Bone's V8 Disco 2 Build Log

Bone9 · Feb 13, 2022

Thinking of going for this https://simssuzukiparts.co.uk/produ...tone-guard-under-seal-500ml-surface-protector for the wheel arch liners and floor and then https://www.arc-rite.co.uk/corroless-s-rust-treatment-killing-inhibiting-primer-choose-size and then this for the topcoat https://www.arc-rite.co.uk/corroless-rf16-glass-leaf-impregnated-gloss-top-coat-any-colour-10138 for the chassis and axles.

What do you think?

Bone9 · Mar 6, 2022

Done a few more jobs recently. My bearmach heater matrix hoses and my lpg hoses both decided to leak through the ends of the actual pipes where the braid is even know they are new pipes. Very annoying

So I've fitted genuine heater matrix hoses and ash silicone hoses for the lpg. Hopefully this will do the trick, they do look much better

While I was at it I greased the props and removed the sidesteps for better access for when the painting commences.

Today I fitted a new aux belt and another rear ace pipe bracket.

Bone9 · Mar 28, 2022

So I've managed to find a fully reconditioned transfer box with a custom 1.3 ratio done by ashcroft! This was done in 2019 but has never been used, only installed in the chassis. Not even had oil in it. The chap was doing a full galvanised chassis rebuild but got ill and had to abandoned the project. I also picked up a upgraded gearbox output shaft that has also done 0 miles. This will put my gear ratio back to stock with my larger tyres.

I also made a stand to help with the removal and fitting.

Bone9 · Mar 28, 2022

The only issue that I've discovered since buying the box is that it doesn't have a high/low switch which means no throttle map changes or hill decent.

Couple of options, swap over the front of my current case to this one or fit a manual switch inside the truck. No idea how much work it is or if you need any specialist tools to do the front case swap.

There are drawings on the net for the bracket if you fancied making one? Also need to get some long m10 bolts to make up 3 aligning pins.

RAW111111 · Mar 30, 2022

Bone9 said:
I also made a stand to help with the removal and fitting.

That bracket is a brilliant idea. Having spent a rediculous amount of time wrestling a gearbox and transfer case into a p38 single handed on the drive way, something similar to that would have been far superior to two trolley jacks and some blocks of wood! I’ll have to keep that idea in mind.

Your Discovery looks great by the way. Nice work.

Rich

Bone9 · Mar 30, 2022

RAW111111 said:
That bracket is a brilliant idea. Having spent a rediculous amount of time wrestling a gearbox and transfer case into a p38 single handed on the drive way, something similar to that would have been far superior to two trolley jacks and some blocks of wood! I’ll have to keep that idea in mind.

Your Discovery looks great by the way. Nice work.

Rich

Yes should make things a bit easier! Cheers buddy. Big changes coming at the end of April.

Bone9 · Apr 24, 2022

Been playing around with the exhaust again trying to get that perfect sound without any drone etc. So first off I welded in a smaller centre box.

This is currently on and being tested, in a few weeks I'll remove and weld in my adjustable length j pipe I made to cancel out the drone frequencies.

Then I decided I didn't really like any of my tips so I made my own 2.75" pie cut one in stainless.

Bone9 · May 11, 2022

Right guys BIG update!!!!! Been very busy over the course of 9 12+hour days!

Loaded up.

Day 1 - Strip down ready for clean up etc. This involved front bumper with all panels and arch liners, rear bumper, rear mud flap brackets, petrol tank, shocks, springs, airbags, turrets, drop links, exhaust, wheels, suspension height sensors, compressor, charcoal canister, crossmembers, panhard rod, steering damper, ace block and other brackets, think that's it for removal!

Day 2,3,4 & 5 - Clean up. This was the hardest ****test job I've ever had to do, took so long and was such hard work and awkward. Very happy with the result and a decent solid chassis. Stripped most of it down to bare metal and removed all the scale/rust flakes.

Day 6 & 7 - Paint chassis, floor and arch liners with Corroless QDR3 black paint, 2 coats were applied. Boot floor and arch liners were given 2 coats of wurth stone guard. Not many photos of this stage but you'll see the paint in the parts install photos.

Day 8 & 9 - Fit most of my new parts etc. This included, +2" fox shocks, +2" medium duty OME springs, contitech airbags, genuine height sensors, OME steering damper, Ratel x turrets, Ratel x +2" rear lift blocks and many other bits!!!

Then I had a few days break until today, tyre fitting time!!

Hope you like. I had to leave a few bits for another day as the whole job took much longer than expected. Still need to do the ace rams and antiroll bars, sills and floor between out riggers. I plan on getting adrenalin radius arms and sumo bars for the steering so no point doing those bits. I still have my diff guards sitting here ready to install and my extended brake lines. I've also got coming some front spring retainers. I need to do the front ball joints so will paint that area and the disc shields once that's done.

RAW111111 · May 11, 2022

Looks awesome. You're braver than I am if you're going to use any of the capability you just fitted in a shell as tidy as that! I really like the fact that you're not just ripping out the technology.

Look forward to seeing the next step.

Rich

Bone9 · May 11, 2022

RAW111111 said:
Looks awesome. You're braver than I am if you're going to use any of the capability you just fitted in a shell as tidy as that! I really like the fact that you're not just ripping out the technology.

Look forward to seeing the next step.

Rich

Thanks mate! I'll be looking after the whole truck, so no destroying it off roading etc. I just like to fit high quality parts and knowing that I can if I want to. I might do some light non scratchy green laning at some point. Its more built for adventures with my family.

ACE and airbags are so cool imo I've no idea why people remove them. Love it!

Bone9 · May 15, 2022

Here's a few pic's of my completed adjustable j pipe center section. It has 10" of adjustment.

Bone9 · May 15, 2022

Picked up some front spring retainers as at full droop my springs just start to move out of the spring seats.

Bone9 · May 18, 2022

Ratel-X front and rear diff guards fitted.

Bone9 · May 18, 2022

ifloochies · May 18, 2022

Bone9 said:

How does it drive with the bigger boots on?

Bone9 · May 18, 2022

ifloochies said:
How does it drive with the bigger boots on?

Drives well, quiet and grips great. Flat in the corners but is sluggish for now till I get my 1.3 transfer box in anyway. Steering not quite as nice but I'm going to make an adjustable panhard bar to align the axles. Should give an improvement. Will also fit 3° front radius arms to correct the castor.

Bone9 · May 29, 2022

Fitted my 2+" braided brake lines and front spring retainers on Saturday. Now my axles can fully droop with no issues.

Bone9 · Jun 8, 2022

Quick pic from the forest.

Bone9 · Jun 8, 2022

Got a few bits ready to swap the nose over on my transfer box. New input seal, front output bearing, front output flange kit, some washers for the switches etc and some long bolts that I'll make into aligning pins.

Bone9 · Jun 8, 2022

More shiny bits

Adrenalin 4X4 HD steering arms.

Bone's V8 Disco 2 Build Log

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