, item thats fitted in the Ninety's binacle / cluster thinggy

)

so trawled the internot & captured the distructions

https://www.laltraranda.it/sites/de..._manual_vdo_cockpit_vision_international1.pdf

slow?

turning the vss drive 'bit' makes the needle move & odometer reading increase so I take that as successfull

vss sender wiring is +12v / earth / signal. (earth in middle & I hope the +12v / signal are interchangable

)

now to see if the sender fits

Rich.

Zed. · May 10, 2022

right-e-ho...

the vss sender does fit (but more of that later

)

now, you might understand this photo, it describes previously-rounded propshaft nuts AND my dislike for leaky transferbox output oilseals

when the drum assembly eventually relented I was confronted with oily-mud

so a new oilseal & flange will be ordered

anyway, a pint or so of brake-cleaner, a wire-brush and some swearing later & it was slightly cleaner

the Puma vss sender does fit

nearly shiney

back to the disc handbrake setup...

I'd bought a Disco / RR type X-Eng. kit for cheap in Newbury, I must confess to not being knowledgeable in the dark-arts of disc handbrakes (so didn't actually ask the seller what it fitted

), obviously there was no difference in Ninety / Defender kits?

ok, so there is....

what with one thing & another I've decided to try fitting in the Disco's fashon.

but the caliper clashes with the silencer (200tdi 110 shortened to fit the Ninety) so...

so I fitted the propshaft 'fingertight' then tidied up as I was bored with it

hopefully tomorrow I'll fasten the prop to the diff & transferbox and get the new handbrake cable fitted & adjusted

I'll be rebuilding my spare Disco 200tdi 1.2:1 ratio transferbox to improve cruising drivability as the Ninety has either the 1.4:1 or (worse for our uses) the 1.6:1 ratio

Rich.

Zed. · May 11, 2022

the wiring socket was delivered today so I made one end of the vss loom & started test-routing the cable.

I'm using 2 core cable for power & reference / signal that will connect with the speedometer and a seperate 'flying' earth lead that will be locally connected to earth on the transfer box.

also, tried a 200tdi Defender handbrake cable to check possible (hopefull

) fitment & that its not a torturous route and not interfereing with anything important

seems to be a go-er

hopefully I'll get the caliper bolted up properly with possibly some handbrake cable action

waiting on new propshaft bolts and a silencer-free exhaust midpipe, ebay is responsible for a lot of crimes against my bankballance

Rich.

Zed. · May 14, 2022

eventually reassembled the grille-surround & brace so time to combat fitting rad top support brackets, call for the rivnut fitting tool....

there were convieniently placed holes already there so drilled out to 9mm diameter and fitted some m6 rivnuts.

like this.

I repurposed the Discovery's side-mount pins with some grinding to remove from their brackets snd stitch-welded through the rad-supports top frame after marking through the newly fitted brackets.

the pins protrude through the frame, the intercooler side is through the warning sticker (& the bracket covers this anyway).

Done.
brackets from ebay...

plastic grill back on & some jubilee clips on the top intercooler hose.

next job is to make a lower intercooler connecting pipe.

looks to be a straight run and hopefully not rub against the pas pipework.

another job is new 8mm hose between the expansion-tank and radiator, one thats been missed so far

hopefully dry weather tomorrow and I might finish the exhaust

Rich.

Knappster · May 15, 2022

Nearly there! And it’s looking good.

That chassis needs some rust treatment whilst the bumper’s off…

Zed. · May 15, 2022

Knappster said:
That chassis needs some rust treatment whilst the bumper’s off…

its getting painted at some point in the near future, I consider this work as a dry-run because of all the snapped bolts & replacements having acf50 grease applied

will be lifting the bodywork in sections for access & also replacing the tired polybushings that the previous owner fitted ~ 8 years ago - will be using rubber & genuine LR parts if I can find them cheap enough

Rich.

Zed. · May 29, 2022

loads of little things done but havn't posted about them

exhaust ~~bodged~~ completed - straight-through 200tdi midsection with a homemade adapter to accept the 2.5nad tailpipe so exiting behind the rear wheel & adding soot on the mudflap

coolant hoses & intercooler pipework completed - tried to use genuine LR but some not available and most expensive

fuelfilter replaced etc.

today I fiddled with the electronic speedo conversion...

wiring time, connected the illumination...

spaghetti?

the origonal gauges have a green tint / filter and are a little dim

bulbs are lit...

all bulbs except the 'boost' gauge run capless '501' type so should be equilly bright - the green tint filter obviously responsible for the dimness.

powered the speedo, scrolled through the calibration menu...

the manual suggests a few methods, the 1 mile drive could be the easiest

so, next is the sensor wiring.

3 wires on the sensor I'm using.

the difflock warning has never worked....

now know why - bulbs ordered

more to follow...

Rich.

Zed. · May 29, 2022

so....

it's fitted & wired

can really see the difference between the green 'tinted' bulbs and the normal, think I'll use a drill to de-green them

and typically, the oilpressure warning doesnt anymore

and I cannot find the bag of dashboard bulbs....

Next.....

Rich.

Knappster · May 29, 2022

That speedo looks like a period feature and original.

Zed. · May 30, 2022

Knappster said:
That speedo looks like a period feature and original.

no idea, was £20 on ebay if that helps

presumed it was ~20 years old but a VDO pdf I found (& bookmarked) suggests 2010

file:///Users/zed/Downloads/2010_vdo_product_information_en_cockpit_international_100mm_speedometer.pdf

Rich.

200tdi 3 door Disco's (& other ramblings...) also '86 Ninety 200tdi hybrid...

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