Discovery 300TDI (big) rebuild

Aljosa · Nov 29, 2016

Hello to all readers,

Here is my attemp to rebuild Land Rover Discovery 300TDI ES (1996) I bought last year from third owner. Car was in quite bad shape - It' was not a surprise. I must say that It's almost impossible to find rustless Discovery here in Slovenia as we have a lot of snow in the winter and also a lot of salt on the roads. However after 1 year of renovation car is in much better condition now

I hope It will be back on the road next spring.

...and sorry for my english...

Aljosa · Nov 29, 2016

day 1 - beginning

surprise surprise....rust all over the place

Aljosa · Nov 29, 2016

after 1 month...we were still motivated

Finally some new parts on the car:

Aljosa · Nov 29, 2016

Body said goodbye to chassis...

later in the evening

Aljosa · Nov 29, 2016

Chassis back from sandblasting - It was in a good shape:

Aljosa · Nov 29, 2016

chassis painted with Raptor U-Pol

motor was completely rebuilded

OME 2" lift with HD springs

Everything back together:

Aljosa · Nov 29, 2016

Successful attemp to repair swivel ball

Aljosa · Nov 29, 2016

Axel rebuild and repaint:

Aljosa · Nov 29, 2016

Some bodywork:

Aljosa · Nov 29, 2016

It's time for new paint - Raptor U-Pol Tinted version (Land Rover Vesuvius Orange tint)

Aljosa · Nov 29, 2016

And current state....few more months and It will be back on road

julianf · Nov 29, 2016

Im always really impressed with disco re-builds.

Its nice to see people putting in the effort with cheaper motors.

markomate2 · Nov 29, 2016

Živjo!
Great thread, your English is fine!
Love your scenery! Very inspiring!
Like the way you removed the body, ingenious!
Interesting that your chassis was in such good condition, maybe they did have good and bad batches of steel!
Good to see more.
Mark

Saltlick · Nov 29, 2016

Aljosa said:
Successful attemp to repair swivel ball

View attachment 111685 View attachment 111686

I like your work - what have you used to repair the swivel with please?

Aljosa · Nov 29, 2016

Saltlick said:
I like your work - what have you used to repair the swivel with please?

putty for metal surface...and a lot of sanding (2-3 hours to get nice smooth finish). First you need to clean rust and grease from the surface. At the end It was painted with 2K paint with spray gun.

Gazbo · Nov 29, 2016

Aljosa said:
putty for metal surface...and a lot of sanding (2-3 hours to get nice smooth finish). First you need to clean rust and grease from the surface. At the end It was painted with 2K paint with spray gun.

Really nice job you are doing there, it will be hard to get it back on the road and get it dirty again with it looking so good, of all the Disco colours that is my favourite, once again great work. It will give you lots of good service.

iwantone · Nov 29, 2016

Fantastic work! Only wish I would be able to do a rebuild like this. Your English is much better than my Slovenian

Aljosa · Nov 29, 2016

iwantone said:
Fantastic work! Only wish I would be able to do a rebuild like this. Your English is much better than my Slovenian

Do you know any Slovenian word?

Aljosa · Nov 29, 2016

Gazbo said:
Really nice job you are doing there, it will be hard to get it back on the road and get it dirty again with it looking so good, of all the Disco colours that is my favourite, once again great work. It will give you lots of good service.

Thank you...currently It's my hobby to renovate it...but at the end It will be my daily driver.

David_Cooper · Nov 29, 2016

Very nice. We have 'lots' of Discoverys remaining over here, I think they must have built more than any other Land Rover. Sadly, ours are all as bad/ worse for rust as yours was!!
Looking forward to seeing the finished product. Should last for years if you get some rust-proofing wax in there.

Discovery 300TDI (big) rebuild

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