steve24v
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- Romsey Hampshire
Haha, I do it for a living (not on vehicles though) so it's not that bad.
Steve's disco 2 rebuild
- Thread starter steve24v
- Start date
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Haha, I do it for a living (not on vehicles though) so it's not that bad.
steve24v
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- 540
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- Romsey Hampshire
Drivers side sill/floor is now painted and the carpet and seat is fixed back in.
Stripped the passenger side area out and as expected its rotted in places. Need to weld a plate in the footwell. A - b pillar section of the sill was quite solid, but the section near the rear wheel arch was completely gone. Looks like someone in the past has tried to fix the inner sill/body mount area (clearly failed, just like all the other bodges I've had to sort out).
Also, anyone know what the long plug is for under the passenger seat? Wasn't connected to anything
Cheers
Steve
Stripped the passenger side area out and as expected its rotted in places. Need to weld a plate in the footwell. A - b pillar section of the sill was quite solid, but the section near the rear wheel arch was completely gone. Looks like someone in the past has tried to fix the inner sill/body mount area (clearly failed, just like all the other bodges I've had to sort out).
Also, anyone know what the long plug is for under the passenger seat? Wasn't connected to anything
Cheers
Steve
steve24v
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- 540
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- Romsey Hampshire
Thanks, it's slowly getting there
steve24v
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- Posts
- 540
- Location
- Romsey Hampshire
Nearside sill is now welded in, had to cut more out than the offside as bits of floor sections were rotted. Might look at making some body mounts at work if I get a chance next week.
Just need to weld in some plate for the front and back footwells and slap some paint over it, then thats the welding done (unless I find anymore rot of course).
Just need to weld in some plate for the front and back footwells and slap some paint over it, then thats the welding done (unless I find anymore rot of course).
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steve24v
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- 540
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- Romsey Hampshire
Finished off the welding today on the nearside floor, all painted up ready for the carpet and seat to be refitted. Still need to make the body mounts.
Also managed to borrow a torque wrench, so the wheel hubs are now torqued up to 490nm.
Also managed to borrow a torque wrench, so the wheel hubs are now torqued up to 490nm.
kurtjohnson10
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Great job and great thread - many thanks for sharing. Keep up the good work 
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- Shetland
I'm suffering from deja vu looking at those last lot of pictures. Wish I'd thought of using box section for the sills. Would have saved me some time and money. Good work.
steve24v
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- 540
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- Romsey Hampshire
Thanks mate, originally I was going to fold up some sill sections at work but figured it would be alot easier to use box as there would be less welding. Hardest part was cutting the area around the a pillars (struggled to get the grinder in there).
steve24v
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- 540
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- Romsey Hampshire
Been a while since I've worked on my disco, been away kayaking. last couple of weeks ive been in hospital twice for chest infections (possible pneumonia) been off work this last week struggling to breathe.
Anyway got a bit done today, fabricated and welded the body mounts onto the offside sill, would have been easier if they were welded on before the sills were fitted but nevermind. Also got the passenger front seat fitted back in.
Won't be doing anything to it for the next 3 weekends, got to go on holiday with the in laws, then going to Dorset steam fair when we are back
Anyway got a bit done today, fabricated and welded the body mounts onto the offside sill, would have been easier if they were welded on before the sills were fitted but nevermind. Also got the passenger front seat fitted back in.
Won't be doing anything to it for the next 3 weekends, got to go on holiday with the in laws, then going to Dorset steam fair when we are back
codfather79
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- 649
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- Kent
Excellent rebuilding
Just wish I had had the courage to do it to my d2.
Just wish I had had the courage to do it to my d2.
steve24v
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- 540
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- Romsey Hampshire
Thanks mate, it's not too bad to rebuild, just alot more expensive than when I did my 90. And a load more electric cr4p lol
codfather79
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- Kent
I bet if I had done my d2 it would have been a dam sight cheaper than Noel the S3. Looks like everything that is ungalvaised steel has rotted
tyregeezer
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- Rural Norfolk
Hi mate great work, good idea box sills, once the rot has gone one of the worst jobs will be out of the way. Great thread, best of luck and take care of yourself TY
steve24v
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- 540
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- Romsey Hampshire
Hi mate, thanks. Hopefully the rust is sorted now, there's a little patch in the offside rear wheel arch that needs sorting.
Will be back working on it on Saturday so I should get the last 2 body mounts made and welded on the sill.
Also need to finish off the exhaust (tail section) so might take a look at that to
Will be back working on it on Saturday so I should get the last 2 body mounts made and welded on the sill.
Also need to finish off the exhaust (tail section) so might take a look at that to
steve24v
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- 540
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- Romsey Hampshire
Finally done, took longer than expected as I had to make the tube insert thing that goes into the rubber mount, (lost the old one). Will paint it all up tomorrow unless it's pi55in' down with rain.
steve24v
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- 540
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- Romsey Hampshire
Bled the power steering system today, had a little incident with the clear pipe I put on the bleed nipple that popped off sending fluid everywhere. Managed to stop it quickly so wasn't too bad.
Also moved it for the first time since I parked it up and gave it a quick clean as it was a bit mouldy.
Still need to bleed the brakes, planning on doing this next weekend.
Couple of electrical gremlins have appeared, will ask in the discovery forum section.
Also moved it for the first time since I parked it up and gave it a quick clean as it was a bit mouldy.
Still need to bleed the brakes, planning on doing this next weekend.
Couple of electrical gremlins have appeared, will ask in the discovery forum section.
steve24v
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- Posts
- 540
- Location
- Romsey Hampshire
Made some progress today, bled the brakes after fitting new calipers (old ones needed a rebuild ideally as some were seizing on after bleeding them). Still need to do a power bleed which I will do later.
Started to make a rear bumper, folded some 4mm steel up at work yesterday, just need to make the ends up and some brackets to mount it to the chassis.
Fitted a new brake light switch as the old one packed up on me last weekend.
Started to make a rear bumper, folded some 4mm steel up at work yesterday, just need to make the ends up and some brackets to mount it to the chassis.
Fitted a new brake light switch as the old one packed up on me last weekend.
steve24v
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- Posts
- 540
- Location
- Romsey Hampshire
Evening all, did some work on the bumper today, mitred the ends and cut some corner bits which still need finishing off.
I've decided to use the standard bumper lights so measured and cut out the holes for them (measured once and cut about 3 times to get it right).
Then made some brackets to mount to the chassis, just need to reinforce it a bit.
Also need to make and weld in a plate to use the 14mm bolt holes on the xmember. Not sure what to do for a recovery point yet, maybe just a hoop in the middle of the bumper will do. Hopefully I can get it finished next weekend, anyway here's some pics:
I've decided to use the standard bumper lights so measured and cut out the holes for them (measured once and cut about 3 times to get it right
).Then made some brackets to mount to the chassis, just need to reinforce it a bit.
Also need to make and weld in a plate to use the 14mm bolt holes on the xmember. Not sure what to do for a recovery point yet, maybe just a hoop in the middle of the bumper will do. Hopefully I can get it finished next weekend, anyway here's some pics:
steve24v
Well-Known Member
- Posts
- 540
- Location
- Romsey Hampshire
