My disco build thread.

[steve's P38 RR]

Well finished sealing the a pillars but haven't got any pictures may put a another layer on top yet.

Now jumped into the next job, more of the chassis to clean and protect. sorry some of the photos are poor due to light under the D2.

Before









After a wire brush and clean













I get 45 mins on the ramp at work on my lunch break, so took all week.






Masking up.



Front of center section (as I call it) primed



rear center section done


Some randoms where I could get good light.

 

[steve's P38 RR]

Rear prop drive coupling (donut ) replaced and handbrake shoes cleaned and adjusted this week.

Genuine item

 

[steve's P38 RR]

Right for the last month I have be trying to decide what shocks to go for as I have found a set of genuine winch spec front springs that are on the list. after a lot of thinking a changing my mine from terrfirma to genuine land rover I'm now set on getting some old man emu nitrochanged shocks to go all round, they are +25mm and heard good reports on them still being good after 8 years of hammering, As I like to do a job once it has got to be these so now to find a supplier that will give me there best price.

 

[dervpower]

Hi

Mate how hard was it to fit the cruise control as I've got a 51 plate es and it's the only thing it's missing and could do with it for the long drives

Cheers liam

 

[steve's P38 RR]

Hi

Mate how hard was it to fit the cruise control as I've got a 51 plate es and it's the only thing it's missing and could do with it for the long drives

Cheers liam

Easy aslong as its a td5, just have to fit the 2 switches and it works straight away, hardest bit is cutting out the plastic part on the back of the steering wheel, but you can remove the stereo controls and make a template off that side and flip it over. Make sure you get a mount for the steering wheel cruise switch or again make one as I did by copying the stereo one.

Thought all ES models came with it. I've always loved cruise.

 

[steve's P38 RR]

right been doing some repair's and more mods

Rear work lights wired up so a switch in a boot only at the min but they have been so handy





Right the search for the water leak into the drivers foot well is back on. after the rain at the week end the carpet was wet again. So this time its coming right out, as holding it up with a bit of wood and the windows open isn't going to work this time of year.

It wasn't that bad just the edge wet at the bottom of the A pillar. the white mark is from last time. lol






Then hosed it down and had water dripping down the inside of the A pillar on the the wiring loom that passes though to the door. Its not coming in at the top like before as it comes in with the hose at door mirror height.

Looking closely the door check strap has a big hole behind it, the other side does have a bit of rubber round it but that still don't look sealed completely, The drivers side is missing due the check strap mount being broken when I got it, so I had to weld it up, I Prob should of looked at the properly then but just wanted to stop any more damage from the door / wing.

today I took the door off



Cut the the mount as notice it I the weld was cracked again and the backing part in the pillar all bent.





That is what I was left with have now welding up the little cracks and made it neat and flat. I'm them going to get some thicker plate and welding over it with the mount welding to it.

So the hole will be completely covered and the the check strap fixed to a strong plate, Hopefully 2 fixes in one.

The plate is made



not my welding that's one thing I cant get the hang of and don't enjoy hence never owning a D1 or fender.



Replacement hinges painted and now on also is the replacement door, setting up the hinges was a right pain. still got to come off tomorrow to finish painting. and got to swop the window, frame and door handle



This is why I replaced the door






Striped the old door


Then changed everthing over to the replacement door and refitted the carpet. job done I hope.

 

[steve's P38 RR]

Busy week, fitted all 4 new old man emu shocks and a set of genuine land rover winch spec pink / brown H/D springs and spring retainers
Also changed the engine mount's also genuine land rover items, Easier to do with the suspension turrets off. Painted the chassis behind the shocks and springs also while it was apart.

Here as normal is the pictures

out with the old




Access made to change the engine mounts




Jacking the engine up, all ready removed turbo pipe and fan as per up's tips





New mounts in


wire brushed cleaned and painted chassis behind springs

 

[steve's P38 RR]

In with the new







and the rear's before



after

 

[steve's P38 RR]

These didn't look the best when I was doing the engine and may be I should of done them then but cash was getting tight after the engine rebuild.



These weren't on the bottom when I changed but you can see they do hit the bottom by the 2 dirty dots.

 

[steve's P38 RR]

Thought I'd add some details of minor jobs I've been up to at the end of 2013

Got my sls suspension re-calibrated so now sitting level.

Also replaced both horns after getting cut up by a bmw last week and they both stopped working, I only had one in my garage from breaking my P38 range rover but the other I gave away so made a escort one fit just by changing the plug for a blade connector
and removed the foam water trap's



Then adjusted my steering stops by a couple of mm as tyres were very close to radius arms, Already changed from originals. Now its ready for MOT tomorrow.

So started fitting my new head unit.





Not bloody land rover badge





phone


sat nav a can't get to pick up at the min


more stuff I don't know how to use lol



I now have a D2 size computer just incase the height barrier is in ft in, not m and cm's



Covered / insulated the aux battery, came from a Vauxhall don't think it will make much difference but looks neat.



Also got myself a facelift grill so going to offer that up see what I think.

 

[steve's P38 RR]

Love's it when a plan comes together, I rewired my dvd head unit to run from my aux battery via a relay so the ignition still turns it on as normal but also has a switch on the dash, so I can turn it on without the key and it will only draw power from the aux battery so me and little one can sit and watch pepper pig while mummy does the food shop and the car will (I hope) still start when she's done :tup:. Also repaired and connected the illumination wire to the head unit as it had been cut short by the last owner.



The 12v live is easy, cut from original loom and wired to aux battery via fuse

Then the igniton live cut and feed to tigger the relay

then live to the relay and to the switch fromt the aux battery then the switch live to the radio is either powered when the ignition triggers the relay or so not to use any power from the main battery you can switch the switch, this meaning no need to have keys in at all if your camping or working on it and can still have the radio on and keys in a safe place.

The switch used when key is out it turns radio on,



Not the must exciting mod but very useful.

 

[steve's P38 RR]

This is my front cross member mod to stop the prop hitting when at full drop as the OME shocks are 25mm longer.

 

[steve's P38 RR]

My D2 got its xmas present a day late,



Ordered sat 22nd dec came xmas eve was put straight on charge then fitted boxing day morning, 1000 cca 130 ah

Alphaline Heavy Duty Battery / Alphaline Batteries / Batteries by Application

 

[shenton24]

Youve done a fantasic job mate you should be very proud

 

[andyfox2005]

Great job

 

[steve's P38 RR]

Cheers, been doing more maintance, well it is a land rover so that's most day.

Lately I've been working on my 2 trailers jacking one up to match the height of the D2 and changing the hitch, Then totally re-wired my car trailer with LED lights front and rear, and soon to have new bearings and leaf spring bushes.

But did get time for a bit of D2 work over the weekend, New genuine towing electrics on the D2 (to match the trailers) Old wiring had gone green inside and always collected water in the socket some how, so this time made sure it kept dry.







them rebuilt me sls compressor, started with a good clean out lol. new piston ring and replace the 'stuff' for the dryer.









Not many pictures as was a busy day , but you can see the spring and where it was sat in the last picture which was rusty showing it has been damp in there.

All air lines where blown out before re-fitting compressor to car and order new inners for the sls air filter.

Well I've just ordered a few pieces, amazing what bits add up to.

ERR7047 COVER COOLAND PUMP Brand New (Genuine) 1
ERR6711 RING SEALING WATER PUMP Brand New (Genuine) 1
ERR7098 ENGINE OIL COOLER O RING Brand New (Genuine) 1
LRJ100000 GASKET OIL DRAIN PIPE Brand New (Genuine) 1
ADU6847L WASHER SEALING Brand New (Genuine) 2
PYB100140 COOLING SYSTEM DRAIN PLUG Brand New (Genuine) 1
PYF100860 SEALING WASHER Brand New (Genuine) 1
STC970 AIR SUSPENSION FILTER ASSY Brand New (Genuine) 1
JZL100120 FOAM Brand New (Genuine) 1
BDM100050L DOOR CHECK PIN Brand New (Genuine) 2
1 x FB110201L, BOLT M10 X 100MM FLANGED HEAD
1 x HJI100020LPW, FRONT ARMREST PLUG SMOKESTONE DIS11
1 x BHB700051, DOOR HINGE LOWER REAR DISCO 1+11
SPRING CLIP PLENUM INTAKE DISCO11

Mainly seals and gaskets to the water pump, and a few other bits but nothing exciting for £150

 

[steve's P38 RR]

Well got some bits but not everything to do the water pump so that wont get done this weekend. Have been finishing off some little jobs that I keep forgetting about and used parts that have been sat around my car for months.

The parts




Replaced the missing arm rest grommet



Also the rubber surround around the ignition lock.
And fitted an LED light strip to the glove box in place of the normal light, not as bright as I expected but I like my led interior lights

 

[steve's P38 RR]

Remember my speaker crossovers in the door pocket,



well a bit of this


Now look like this



Also sprayed the new lower tailgate hinge.

 

[steve's P38 RR]

Another few bits



So I fitted a couple today

foam pollen filter and a few extra clip to hopefully make it last.



Then changed the SLS compressor filter.





The old one wasn't worth cleaning again as it was breaking up.



The old and the new



I also cleaned in the panel behind the light, full of dust.

I've heard from a local garage of water getting in to the compressor, there turned the filter upside down ???? with the cap on (not shown in my photos) I can only think this would be worse. So anyone had this problem or moved the filter? Thought about moving mine up about the light, So any water leaking past the light wouldn't go on it.

 

[steve's P38 RR]

Found my oil leak, easy fix and replacing the grommets on the rocker cover to due to taking advice off forums

Looking in my little mirror on a stick (wouldn't of found it without it) cleaned it down and ran the engine for 10 mins and a drip started from the half moon part of the rocker cover gasket.

Then cracked on with the maintance today, well started last night by taking the water pump off,

the leak




began by draining the anti-freeze





Pump out



old pump and cover



New cover



new pump in



also swopped the filter housing as the old one looked liked it had been heli-coiled or something





Then fitting new rocker cover gasket and injector loom as the old one had been in a year and a half and was brit-part so replaced with a oem of peace of mine.

Then removed the tailgate door handle to replace the seal on it as water was getting into the number plate lights, also made a gasket for behind the replace handle its self. Oh there was a bit little tiny bit of dirt behind it.