Disco rebuild project

THE BUDDAH · Jun 24, 2012

Hi Rob,

Looking really good.

I welded a repair onto the bottom of the middle post, first welding iv'e done on a vehicle and managed to blow a couple of small holes. I dare say as the project continues i'll get better.
Iv'e also cut and shaped a couple of other repair sections that will be welded once the weather improves and i'm off work.

I'll keep your project on watch cos it will help next year when i start the front of my disco.

whatty · Jun 24, 2012

Good work buddy. I have just finished doing this job myself. I was just to tight to buy the panels so I made my own out of 1.6mm zintec steel. I now have a very close relationship with my metal folder lol.The wife became a widow........

RobP · Jul 6, 2012

whatty said:
Good work buddy. I have just finished doing this job myself. I was just to tight to buy the panels so I made my own out of 1.6mm zintec steel. I now have a very close relationship with my metal folder lol.The wife became a widow........

Cheers, I did consider trying to make the parts but decided my fabricating skills just weren't up to it.

Got all the replacement bits from YRM

RobP · Jul 6, 2012

THE BUDDAH said:
Hi Rob,

Looking really good.

I welded a repair onto the bottom of the middle post, first welding iv'e done on a vehicle and managed to blow a couple of small holes. I dare say as the project continues i'll get better.
Iv'e also cut and shaped a couple of other repair sections that will be welded once the weather improves and i'm off work.

I'll keep your project on watch cos it will help next year when i start the front of my disco.

Thanks Mike, give me a shout if you need any advice on the front end.

Now I am back from my holiday I am planning on making a start on the sills next

RobP · Jul 22, 2012

Apologies for the lack of updates.....

Going on holiday and then returning to continuous torrential rain meant that I hadnt done any more for a month.

Managed to get some bits done this weekend.

In my last post I realised that there was something missing here as there was nothing to secure the headlight trims too

So I fabricated these brackets

Fitted them like this

Which then allowed me to attach the trim like this

Fitted a newer connector to suit the new indicator

Front end finished!

Tidied up the front axle too

Just got to refit diff guard, steering guard and winch bumper then I can start on the sills.....

Mr Noisy · Jul 23, 2012

VERY nice job, done a better job than me

And thanks for the mention!

RobP · Jul 24, 2012

Mr Noisy said:
VERY nice job, done a better job than me

And thanks for the mention!

No problem, thanks for the inspiration

RobP · Aug 6, 2012

Time for an update.

Got all the front end back together.

Then made a start on the passenger side sill.....

Took ages to strip out the interior and then stated to drill out the spot welds

Decided to remove the rear ¼ panel to make things easier and also allow me to do the job properly.

This is why the sills need doing!

Shouldnt be able to see daylight here....

Looks like I will need to do the seat belt mount too

A quick investigation with the wire brush left it looking like this

So it looks like this thread will continue for a while yet.......

1spin · Aug 6, 2012

good lad.... you going for it then.... keep up the good work

keep the pics coming....

Mr Noisy · Aug 7, 2012

Quarter panels off is the best thing you can do to a disco, great work!

RobP · Aug 7, 2012

Mr Noisy said:
Quarter panels off is the best thing you can do to a disco, great work!

Its amazing how much rot and crud the 1/4 panel hides!!

THE BUDDAH · Aug 14, 2012

Hi Rob.

I'll be back working on mine soon, just get the next holiday out of the way.
Why is it whenever you start a project of some kind other thing start popping up and stopping you.....lol

duker996 · Aug 18, 2012

Good work, I'm really enjoying this thread, as I did Mr Noisy and Green Hornets! Mines been in a half stripped state for months now and I've been unable to make a start. The MOT expires end of September so I'll try to get stuck in then. Oh and I need to try and source somewhere to do it too

Mr Noisy · Aug 19, 2012

Nothing like getting stuck in! You **** yourself cos you've just wrecked your own car, you're petrified cos you don't know i you've got the capability to finish the job, you're cheesed off cos 'the damn thing is such a rotten bag of ****' and you're distressed at how much it costs to repair it all.

Then when it's finished you can be happy

RobP · Aug 19, 2012

Mr Noisy said:
Nothing like getting stuck in! You **** yourself cos you've just wrecked your own car, you're petrified cos you don't know i you've got the capability to finish the job, you're cheesed off cos 'the damn thing is such a rotten bag of ****' and you're distressed at how much it costs to repair it all.

Then when it's finished you can be happy

That sums it up really well! Got some bits done yesterday but it was so hot I was getting sunstroke! Just about to go and start again now. Will hopefully hve some updates to post tonight

RobP · Aug 19, 2012

duker996 said:
Good work, I'm really enjoying this thread, as I did Mr Noisy and Green Hornets! Mines been in a half stripped state for months now and I've been unable to make a start. The MOT expires end of September so I'll try to get stuck in then. Oh and I need to try and source somewhere to do it too

The first cut with the grinder is the hardest...for me it is just working out what bits to cut and drill out

RobP · Aug 19, 2012

Managed to make some progress this weekend although at times it was too hot to work in.

Rear ¼ panel off

Door lifted off hinge pins to aid access

Chopped the sill in half to make things easier

This lot came out of the sill!!

Too late to turn back now

Another bit for the scrap pile

Chassis wire brushed and treated with Fertan

Then painted with red oxide

Next step will be to top coat the chassis with the Sigma paint and tidy up the edges of the floor and then I can start putting new bits back in

JonnyP · Aug 19, 2012

Nice work..

How much hassle was it to remove the rear 1/4 panels..? I never took mine off on my re-build as I did not know how to redo the spot welds at the doors. Otherwise I would of loved to got them panels off..

Mr Noisy · Aug 19, 2012

They're not too bad to remove, just bolts, screws hidden under sealer, of which there is LOTS of and plenty of adhesive too

Perseverance and fire did it for me!

RobP · Aug 19, 2012

JonnyP said:
Nice work..
How much hassle was it to remove the rear 1/4 panels..? I never took mine off on my re-build as I did not know how to redo the spot welds at the doors. Otherwise I would of loved to got them panels off..

Noisy beat me too the reply but I have attached the three pages of the Rave body manual showing how it comes off

Disco rebuild project

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