My disco build thread.

[steve's P38 RR]

Good good, Sorry for the spelling and miss type's, I enjoyn writing it up but dont get a lot of time and rush it a bit,

Well starter, altenator,power steering pump, new thermostat are all on couple of water pipes connected up, thats the good news the bad new is i've lost a bell housing bolt and a starter bolt some how, I'm sure there about and will turn up soon.

 

[thebiglad]

Good good, Sorry for the spelling and miss type's, I enjoyn writing it up but dont get a lot of time and rush it a bit,

Well starter, altenator,power steering pump, new thermostat are all on couple of water pipes connected up, thats the good news the bad new is i've lost a bell housing bolt and a starter bolt some how, I'm sure there about and will turn up soon.

Just in case you don't remember Steve, the starter is held in place by 2 x 13mm bolts and 1 x 15mm nut.

 

[jamesmartin]

m10

 

[steve's P38 RR]

Just in case you don't remember Steve, the starter is held in place by 2 x 13mm bolts and 1 x 15mm nut.

Thanks, got the nut and one bolt, We have m10 bolts at work but not with a 13mm head, would like to keep it the same as it makes life easier in the future when working on it, most of the stuff on the engine is 10mm and 13mm, I'm going to see what I have in my box of used bolts at work.

 

[steve's P38 RR]

it's been a couple of days and I finished the head today as the fpr came yesterday and I refitted the manifold and injectors include setting them up, I didn't get many picture's as a hours lunch break soon goes when your working on cars.

Then tonight got the starter bolt in, clutch slave cylinder in and wiring loom sleaving repaired or replaced where needed and starter altenator oil pressure switch and crank sensor all plugged in.

then with my dads help the new dowels in, head gasket on and head back on, there the tightest head bolts i've ever done, and had a little trouble with the timing but all done now using timing pin set (a must if removing the chain / head) happy with that.

we did have to make a shelter because of the weather pic's of that tomorrow lol.

 

[Paul D]

Looking good.

 

[Timpo]

Fair play lad, I'm liking your work there, well done so far.

 

[steve's P38 RR]

well this is some of the wiring i sorted out and recovered all of it that runs close to the engine in the end,

put a push fit fitting in my air box as the original pipe had been broken off for the vacuum solenoids that work the egr

 

[steve's P38 RR]

As well as connecting everything up on the inlet side, (can't do the exhaust side yet as waiting for my exhaust manifold to be skimmed)

Took my radiators all apart and gave them a much needed clean.

Also as i've re-moved the egr valve i thought theres no need for the cooler so made up a bit of pipe to go straight into the expansion tank from the metal pipe under the inlet.

so its now looking like this :clap2:

 

[Funkykipper]

Fantastic thread. Have been considering a D2 project for a while.

 

[steve's P38 RR]

Manifold is back and all looking nice gave it a couple of coats very high temop paint and started to fit it, then all went down hill found1 of my exhaust manifold studs was holding on but about 1mm of metal and broke as soon as i touched it, started to drill it out but still could not get the broken bit out so going to re drill and tap the head and put a steel insert in there,

a bit dark here but you getthe idea

 

[steve's P38 RR]

well friday night I got drilling and re-threaded the head and fitted a steel indert in there to take the same size stud, then got all the manifold and turbo back on and connected up, got my new silicone blue hoses as the of my old hoses had the layers coming apart on the inside, not many pictures as it was dark and time to head down the pub,
saturday morning I got it started and running a little tappy at the min but I'm hoping with a good run it will quiten down,

Next job was to change the front axle as I had a bad bearing noise from it when it was last on the road, so we made this, it was my mk2 tent as the first one did not hold up to the wind, shame after me and my dad put it up we found out it was very dodgey jacking the car up high enough on my sloped drive, feeling a bit fed up with wasting so much time, we started stripping the doors off my white p38 as they were being collected the next day.

Then we decided to load the car up with tools and axle and take it all round my dads on his nice wide flat smooth drive, and we cracked on taking the axle off quite easy job and radius arm bolts were vert tight but apart from the it all came apart a lot easier then taking a lower arm off a discovery 3 I did at work a few months ago.

 

[50 pence]

Nice job.

You just keep going dont you ?.

Well done.

 

[thebiglad]

Fantastic work Steve, very inspirational.


You don't seem to be leaving anything undone? I'll have that DII off you, when you're finished with it


Is that a pallet truck in the pic? Handy thing that.

 

[steve's P38 RR]

Nice job.

You just keep going dont you ?.

Well done.

yeah have to keep going loads to do not sure it will ever be finished I could go on and on if my wallet allowed it, Wish I'd started this on the D2 site as think there would be more interested, may have to copy it over when I get time.

 

[steve's P38 RR]

Fantastic work Steve, very inspirational.


You don't seem to be leaving anything undone? I'll have that DII off you, when you're finished with it


Is that a pallet truck in the pic? Handy thing that.

I'm trying to make it the most reliable d2 about but we will see, That is my dads pallet truck was so hand, firts plan was to leave the wheels on the axle and roll it out on them but you just can't get the car high enough and this worked out a lot easier in the end, you do need a good smooth drive for it tho.

 

[thebiglad]

yeah have to keep going loads to do not sure it will ever be finished I could go on and on if my wallet allowed it, Wish I'd started this on the D2 site as think there would be more interested, may have to copy it over when I get time.

I'm sure the D2 boys club members would be very interested. I can post it over there if you'd like?

Dave

 

[JonnyP]

Excellent thread.. I wish I had you're knowledge on fixing up engines and stuff..

 

[Bennehboy]

I'm sure the D2 boys club members would be very interested. I can post it over there if you'd like?

Dave

There's a fair number of us watching from afar

You're doing a great job on the truck!

 

[steve's P38 RR]

cheers, hit a few snags lately, its not starting very well, changed my air bleed valve and haven't managed to get it started again, think it could be due to being on a slope with very lower fuel level and a poor battery.

will get some fuel in her and a good charge. If any one has any other ideas what it could be let me know