Robb's disco improvement thread

[robbh]

Anyways. Update time.

Rear axle was an arse to get out but it's out!






More to come later

 

[robbh]

Here's what I've done so far today.

As I has this much access to most of the chassis/underside I thought it'd be rude not to slap some paint on so her back end (by the time I'm done) will have had a good service.

So spent most of last night rubbing her down. then gave the chassis some love with some rust treatment. I've used fertan as I've heard good things about it.

Then this morning was up bright and early to slap some zinc phosphate primer on followed by a top coat.







Once that was dry (well almost dry) it was time to start getting this lovely recon rear axle put on.





Just need to tighten everything up whack the diff in which is now painted.




Springs on, new calipers when they arrive, bilstein shocks on, then run the new brake lines in the non abs format.
Will get some more done this evening/tomorrow and hopefully get her back down on all four wheels.

 

[robbh]

Good evening all.

Little more done today. But then once it came to remove abs etc....... Well you'll see soon enough

Anyways this morning I got the diff fitted in the recon axle with new gasket and some sealant. This f***er ain't leaking!







Unfortunately I've had to put on the knackered old springs for now. Until I get all the bits for a lift kit. Planning on a 2" suspension lift and a 2" body lift for now. Should give me some choice when it comes to tyres.
Main reason for not going with a silly suspension lift is I can't be arsed with all the additional kit I'd need and I'd rather spend the money on air lockers.


Next came to removing the abs. And this is turning out to be more of a Ballache than planned but that's land rovers for ya.
Started by making some new lines to run across the rear axle. Although still waiting for my new calipers and clips to hold it all on.




And that's high temp paint I bought earlier for the new calipers. May as well make em nice whilst they are new

Then proceeded to remove the abs unit on the inner wing.





Now loads of room! Then removed the washer bottle and found this

 

[robbh]

Homemade rock/treesliders!







Just need to get the silly plastic trim things off and work out how to mount them. Thinking of bolt on for now just in case (sorry when) the sills need replacing in future.
Then they need a few more welds cleaning up and a paint.

 

[aaronmorris]

Good work so far dude.
Only just seen this thread but should be good judging by other work you've done in the past
Got to wonder how that clutch get stuck on like that though

 

[Co-Pang-Yang]

Subscribing to this thread looks excellent work so far.

I've never liked the auto box in my ES and on the way back from Billing it finally poo poo'd itself completely lol.
Bought everything (bar centre console) to convert it to a manual so once I've cleared space up the unit that's gonna going in for some surgery.
My abs doesn't work so very keep to watch your progress on this. Also have a rear locker and AEU2522 front and rear setup that I plan on fitting so could be a busy few months lol.

Can't wait to see more of your project unfold

 

[robbh]

Good work so far dude.
Only just seen this thread but should be good judging by other work you've done in the past
Got to wonder how that clutch get stuck on like that though

Cheers Aaron! Got plenty more to do yet mind. Plenty of steel to buy also to build my own off road gear rather than buy it.
No idea but was a right pain getting that box off!

Subscribing to this thread looks excellent work so far.

I've never liked the auto box in my ES and on the way back from Billing it finally poo poo'd itself completely lol.
Bought everything (bar centre console) to convert it to a manual so once I've cleared space up the unit that's gonna going in for some surgery.
My abs doesn't work so very keep to watch your progress on this. Also have a rear locker and AEU2522 front and rear setup that I plan on fitting so could be a busy few months lol.

Can't wait to see more of your project unfold

Cheers mate!
Never been a fan of auto boxes myself so never bought one. Have always preferred a manual. So yea get on and fit it

Abs removal is simpler than I thought if not a plan because of all the rusty brake lines, so far it's been a case of remove the pump. Run a new primary circuit line from m/c to bias valve as the old one is way too long and a pain to flare. Remove 1 brake line to rear and fit a 3 way t piece. And make a longer line from n/s front wing to bias valve. That's pretty much it. oh and remove the bulb from the dash All new rear axle lines etc are optional. Necessary in my case as they were so corroded!

As for the air locker...... Which one have you got? I was thinking of getting the one from ashcroft along with the diy pegging kit. Seems to be a good one from what people say. If I can afford it I may get all the HD shafts etc from them too but that's mega money!

As for front setup. Not sure what I want to do. Was thinking maybe an lsd in the front rather than locker. Along with upgraded internals. The AEU2522 route maybe. Still unsure.

But yea slowly but surely I will get there with this project. Once the brakes are sorted the plan is to try and get her through an mot.

 

[ifloochies]

Good work so far dude.

Got to wonder how that clutch get stuck on like that though

Was asking myself the same question... Doing it by myself on the driveway like he did, I would probably have given up on the job at that point when I realized it was stuck on.
Anyway, fabulous job mate and love the pace of your work.

 

[aaronmorris]

Cheers Aaron! Got plenty more to do yet mind. Plenty of steel to buy also to build my own off road gear rather than buy it.
No idea but was a right pain getting that box off!

I can imagine
Sounds good Rob, I also like to make my own stuff if I can. Not only cheaper but more satisfaction and exactly how you want them.
Although I generally have ideas then nothing happens

Was asking myself the same question... Doing it by myself on the driveway like he did, I would probably have given up on the job at that point when I realized it was stuck on.
Anyway, fabulous job mate and love the pace of your work.

You're a landrover owner, Yer can't give up that easy

 

[robbh]

Was asking myself the same question... Doing it by myself on the driveway like he did, I would probably have given up on the job at that point when I realized it was stuck on.
Anyway, fabulous job mate and love the pace of your work.

Haha! Thing is though I'm more stubborn than the box was so it came off eventually Not gonna lie though, it would have been so much easier on 4 post lift

I can imagine
Sounds good Rob, I also like to make my own stuff if I can. Not only cheaper but more satisfaction and exactly how you want them.
Although I generally have ideas then nothing happens



You're a landrover owner, Yer can't give up that easy

Exactly. Definitely more satisfaction in building your own bits. And I too have lots of ideas. Whether they get done or not is another matter

On the plus side I will be ordering a terrafirma 2" lift kit from mm4x4 at the end of the week so at least that will happen...... And maybe a few other bits. may as well spend all my wages now I suppose

Also want to get some marine ply so I can plyline my boot van style. Should stop tools/spares/recovery gear from flying around off road.

 

[Co-Pang-Yang]

Yer same, only bought this one cause I knew the truck and was silly cheap.

Ok I was hoping it was a relativity simple task and it sounds like it is.
Bulb already came out for last MOT lol, constant problems is the reason I want to get rid of it.
Mr. noisey (who's thread I am glued too) has complely braided his lines throughout which I quite like the idea of.
Did yours already have a bias valve on the bulkhead as mine doesn't seem too.

Er pretty sure it's an Ashcroft, it's actually mr. noisey's old setup so pretty well tested.
I've love HD shafts, hubs, etc. but mega money as you say.
Pegging is still something I don't understand lol, really need to read up on it.
I'm gonna leave the front diff open for the forseeable future unless a cheap locker comes up. Rather put the money toward trick suspension, winch then strengthing the rear axle.

Yep never ending project like mine. Gotta sort dragging it up the hard and rebuilding it ready for winter!

 

[aaronmorris]

Exactly. Definitely more satisfaction in building your own bits. And I too have lots of ideas. Whether they get done or not is another matter

On the plus side I will be ordering a terrafirma 2" lift kit from mm4x4 at the end of the week so at least that will happen...... And maybe a few other bits. may as well spend all my wages now I suppose

Also want to get some marine ply so I can plyline my boot van style. Should stop tools/spares/recovery gear from flying around off road.

Tell me about it, I've not worked for about 4 months and it's fair to say I'm skint
Well actually I've been 2/3/4 days a week at work for the last 3 weeks.

Nice to have some money coming in but it's ever so tempting to buy some goodies
But need to control myself as job is on for anther couple of weeks then no work again.

I've got a list as long as my arm that I want
First port of call is get the bloody thing on the road though

 

[robbh]

Yer same, only bought this one cause I knew the truck and was silly cheap.

Ok I was hoping it was a relativity simple task and it sounds like it is.
Bulb already came out for last MOT lol, constant problems is the reason I want to get rid of it.
Mr. noisey (who's thread I am glued too) has complely braided his lines throughout which I quite like the idea of.
Did yours already have a bias valve on the bulkhead as mine doesn't seem too.

Er pretty sure it's an Ashcroft, it's actually mr. noisey's old setup so pretty well tested.
I've love HD shafts, hubs, etc. but mega money as you say.
Pegging is still something I don't understand lol, really need to read up on it.
I'm gonna leave the front diff open for the forseeable future unless a cheap locker comes up. Rather put the money toward trick suspension, winch then strengthing the rear axle.

Yep never ending project like mine. Gotta sort dragging it up the hard and rebuilding it ready for winter!

Yea mate its very simple! If you need any help with it if you get round to it don't hesitate to give me a shout.

Ah yes Mr Noisy's thread....... I am also glued to it. And to be perfectly honest after rereading his entire thread over the last few days I'm so tempted to give llama4x4 a call and do the sexual braided brake line mod also

I will ring them Friday and get a price!

And yep I already had the bias valve. It should be on the passenger side inner wing. Near the exhaust downpipe. If not got a spare you could have if you need one.

Ah nice. Cool. Definitely be good then.

Regards diff pegging. It's very simple. Simply you will have a phosphor bronze pad I believe sat against the back of the crownwheel to prevent the Crown wheel flexing and riding up the pinion and causing damage if the transmission is shock loaded. Usually more likely to happen with big/extreme muds fitted.

Trick suspension is nice but once I've done the 2" lift it'll stay that way until I'm on lockers. Then maybe if I feel the need may also upgrade suspension.

Discos are always never ending..... Tis always something to mod, fix, weld up, or bodge

 

[robbh]

Brand spanking new calipers turnt up this afternoon. Not bad @ £70 posted off eBay.






Then proceeded to paint them in hope they will stay nice and not rust solid.






New suspension was ordered today also
And now tempted to replace all brake lines with braided hose. (blaming Mr Noisy and his thread for this)

 

[robbh]

Tell me about it, I've not worked for about 4 months and it's fair to say I'm skint
Well actually I've been 2/3/4 days a week at work for the last 3 weeks.

Nice to have some money coming in but it's ever so tempting to buy some goodies
But need to control myself as job is on for anther couple of weeks then no work again.

I've got a list as long as my arm that I want
First port of call is get the bloody thing on the road though

Tbf though you have done an immense job on that conversion
A lot of time and money gone into it that's for sure.

I think my list maybe longer..... tis always something I see browsing on here or the parts sites that I see and think, yea I like that I shall add it too me list.

Damn land rovers!

 

[Co-Pang-Yang]

Cheers bud, I shall be sure to bend your ear if I come a cropper.
But as you say looks pretty simple.
Should be made a lot easier for me as the engine and box are coming out for the manual conversion so will de-abs it at the same.

I find his thread is simply a list of everything I want to do to mine but don't have the time/skill/money to achieve lol.
Ha ha let me know a price on the lines!!

Ok I'll have a look, remember on my old truck it was on the bulk head. But didn't check the inner wing so will have a look.

Cheers for the info, seeing as I'm getting 33" extremes for mine should probably look into it.

Mines currently at 2" which is fine but had +5 rears on my old truck and the difference it made at off road sites was awesome!
I miss it so wanna go up a level and have it alround this time.

 

[robbh]

Cheers bud, I shall be sure to bend your ear if I come a cropper.
But as you say looks pretty simple.
Should be made a lot easier for me as the engine and box are coming out for the manual conversion so will de-abs it at the same.

I find his thread is simply a list of everything I want to do to mine but don't have the time/skill/money to achieve lol.
Ha ha let me know a price on the lines!!

Ok I'll have a look, remember on my old truck it was on the bulk head. But didn't check the inner wing so will have a look.

Cheers for the info, seeing as I'm getting 33" extremes for mine should probably look into it.

Mines currently at 2" which is fine but had +5 rears on my old truck and the difference it made at off road sites was awesome!
I miss it so wanna go up a level and have it alround this time.

No worries bud!

Definitely will be easier with the engine out the lines running round the back of the head are a bit of a pig to get at.
And yep agreed about his thread! tis an awesome beast that disco.

Regarding brake lines...... I've been on the phone to to Dave @llama4x4 already. I couldn't wait.

Anyway depending on how simple (harder to repair) or complicated (easier to repair) you want to make it will depend on how much it costs.
Price will range from £150 to £250 depending on what I want. To keep it cheap just have long hoses with minimal connections.
Although I can see mine costing the upper end of the scale. Want it easy to repair so plan to have small replaceable sections near the caliper. Just in case something is snapped or ripped off.

I'd love 33's but for now the a/t's will have to do money needs spending elsewhere atm.

Was thinking of buying longer shocks but decided to just buy a kit. Maybe will upgrade to longer shocks soon.

 

[Co-Pang-Yang]

Yer that's what I'm thinking. Hoping to get really carried away and undersealing the body whilst the underside is bare.

Hmmm something I'll have to think about. Reckon I'd want the ease of repair as well. Local hydrolics place might be able to help, I'll look into it.

Currently running 35x12.5 MT's but they were only ever going to be temperary. There's a set of 285 extremes for sale near me that I'm hoping to get. Nearly new and a good saving over brand new.

Longer shocks are well worth it, Terraferma's seem to be a good choice for the money.

 

[robbh]

Update.

Today have been tidying up the sills ready for working out how to fit the homemade rock/treesliders. Had a couple of small holes to patch but nothing major. Mainly under the rear doors.

Forgot to take photos whilst I was doing it. But here's it finished.





Also rear calipers are now done and ready to fit.







Also been on the phone again to Dave @llama4x4 this evening and should have new braided brake hoses delivered some time next week.
For a complete set to replace every single line cost just shy of £240 Inc a spare. But is being made exactly how I want it and as easy to repair as possible incase the worst should happen.
All lines from chassis to calipers are exactly the same so is easy to change just the one.

 

[robbh]

Also cleaned out the engine bay with the jet washer this evening.




Then I'm going to get on and fit this this weekend as my lift kit hasn't arrived yet