Steve's disco 2 rebuild

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DefenderPilot said:
Looks really good. How will it mount? You making mounts yourself or will it bolt to roof bars?
Click to expand...

Thanks, I've made some gutter mounts for it, cut them out of some 100x50 aluminium box section and folded some 2mm stainless clamps with 8mm threaded bar welded on. Will need to take off the roof bars as they will clash with the new rack.
 
This sequence of pictures shows how I make up brake pipe flares. This was a quick and dirty one for show, as you can see the hole in the flare is off centre. This how I did them all on my disco and I had no leaks on first fitment.

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upload_2023-1-16_10-27-53.jpeg


upload_2023-1-16_10-28-21.jpeg


upload_2023-1-16_10-29-14.jpeg


upload_2023-1-16_10-29-43.jpeg


upload_2023-1-16_10-30-48.jpeg
 
Thanks for that, it's the same as mine then. Don't have any problems with the kunifer pipe, think it struggles to to the steel pipe. I will make up new ones out of the modulator. Thanks again
 
Evening all, just a quick update, ordered 5 new tyres from blackcircles yesterday so hopefully they should be arriving soon (estimated tomorrow). Went for 265x60r18 toyo open country at+.
Will be refurbing the wheels as they are a bit crusty in places so they will be coming off this weekend.
Also the roofrack is currently at the powdercoaters which should be back before the weekend. That's all ready to go on as I removed the roof bars last weekend and sealed the holes up.
Sealed them by putting a 10mm s/s bolt into the hole, filling it up with sika sealant and then capping it off with a plastic bung (the kind of bung you get for capping a 40mm metal tube, found them at work so thought I'd give them a go).



 
Evening all, here's a little preview of the roofrack which I will fit on Saturday. Powdercoaters dropped it off yesterday (after having it for about 3 weeks).
Looks alot better now it's painted.
They also picked up my wheels which they will recoat for me so waiting for them to come back (probably another 3 weeks, lol).
Anyway here's the pics:-









Will update on Saturday when it's fitted with some more pics
 
Here it is, rack is bolted down. Havent properly wired up the lights yet, want the switch to be in the back so i will make a switch/extra socket panel where the plastic removable vent is near the back door. Just need to work out the best way to get the wires into the vehicle, was thinking where the original roof rails bolted through but not sure if I can make it waterproof.








 
So after 3 weeks of waiting, I've now got the wheels back and fitted them. Had a bit of welding to do in the rear wheel arch which is now sorted. Sprayed the arches and the inner edge of the sills with dinitrol 4941. It's all pretty much finished now apart from some small jobs like getting the tracking roughly lined up and checking all the bolts underneath.
Now for the bad news, first thing the rf receiver has packed up (key light flashes when button pressed but has no effect on vehicle), opened it up and can see some green crusty corrosion on the board so I've ordered one and hopefully will get it soon, pain in the arse having to enter the EKA code.
Second thing is I have an oil leak coming from the bellhousing. My luck it will be the rear main seal. So will look at that last, can't wait, lol.
Anyone know if it could be the sump gasket?



 
Quick update, been doing all the finishing off jobs over the last couple of weekends. Fitted the new rf receiver so that's sorted the locking problem out, did the tracking using a bit of string (will get it properly done when it's on the road).
Yesterday I replaced the sump gasket (and did the oil pump bolt while I was in there) which looks like has fixed the oil leak, fingers crossed. Did notice the power steering pipe was rubbing on the corner of the sump, which was wearing the pipe away. Will need to be replaced soon as its probably worn about half way through. Temporarily fixed it with a hose clip
IMG_20230527_193815.jpg


Just need to mot and tax it now, hopefully will get it done Saturday after next
 
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