LOL maybe once upon a time it was but not so much now...it still faintly smells of dog but at least it's looking good eh ;)
 
Looking good! What is the running total cost so far? You started listing it and I've either missed it or you've stopped! :)
 
Costs so far...
The Discovery Project...Posted by Nicky Smith Sat, September 05, 2015 19:12:13
It has been pointed out to me that I started to keep the costs of my Discovery project at the begging but now that seems to have fallen by the wayside.
They are indeed correct I have not been keeping the costs written down and there are two reasons for this...
1) Brian is my run around unlike Mator (the series 3 rebuild) who was a full rebuild project so Brian really is ongoing all of the time because he is used a great deal week to week.
2) Honestly I just forgot about doing it and reason 1) is just hot air and a big fat excuse for my mistake :)

So after some scratching around and adding up of sums here is the latest cost listing to date...

Discovery Project Cost's
Discovery £700
Remote Batteries £8
2nd Hand 2" lift springs £30
2" lift shocks set £122
New blower unit that was not needed £20
200tdi Prop shaft that still needs to be fitted £10
Track rod ends £9
Winch bumper and Winch £170
Light Bar £20
Oil filter £3
Power steering pump that still needs to be fitted £60
CB £20

Total £1172I wish I had not added that lot up! Still in all fairness that's about all I HAVE to spend on Brian but it wont be because there are always little bits that you want to tweak and I hereby promise I will keep a more thorough costing from now on.
 
Climbing High...
The Discovery Project...Posted by Nicky Smith Mon, September 07, 2015 19:46:56
A friend is breaking an old Discovery so I of course started sniffing around to see what was available. I came away with a few bits which I will add on to the price as and when I use them but things were mostly bought for spares back up of which I have bugger all at the moment but there was one piece that could be used straight away and was something I had been keeping an eye out for.

It was a back door ladder making it easier to get up to the roof rack when I have the kayaks up there. It was a bit rough but what do you want for a tenner and once it was fitted with a quick lick of paint it looks ok...

www


It seems to be able to take the weight of my fat arse climbing up and down it as well which is a bonus because hopefully I won't be falling off due to screw failure any time soon.

Discovery Project Cost's
Discovery £700
Remote Batteries £8
2nd Hand 2" lift springs £30
2" lift shocks set £122
New blower unit that was not needed £20
200tdi Prop shaft that still needs to be fitted £10
Track rod ends £9
Winch bumper and Winch £170
Light Bar £20
Oil filter £3
Power steering pump that still needs to be fitted £60
CB £20
Ladder £10

Total £1182
 
Propshafts & Diffs...
The Discovery Project...Posted by Nicky Smith Sun, September 13, 2015 17:26:24
Today is a good day. I went to a car boot sale with Wifey this morning and managed to pick up a spare wheel for our little Ye Olde Tea Shoppe caravan for the bargain price of seven quid! This made me smile because I only yesterday I priced up and brand new wheel and tyre for sixty five pounds and I thought that was quite reasonable so to save myself that much is superb and I could not believe my eyes when I saw it just lying there next to someone's old clothing and tat!

Then we headed straight out for a brisk three and a half mile walk enjoying that last of the summers warmth walking through woodland...

www

but then we headed home for what needed to be done chore wise....Wifey took the indoor stuff and I ignored what I was supposed to do setting to changing out the Diff and doing the 200tdi rear prop conversion on Brian instead.
I have never changed a diff before but I had been told by my landy friends the whole process and how easy it is to do and they really were quite right!
I soon had off the old rear propshaft and doughnut then the half shafts came out no problem...this really was going too well for working on a Land Rover but undeterred I carried on regardless.
I had to scrape off copious amounts of concrete dried mud from several different off road sites to get to the diff housing bolts but they all played ball after a little encouragement and the diff was soon out. They weigh a bloody ton when you are lying on your back under your motor but if you have a cunning plan like I did you can save yourself some strain and pain by getting a plastic box of sturdy construction of course about the same height as the diff and slide it out and onto it then the same in reverse when refitting the replacement.
With that back in place and sealed up I lined up the 200tdi prop and then refitted the half shafts sealing as I went along. After all the bolts were tightened up I filled the diff with oil and took Brian out for a spin waiting for something to go bang because I had done it wrong but no it was all good! In fact the pick up is much better than before and the bang/play of the old diff has disappeared completely...

www


The whole job only took a couple of hours and that was with me not having done it before or much of a clue moving old bolts that have not been moved for years, I have no doubt that the next time I do it it will be much much quicker.

SO that's another job down on Brain and the track rod ends are next I was going to do theses one evening last week but thought as I was about to set to it that seeing as I had a pair of brand new track rod ends I may as well pick up a heavy duty steering bar and change the lot in one go so if anyone has one kicking around for sale let me know!

A good day had indeed and now I am off to have a beef stew dinner :)
 
I'm going to burn it...
The Discovery Project...Posted by Nicky Smith Fri, September 18, 2015 20:22:49
Seriously I am going to go and buy a gallon of petrol then I am going to go and take one of my Zippo lighters from my collection on the shelf, pour the petrol over Brian making sure the windows are left open so the oxygen moves freely throughout the interior ensuring a good flame stand back and watch him burn back to the depths of hell that he was spawned from.

Why oh why does he have to fight me every bloody step of the way when any work needs doing to him? The rear ball joint is fubar and the banging noise has got to the stage now where I will not drive him any more on the road without doing some repairs. Seeing as I am off to the Land Rover Show in the morning I thought I best hold off on ordering any parts online in case some thing turns up there but this was not going to stop me from making a start on stripping out the old ball joint.

It did indeed begin well enough with the first bolt literally falling out of place but that was where my good fortune finished. Nothing else will move...at all...forever I am sure. The split pin has snapped off in the bolt on the ball joint with a bit sticking out of each side which will be just enough to stop the nut from moving. The second bolt holding on the A frame is seized solid not just solid but a big hammer wont move it solid. It took me over two hours to get to the "sod it I'm not doing any more and walking away" stage and nothing more than that first bolt that fell out within two minutes has moved.

On top of that since I fitted the other quieter rear diff it turns out that the rear wheel bearings were about done because the noise coming out of them is horrendous and in all fairness they did look a bit grim when the half shafts were out. The track rod ends want doing and seeing as the MOT id due in 6 weeks Brian can stay off of the road for now be fixed up properly and serviced to boot. That is of course if I can get this sodding rear ball joint off because if I cannot I am getting the grinder out and chopping him into very small bits that I can put in the bins locally a few bits at a time getting rid of the body slowly but surely making sure they can't be traced back to me.
 
Nil desperandum. Rather than mess about with it on the vehicle lying on your back, it might be easier to take the whole A frame out and deal with it in relative comfort. The 10mm bolts that hold the brackets onto the crossmember are usually OK, or at least you can snap them with an impact wrench as I did to several of mine. The nut that holds the ball joint onto the axle wouldn't come undone on mine so I tried getting it of by chiselling it. This didn't go too quickly so I drilled a couple of little holes in it and that enabled me to split it with a chisel much more easily. Once off, it was easier to get the bracket off the arms. I tried unscrewing the nuts and bolts but the impact wrench merely snapped the ends off, whereupon I was able to hammer the remains out with a spare 10mm bolt (or was it a 12?) used as a drift. You're going to replace ball joint, bolts, bushes etc. presumably, so it doesn't matter if they break. Here's mine https://www.landyzone.co.uk/land-rover/springs-and-things.239690/
 
Round 3...let's call it a draw!
The Discovery Project...Posted by Nicky Smith Sun, September 20, 2015 16:10:40
After a pleasant morning meandering around a car boot sale in Tansley then a cheeky relaxed lunch in the sunshine at Matlock park we arrived home to the task of attacking that bolt stuck in the A frame arm and fulcrum again for Brian.

Well nothing had changed but I did come up with a cunning plan of taking it to the local quick fit and bribing them to have a go at it with an impact gun so off I toddled and they willingly obliged but there was no luck with the gun so they stuck it into a press to see if that would have any effect....nope bugger all moving so after another ten minutes they threw in the hat and I brought the bloody thing back home again.

I then set to having a look around the many sheds that litter my back garden I happened across a rather large sledge hammer. I looked at it and decided that seeing as all other options had been exhausted what the hell did I have to lose? I set to lining up a few good blows to try and loosen up the bolt and I did managed to make it move a bit off of the a frame arm which was progress! Smashing away happily making my back ache and sweating like a pig I managed after 20 hard minutes of sledge swinging to get the fulcrum/rear ball joint off of the arm but with the remnants of the bolt still stuck in it because the only way to make any progress was to grind the bolt head off first.
Pleased with myself I put my now freed a frame arm to one side and thought I would drill out what was left of the bolt in the fulcrum bracket but after chewing quickly through three drill bits I threw in the towel to call it a draw. I got the arm back but the bolt kept the bracket so sod it I will splash out and buy a new one with the ball joint already fitted because I have wasted enough of my time on this now and by the time I spend out on more drill bits etc I will be spending about the same anyway!

Hopefully I will get the part delivered one day this week along with new bolts and maybe just maybe refitted by the weekend...
 
Yes, I got a bracket with the ball joint already fitted, because there's no guarantee that the two will ever come apart. Indeed, I put about 25 tons of force on mine (getting the needle on the press well into the red section on the dial) and it wouldn't come out of the bracket. If you know you're going to replace the bracket anyway it doesn't matter if you cut the old one up. Then you've only got to drift the remains of the bolt out of the arm, so it'll put up less resistance.

Are you changing the bushes at the chassis end? You might as well, while it is in pieces.
 
Yes, I got a bracket with the ball joint already fitted, because there's no guarantee that the two will ever come apart. Indeed, I put about 25 tons of force on mine (getting the needle on the press well into the red section on the dial) and it wouldn't come out of the bracket. If you know you're going to replace the bracket anyway it doesn't matter if you cut the old one up. Then you've only got to drift the remains of the bolt out of the arm, so it'll put up less resistance.

Are you changing the bushes at the chassis end? You might as well, while it is in pieces.
Sledgehammer is more likely to shift it than a press, its the shock, and the different angles on impacts. Helps a lot if you heat the bracket red hot first as well! :)

Agree completely abut the bushes, get it all sorted and it will last for years.
 
Well, I bent my bracket (at room temperature), so I wouldn't want to refit it. If I need another one I might try one of those expensive adjustable ones where you can take up the slack.
 
I Win!
The Discovery Project...Posted by Nicky Smith Wed, September 23, 2015 19:47:32
A little brown package was waiting for me when I got home last night from work full of all sorts of shiny things along with the new fulcrum and rear ball joint for Brian. So today when I got in from work at a reasonable hour with some daylight left I thought it would just be a matter of mere minutes to put it all back together getting Brian back onto the road once again...I was sorely mistaken.

The first bolt dropped through like a charm but the second bolt went in a bit but then got stuck, I mean really stuck fast so it wouldn't move in any direction. With a sigh I stripped the whole A frame back off and set to getting the bolt back out with a rather large hammer and a strong sense of de ja vu. With that done I then drilled out the holes again clearing any remnants of crappy rust copper greasing the lot up and the bolts dropped back into place no problem at all. That was more than could be said for the rear ball joint arm that I just could not get the right angle on so I removed the A frame bolts on the chassis again and dropping the ball joint into place. With that done I then had to lever the A frame mounts back into position with a pry bar slotting everything into the place again.
That sounded quite easy didn't it but I can assure you it was fifteen minutes of messing around moving bits around straining like mad to keep the arms still long enough to slot the bolts through with my other hand but a little patience a lot of internal bad language that eventually turned into maniacal laughter and all was well again.

With aching arms I then set to tightening up all of the nuts and bolts then literally throwing all of the tools I used into the back of the Disco, jumping into the driving seat and going off with bated breath for a quick spin to see if the awful loud banging had finally gone. I am glad to say it has! What a difference it has made it is pleasurable to drive once again so now all I have to do is replace the rear wheel bearings and track rod ends...bearings first I think as they are quite noisy so lets see how quickly I can bugger that up and make a meal out of it ;)
 
Great, that's another little job finished and out of the way then. Should be alright for a few years at least. It feels good driving around on nice new bushes and suspension joints that you've fixed yourself.
 
Yep hopefully it should last a while in the long run! We shall see eh, I am sure there will always be plenty to do!
 
First Bar
The Discovery Project...Posted by Nicky Smith Sun, September 27, 2015 19:21:54
It hadn't been going too badly if I am honest. The other evening I decided to tackle the rear wheel bearings and it all went rather swimmingly with the half shafts coming straight off along with their bolts then the problem was instantly obvious with the bearing locking nuts being loose to the touch. I tightened them up and Bob's your Uncle problem solved.

With that done I decided to tackle the track rod ends next on the front steering bar. There was one on each of the bars to be done but I thought start at the front and work my way back it wont take long. Turns out Brian decided it was time for a rematch after me winning the first one of the rear ball joint and my god did he put up a fight. The first track rod end came off of the hub easy enough but would not move off of the steering rod so I decided to remove the whole arm and tackle it off of the motor itself. This is where the real problems began, the nut came away easy enough but I could not get the whole track rod end out of the steering box arm for love nor money. To make things a little more interesting I didn't have the room to whack a hammer on the end to shock it out because of the steering guard and even on full lock it didn't come away clear enough to give it a good whack.
After hitting my own hand and thumb a few times I gave up and decided to buy a ball joint splitter to help out but seeing as all of the shops were now closed it would have to be bought on Sunday morning.

First things first though it was Sunday morning after all so we took advantage of the warm day heading off to a car boot sale. Wifey and I fancied a bit more of a lazy day for a change so we meandered around the sale and to my amazement I came across a chap selling tools who had two types of ball joint splitters for sale brand new so a deal was struck for the pair costing me a grand total of ten quid! This saved me a trip to the shops and is the second time in two visits I have found what I needed at this car boot...someone must be helping me out from somewhere!
When we got home Wifey headed back out to visit her mother whilst I insisted that I had to sort out Brian (score to me I got out of an in laws visit!) and I set to attacking the stubborn arsed track rod end hitting my bloody left thumb with a hammer straight out of the gate (Devil getting me back for the in law thing).

A few good whacks with the fork type of splitter and the arm was free. Using a rather large hammer again I managed to quickly persuade the old track rod end that it's time was up and off it came quite willingly! After counting the turns off and fitting the new one I decided that seeing as the arm was off I may as well replace both ends or I may be doing the awkward job again before long. This does mean I have to buy another pair for the next arm but for the cost at least I will know it's all been done and that's some good peace of mind.

Next jobs then will be track rod ends on the other bar along with replacing the trailing arm bushes and bolts. There is also the sediment filter bypass to resolve and a good service but I really do think that is all that sits on the list for now. No no I am lying the lift pump might want looking at but I will see how the filter bypass does first.
Don't you just love owning a Land Rover!
 

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