Steve's disco 2 rebuild

steve24v · Oct 12, 2021

Started rebuilding my disco td5 back in May due to the usual rust issues. Owned it for about a year and a half now. Drove it daily until the mot ran out without any problems. When I bought it the front prop needed new ujs and I fitted a new headlining.
As of now I have taken the body off the chassis as the back end is completely shot. I have a new galv richards chassis which I'm building back up and replacing with new parts where needed.
progress is slow as I can only work on it at weekends. Will post some pics once I've figured out how
Cheers
Steve

steve24v · Oct 12, 2021

Front bumper was a pain to remove with all the screws rusted solid, all the body mount bolts came undone fine apart from the outrigger ones which just snapped.

steve24v · Oct 12, 2021

Chassis out

Chassis rails fuel tank side had huge holes in, previous owners mastic'd some metal plate over it. Chassis now in the skip

steve24v · Oct 12, 2021

New chassis

T-washed, primed and painted

steve24v · Oct 12, 2021

Had a go at doing the steering joints, made my own press tool to do the job as I'm too tight to buy one. Worked well with the use of a lump hammer

Put the new ones in the freezer before fitting to make it easier. Job went easier than I thought it would

steve24v · Oct 12, 2021

Done a bit of electrolysis rust removal on some parts, well impressed with the results

steve24v · Oct 12, 2021

So this is where I am at the moment

Engine and gearbox is on the chassis now, waiting for new cv joints to arrive so I can finish the front axle. Will have new wheel bearings fitted all round.
Need to make a new fuel tank undertray to fit the tank, will be making it out of Aluminum.
Fixed the wiring loom onto chassis and removed any unwanted wires such as the ace and air suspension as they have been deleted from a previous owner.
Waiting for some new brake pipe to arrive so I can make some new ones as the old ones were just resting on the chassis rails without any clips holding it in place

Knappster · Oct 13, 2021

Looking good!

Nice of the previous owners to bodge the chassis...

FlatbedPilot · Oct 13, 2021

Good job. I'm going to be getting a new chassis for mine soon. How long did it take for you to get yours?

steve24v · Oct 13, 2021

Knappster said:
Looking good!

Nice of the previous owners to bodge the chassis...

Would of been good if they attempted to bodge it, don't think they even tried

steve24v · Oct 13, 2021

DefenderPilot said:
Good job. I'm going to be getting a new chassis for mine soon. How long did it take for you to get yours?

Took just over 3 months, they welded a bracket on wrong and noticed it after it was galvanised so had to wait for them to sort that out.
IN case you don't know you don't get the gearbox crossmembers included, and I've had to ream some holes out to get the suspension bolts through

marjon · Oct 13, 2021

Looking great so far

.

Better get it undercover Winters coming

.

J

FlatbedPilot · Oct 13, 2021

steve24v said:
Took just over 3 months, they welded a bracket on wrong and noticed it after it was galvanised so had to wait for them to sort that out.
IN case you don't know you don't get the gearbox crossmembers included, and I've had to ream some holes out to get the suspension bolts through

Cheers. I know you have to pay extra for the cross members. I'll be ordering those with it. If it takes that long I should get my order in sooner I suppose. I'm hoping to have mine finished and on the road by the 1st weekend of June next year. That's when the Shetland Classic Car Show is. I usually go along with the Shetland Land Rover Club to help out and put my car on their stand.

steve24v · Oct 13, 2021

I phoned them to order mine, he told me it would be 3 months wait, as they were busy. Might be different for you, I would order it sooner though as you will only be waiting for it when you need it, like I was

steve24v · Oct 13, 2021

Are you replacing anything else while you can or just swapping the chassis?

steve24v · Oct 13, 2021

marjon said:
Looking great so far.

Better get it undercover Winters coming.

Thanks,
If I could get it undercover I would have done, rebuilt my 90 in the shed which was nice, wouldn't be able to lift the body off the disco in there though.
I will just struggle in the wind and rain

J

FlatbedPilot · Oct 13, 2021

steve24v said:
Are you replacing anything else while you can or just swapping the chassis?

Oh yes, plenty. Have a look here.

Oh, and did you have to pay a deposit for the chassis?

steve24v · Oct 13, 2021

DefenderPilot said:
Oh yes, plenty. Have a look here.

Oh, and did you have to pay a deposit for the chassis?

Not a lot then ,
interesting build you have there like the look of the flat bed.

Didn't have to pay a deposit, just ordered it and payed in full when it was ready to be collected/delivered

steve24v · Oct 17, 2021

Put new cv's on today, couldn't get them off with a hammer so ended up disc cutting them off.

Front axle all complete now, with new bearings. I will do the hub nut later once I've robbed a big enough torque wrench.
Got the brake lines to do next

steve24v · Oct 21, 2021

Will be looking at replacing the brake lines this weekend, has anyone used 5hitpart braided flexi hoses? They don't have the locking lug that is next to the banjo bolt that stops the pipe from turning on the caliper. Are the goodridge hoses the same if not I will pay the extra and get them (or just get standard ones)

Steve's disco 2 rebuild

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