300TDi Disco running gear onto Series or Defender.

Hello all,
I have a 300TDi Discovery and it's body work has rotted away. First the rear bed went and then other major panels. The engine and drive train are in good condition with new wheel bearings etc.
I would like to know if it's possible to mate the engine, gearbox, axles and electrics to a Series(preferable) or Defender rolling chassis.

Looking forward to your answers.

Jay.

I have 68 reads but know replies, Please guys I really want to save all the good bits on my Disco as they all work well, I think they'll enjoy being in a Defender or Series body and chassis. Are there any major issues to doing this. The only onee I can think of are the wheel base and wheel sizes. Will Defender rims fit on Disco hubs?

Jay

Yes, it could all be used in a defender chassis or probably a series. In terms of causing issues it depends on what you are doing. Is it a brand new chassis you are buying? Or what is the plan?

Also defender rims will fit on disco axles. I use discovery rims on my defender

Hello Chezvegas, I intend to get a Defender or Series rolling chassis and transfer all the running gear and electrics from the Disco to it.
Jay

The axles will fit straight onto a 90, a 110 has larger spring mounts so the spring seats/mounts would need to be changed. The engine, gearbox and transfer box will go straight over, you will need to modify the radiator mounts and weld in new engine mounts depending on which mounts are currently in. If it is a pre 300tdi defender then you will need to use the gearbox crossmember from the disco because the r380 mounts to that instead of to the chassis rails.

You may need to change the output shaft on the rear axle to convert it from the rubber doughnut to the 4-bolt type.

If you swap it over as a complete unit, the gear lever and transfer box lever will come up further towards the rear of the vehicle due to a difference in the selectors (the gearstick will be at the front edge of the seatbox). This does mean it's difficult to fit a centre seat but the position of the lever is quite nice actually.

Should you do it to a series then it will be a bit more work requiring mounts to be welded on for the radius arms, trailing arms, panhard rod, A-frame and spring seats. I am not sure how you would approach the steering set-up because it is not a conversion I have done myself but it would be worth taking the PAS system from the disco and using that also. The only other thing off the top of my head is all the engine pipework may need extending/shortening depending how you locate the engine, that is pretty simple though.

HTH Harry

Thanks Borris113, it seems the Defender is the one to go for. I'd prefer the 110, for it longer loadbed. Any idea which Defender would not require me to weld new engine mounts?
I don't mind not having a middle seat as it's only going to be my wife and I in it.
All this info is gratefully accepted.
Thanks.

If you go for a 110 then don't use the discovery alloys. They aren't rated for the higher load capacity. The only one that would require no engine mounts changing would be a 300tdi defender.

I got a 90 with all disco 200tdi running gear in it and yeah gear lever is back in the seat box but i didn't need a centre seat but I managed to get a cubby box in there and the positioning is actually quite nice

I've also thought about getting some defender bodywork and making it fit the Disco chassis. Similar to what Mark Evans did to when he used his Range Rover chassis and dropped a Defender body on it. I believe the Disco Chassis is 100 inch as well like the Range Rover. This seems to be a route I'd prefer as I have the Mark Evans Rnage Rover to Defender on DVD. Any ideas or thoughts from you fine gentlemen?

Jay

Jayvousden said:

I've also thought about getting some defender bodywork and making it fit the Disco chassis. Similar to what Mark Evans did to when he used his Range Rover chassis and dropped a Defender body on it. I believe the Disco Chassis is 100 inch as well like the Range Rover. This seems to be a route I'd prefer as I have the Mark Evans Rnage Rover to Defender on DVD. Any ideas or thoughts from you fine gentlemen?

Jay

Click to expand...

Your right disco is 100 inch, you would need to put some bulkhead out riggers on and fab a new rear crossmember and some other bits like deciding where you would want the fuel tank, you would also need to shorten a 110 tub to fit and roof and sides if you didn't want a pick up, anything is possible just depends on how much money and time you have to throw at it, personally I'd get an old defender with a good bulkhead and chassis and put all running gear and engine in it, but then that's just me good luck.

Boris113 said:

If you go for a 110 then don't use the discovery alloys. They aren't rated for the higher load capacity. The only one that would require no engine mounts changing would be a 300tdi defender.

Click to expand...

Boost ones are rated I think

I have been looking around on various forums and I saw inner panels mentioned. Are inner front wings available? I'd love to keep my Disco, and if I can learn to weld in the process of replacing all the panels on a vehicle I paid off long ago and end up with a well looked after vehicle I will be chuffed.
How difficult is the job of replacing the inner wings and and the sills?

Jay.