Flat Bed Disco 2 Project

Dave2302 · Mar 23, 2022

Yes the ball joints can be a real bugger to get out without a decent Tool, I have actually slid my press across the floor with a D2 on a lift and adjusted the lift height so I could press the bugger out on one of them

gstuart · Mar 23, 2022

DefenderPilot said:
Thanks chaps, always nice to get some encouragement.

@gstuart: https://www.ebay.co.uk/itm/175106855272?var=474291051078
This was the most reasonable priced stuff I could find on ebay. I bought 8 square meters and it came with some tins of adhesive. I'll need to get some more adhesive though, it's nowhere near enough for that amount of fabric. It's easy to work with and looks pretty good. I intend to redo the headliner and the back of the cab around the window with it as well.

ur so welcome and honestly ur doing a fantastic job there mate

Thks a million and thk u so much for the link , I did wonder that if they sent enough glue , will get some of spray on glue , alas never done it before and I suppose u have to be careful not to spray to much on in the fear of it soaking through or doesn’t that happen plse , many thks

awesome thread and really enjoying the progress , thks for sharing ur project and looking forward to its progress

FlatbedPilot · Mar 23, 2022

I might be being a bit heavy handed with the glue but it didn't soak through. You need to spray both the fabric and the surface you're sticking it to then wait a minute or so for it to go tacky. Then you just press the fabric onto your surface, shaping as you go. It sticks quite well so you need to be careful as it tears if you need to pull it off again if you make a mistake. It's not been too bad for me so far as it's mostly flat surfaces I've done.

gstuart · Mar 23, 2022

DefenderPilot said:
I might be being a bit heavy handed with the glue but it didn't soak through. You need to spray both the fabric and the surface you're sticking it to then wait a minute or so for it to go tacky. Then you just press the fabric onto your surface, shaping as you go. It sticks quite well so you need to be careful as it tears if you need to pull it off again if you make a mistake. It's not been too bad for me so far as it's mostly flat surfaces I've done.

brilliant and that’s very useful, thks so much and good to know if u need to pull it off again and the risk of tears

talking of wishbones etc I bought a bush removal kit a few years ago and was brilliant when I replaced my hub bearing etc

FlatbedPilot · Mar 24, 2022

Stripped down the DS hub today. The ball joints on this side are good so I cleaned the knuckle in situ and zapped it with Kurust then built it back up again with all new parts. So that's the hub, brake disk, caliper bracket, caliper and brake shoes.

Also made a couple of small brackets to fix to the front spring seats for the ABS wire and brake hose.

In other news I've managed to borrow a ball joint press kit so I can get on with the ball joints on the PS sooner rather than having to wait for parts to arrive through the post. I'm collecting that later this evening.

FlatbedPilot · Mar 27, 2022

This weekend's work:

Press out knackered steering ball joints and fit new ones.
Rebuild passenger side hub with all new parts (hub, brake disk, caliper bracket, caliper and brake pads).
Replace engine mounts with new ones.
Fit refurbished front spring seats and lifting blocks.
Fit new Britpart HD +2" front springs.
Fit new Terrafirma +3" adjustable shocks.
Fit new front spring isolators.
Fit new HD steering bars.

I have new HD front suspension turrets to go on but I want to paint them first.

steve24v · Mar 27, 2022

Nice work, good to see it coming along.
What brake calipers did you get for it?

FlatbedPilot · Mar 27, 2022

Thanks. Just got some ebay cheapies:

https://www.ebay.co.uk/itm/153589796007

steve24v · Mar 27, 2022

Thanks, thought about getting some from jgs 4x4 but was a bit reluctant to get them as the price is a bit 'too' cheap. Might get some like yours with the 5 year warranty

FlatbedPilot · Mar 28, 2022

I can't comment on how they perform yet for obvious reasons but I've always bought cheap calipers for my other Landies and never had any issues.

FlatbedPilot · Mar 29, 2022

Back to bodywork. Got the last body mount welded in today and made a start on the inner wings. Stripped everything off the wings and started removing rotten metal on the passenger side. A couple of small repair panels made but not welded in yet. And a little bit of priming on the tow bar steels.

steve24v · Mar 29, 2022

I thought mine was bad, that will keep you busy for a couple of hours lol. Where did you get the body mounts or did you make them?

FlatbedPilot · Mar 29, 2022

Body mounts came from Froggatts. Also got sills and inner wing repair panels from them.

https://froggatts.co.uk/parts-categ...y-2-parts/body-mounts-land-rover-discovery-2/

FlatbedPilot · Apr 1, 2022

Latest update:
Passenger side inner wing repairs finished. This extended to include the front bulkhead body mount and the lower part of the headlight panel.
Front suspension turrets painted and fitted.
Towbar steels finished painting and new socket wired up.
Fuel lines fitted to chassis and tank, including new filter head and chassis clips.
Started fitting/tidying the chassis loom.

FlatbedPilot · Apr 3, 2022

Just a small update today. Knackered old rear control arms swapped over to refurbished and poly bushed items.

FlatbedPilot · Apr 7, 2022

It's been mainly a painty sort of week so far. Got the sills, bulkhead, floor and inner wings painted black, apart from the bit on the DS inner wing that still needs some welding. Cleaned and painted the brake servo. Rescued and refurbished various brackets for the brakes. Managed to get hold of a good used tank strap which I'm also refurbishing. Fitted a new steering damper and bracket and also new power steering hoses. More welding is going to be done this Saturday and if it's not finished then it will definitely be done on Monday. To that end I'm temporarily fitting the body tomorrow to locate the front panel body mounts. Won't be long before the body is ready to go back on permanently.

FlatbedPilot · Apr 8, 2022

Got the body sitting on the chassis with all the body mounts lined up nicely today. Slotted the front panel body mounts into place ready for welding in tomorrow. Modifying the radiator grille as it was cut for a winch. It'll get a winch again and I can cut the panel to suit the new one when it goes on but for now it keeps the front looking tidy. Finished refurbing the tank strap and fitted it with stainless bolts.

steve24v · Apr 8, 2022

Looking good mate, can't wait to get mine back on the chassis.
If it's not too much trouble, could you roughly measure the tank strap as I need to make one (last one was rotted out).
Cheers

FlatbedPilot · Apr 8, 2022

No worries Steve. I'll do it tomorrow. If I don't reply in a day or two gently remind me. I'm very forgetful these days.

steve24v · Apr 9, 2022

Thanks mate

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