Steve's disco 2 rebuild

steve24v · Mar 28, 2022

Hi mate thanks, quite enjoy doing it (plus I'm too tight to pay someone else lol). Hoping it wasn't going to take this long but can only work on it Saturdays.
Next big job on it is to make a stainless exhaust then I can put the body back down on it. Just need to get some silencers and a stainless cat then I can start making it.
Finally finished painting the underside last weekend too, so thats the 5h1tty job done

tyregeezer · Mar 28, 2022

I think many D2 and D3s get scrapped because of the labour charges. I could not afford to run a Land rover if i had to garage Never used a garage in 57 years only for tyre fitting. I am looking for another td5 sold mine about a year ago regretted it ever since (wife reminds me every day) ran perfect for 4 years only issues were rust. wish i had seen your thread before i sold it, again great work keep the faith TY

steve24v · Mar 28, 2022

Totally agree, I was a bit reluctant to get a d2 from the horror stories what I've heard, but it hasn't been that bad of a rebuild so far. I never use garages unless I've had too on any of my cars, (they charged about £200 for a service on my wife's kia which was just an oil change and pollen filter,. Had to have it to keep the warrenty).
Sometimes think why I bother doing it with the cost of parts but can't think of any other vehicle which you can comfortably get 3 kids (plus all their cr4p) and 2 springer spaniels in. Reluctantly sold my rebuilt 90 as it only had 2 seats so wasn't practical.
Thanks for the support

steve24v · Apr 7, 2022

Some shiny stuff arrived today

Need to get some flanges lasered out at work and buy some gaskets then weld it all up. Using some 2.5" tube off my dads vw t5 (sill bars) which he replaced, so I won't have to buy any tubing.

steve24v · Apr 7, 2022

Turns out the tube is 2 1/4", but managed to source a piece of 2.5" about 1800mm long for £20

steve24v · Apr 23, 2022

Finally some decent progress has been made today that isnt painting. Started cutting and tacking up the exhaust. waiting for some v band clamps to arrive, was going to use flange joints but these will mean I don't need to replace gaskets if I need to remove the exhaust. Will weld it up during the week after work if I get a chance,
Anyway here's the pics-

Flange I got laser cut at work

steve24v · Apr 23, 2022

Just need to do the backbox section and make a tailpipe, will do this when the body is back on the chassis

Chazb5046 · Apr 28, 2022

This is awesome Steve. Really nice to see a D2 being cared for. Good luck!!!

steve24v · Apr 28, 2022

Chazb5046 said:
This is awesome Steve. Really nice to see a D2 being cared for. Good luck!!!

Thanks mate, appreciate the interest.

steve24v · May 5, 2022

The exhaust v clamps finally arrived today, plus I made some hanger bars up at work. So the plan this Saturday is to finish tacking the exhaust up then I can weld it up fully during the week when I get a chance, then hopefully start putting the chassis back under the body.
Also last weekend I sprayed the underside of the body with dinitrol and removed the foam cover on the bulkhead in the engine bay as it was falling to bits. Just need to finish painting the inner wings when I get really bored

steve24v · May 8, 2022

Had a good weekend, got the exhaust tacked up ready for welding (minus the tail pipe section which I will do later).
Then managed to get the body almost lowered to the chassis, just need to connect the gearbox wires, hi/low and handbrake cable up then I can lower the front down.
Also ordered a new clutch master and slave cylinder with a new flexi pipe.
Here's the pics-

steve24v · May 8, 2022

steve24v · May 15, 2022

So after a year on stands, the body is now back on the chassis. Took a while lowering it down having to lower one jack at a time and making sure the mounting points lined up.
Fitted a new master and slave cylinder joined up with a flexi pipe.
Realised I need to make some spacers for the fuel tank cradle to lower it as it sat a little too high.
Also managed to start welding the exhaust up today, nearly done just have a couple more welds to do then I can put it back on

steve24v · May 28, 2022

Ive spent today plugging all the wires up and refitting all the coolant hoses (swapping the pain in the ar5e spring clips for jubilee clips as I go). That metal coolant hose contraption took me ages to refit.
Also faffed about changing the bolts that hold the headlights on as the old ones were bodged in with a mixture of fixings that had rusted in or snapped off.
Tomorrow I'm planning to connect the brake lines up (need to renew the osf as the union has rotted) and finish off bolting the body to chassis.

steve24v · Jun 4, 2022

Looks like next weekends job will be fun.
Will be 'borrowing' some 100 x 60 box section from work to weld in. I was going to fold a section up but as the floor needs doing might as well use box section.
Not sure what to do with the carpet once I've repaired the floor/sill, the sponge like material is soaking wet. Tempted to get rid of the backing of the carpet and stick it back down to the floor (stick on velcro strips maybe?) to make it easy to remove.
Anyone have any ideas? Don't want to just paint it

FlatbedPilot · Jun 6, 2022

Looks like your floor has suffered in the same areas as mine. I just cleaned and dried my carpet and put it back as was when it was all repaired. I'll just keep an eye on it.

steve24v · Jun 6, 2022

Think the nearside is worse, a bit of the footwell will need cutting out plating. Will sort that side once I've repaired the offside. I have the carpet drying off, if it gets wet again I will take the spongy material off, don't want to be welding it up anytime soon.

steve24v · Jun 11, 2022

So, I butchered the offside sill off today ready for the bit of 100x60 box I nicked from work. Worse but was cutting out the section behind the 'A' pillar. Hopefully I will be welding it up next weekend

steve24v · Jun 18, 2022

Got the offside sill welded in today, just need to fabricate some body mounts which I will do once I've replaced the nearside sill. The size of the sill (if anyone is interested) is 1410mm long by 100 x 60, I folded a bit of 17x17 2mm angle and tacked on the sill for the door seal.
Anyway here's the pics -

Will be cutting off the nearside sill next weekend, maybe tack the new one on if I don't run out of time

Interceptorxj · Jun 20, 2022

Someone is a dab hand with the old metal glue.

Steve's disco 2 rebuild

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