Lowering Radiator

OK Here is my next Challenge.
Disco 30tdi engine in to defender LT77, Think I've got all pipe work just about done, ready to fit wings, had to extend everything but all seems to fit fine just need a tidy up,
Anyway I believe/ think I have to lower the Radiator as it sits a bit high over the engine, I've read a bit about this but the only thing is I Cant weld and even if I could I don't have electricity in my place, I'm running off solar panel for lights and generator for power tools ect,. Cant afford to get someone to do it or have the resources to move the whole thing to somewhere to get it done.
So Question is there a way to do this without welding, I was thinking of cutting the mounts on chassis down to correct size and somehow bolting them back in to place. Has anyone done this before, or know of a different way I can get round this.

border said:

OK Here is my next Challenge.
Disco 30tdi engine in to defender LT77, Think I've got all pipe work just about done, ready to fit wings, had to extend everything but all seems to fit fine just need a tidy up,
Anyway I believe/ think I have to lower the Radiator as it sits a bit high over the engine, I've read a bit about this but the only thing is I Cant weld and even if I could I don't have electricity in my place, I'm running off solar panel for lights and generator for power tools ect,. Cant afford to get someone to do it or have the resources to move the whole thing to somewhere to get it done.
So Question is there a way to do this without welding, I was thinking of cutting the mounts on chassis down to correct size and somehow bolting them back in to place. Has anyone done this before, or know of a different way I can get round this.

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if its a disco rad frame,you grind the existing mounts off drill 2 holes were they were and use a couple of 8mm nuts and bolts as new mounting pegs

jamesmartin said:

if its a disco rad frame,you grind the existing mounts off drill 2 holes were they were and use a couple of 8mm nuts and bolts as new mounting pegs

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Not sure if its Disco or Defender James is there any way of telling here's another pic.

border said:

Not sure if its Disco or Defender James is there any way of telling here's another pic.

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if its defender it will have mounting pegs welded to bottom frame, if disco pegs are mounted on a bent steel mount to lift rad

You could remove the original brackets totally and make new ones the right hight that can be fitted with rivnuts.

tottot said:

You could remove the original brackets totally and make new ones the right hight that can be fitted with rivnuts.

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Was thinking of cutting them down to right height then folding the top back on overlapping the sides with bolts through, if you know what I mean

jamesmartin said:

if its defender it will have mounting pegs welded to bottom frame, if disco pegs are mounted on a bent steel mount to lift rad

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Found old pic have circled pegs on bottom, can you tell which one it is from this.

border said:

Was thinking of cutting them down to right height then folding the top back on overlapping the sides with bolts through, if you know what I mean

Found old pic have circled pegs on bottom, can you tell which one it is from this.

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dont alter the chassis brackets rad sits correct when bottom frame sits on the rubbers, yourslooks like a disco frame the bottom pegs should be direct to bottom frame and 2 pegs on top to take securing brackets

border said:

Was thinking of cutting them down to right height then folding the top back on overlapping the sides with bolts through, if you know what I mean

Found old pic have circled pegs on bottom, can you tell which one it is from this.

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Looks like disco.

bottom should look like this, except use nuts and bolts as pegs if you cant get them welded

jamesmartin said:

dont alter the chassis brackets rad sits correct when bottom frame sits on the rubbers, yourslooks like a disco frame the bottom pegs should be direct to bottom frame and 2 pegs on top to take securing brackets
View attachment 199070

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Will take better pics tomorrow to , Mine has No Pegs on top, and don't think they are direct to bottom as there is a gap in between arrowed in pic.
Should I fit wings in place First to see exactly where and what to cut, ??

border said:

Will take better pics tomorrow to , Mine has No Pegs on top, and don't think they are direct to bottom as there is a gap in between arrowed in pic.
Should I fit wings in place First to see exactly where and what to cut, ??

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those need to come off and pegs direct to frame top is best held with pegs and brackets as pictured, its just how a disco frame is altered to fit a defender, i done scores

jamesmartin said:

those need to come off and pegs direct to frame top is best held with pegs and brackets as pictured, its just how a disco frame is altered to fit a defender, i done scores

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OK So cut them off and use a couple of bolts through bottom as pegs, then sit back on to mounts on chassis, Should that take it down to correct height. ? might fit wings first to get a good idea .

border said:

OK So cut them off and use a couple of bolts through bottom as pegs, then sit back on to mounts on chassis, Should that take it down to correct height. ? might fit wings first to get a good idea .

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you can fit wings but if everything is fitted correctly those pegs need to be direct from bottom of frame,so your right with that

jamesmartin said:

you can fit wings but if everything is fitted correctly those pegs need to be direct from bottom of frame,so your right with that

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Not sure how much that gap is between bottom and peg, maybe roughly 15 to 20 mil, then again I could be wrong so will measure it tomorrow. Think I've got a better idea of what to do now, Thanks

border said:

Not sure how much that gap is between bottom and peg, maybe roughly 15 to 20 mil, then again I could be wrong so will measure it tomorrow. Think I've got a better idea of what to do now, Thanks

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it doesnt matter lower rad frame has to sit direct on to the rubbers,hence removal of the disco higher mounts

jamesmartin said:

it doesnt matter lower rad frame has to sit direct on to the rubbers,hence removal of the disco higher mounts

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Thanks mate, Glad I didn't start hacking bits off chassis before I asked I was going off this Vid

border said:

Thanks mate, Glad I didn't start hacking bits off chassis before I asked I was going off this Vid

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mans a fool,should have looked at both frames and seen the difference

jamesmartin said:

mans a fool,should have looked at both frames and seen the difference

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Thanks Again Made my Job a lot easier now.

Had a quick measurement tonight, Does the top of Rad frame have to be level with top of Slam Panel ?? Not sure if this is going to work, as there looks like its going to be around 10 mil or so out, unless I'm missing something.

border said:

Had a quick measurement tonight, Does the top of Rad frame have to be level with top of Slam Panel ?? Not sure if this is going to work, as there looks like its going to be around 10 mil or so out, unless I'm missing something.

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the top part of rad frame sits just above the slam panel which it will when pegs are directly mounted to lower frame and the brackets removed