Alex458
Member
Been a while but been busy with work and not had much time to tinker with the disco.
Finally got the paperwork back from the DVLA, took 4 Months but they changed all the details with no additional stuff needed so I’m happy!
I’ve been using the disco daily for the past few weeks to commute to work and back as it’s mainly back lanes and only around 8 miles so if anything did go wrong I’m not too far from home or work.
things on the whole have been good, I’ve turned the injector pump up a bit and turned the boost pin which has livened things up nicely.
I’ve fitted an air tank and regulator, piped it up to enable me to use the air assist clutch which is superb I must say.
Finished the exhaust off, although I’m going to change the tip to 4” angle cut I think.
Also made a cover for where the turbo and air filter stuck through the bonnet, not 100% happy with it though and want to re draw and make it full width of the bonnet and match the curve to the swage line.
Just bought a second hand bonnet too in the same colour as mine has a nasty dent in the front and is bent along length where my father in law accidentally removed a 12” gate post!
Other bits I will be doing in the coming weeks are,
Transfer box ratio change - got a 1.003 gearset on the way from Ashcrofts as it’s a low revving engine it’s too low geared currently for my liking.
3200 RPM Pump Govener spring - current one in the pump limits me to 2500rpm and starts to de-fuel around 2100. Coupled with the higher ratio transfer box should be good.
Injectors - got a set of +50hp injectors on the way from the states, not that I want the extra 50hp but it gives me headroom and The current injectors are rather tired and I have a little more diesel knock than I should.
Also going to retime the diese pump when I fit the injectors as I think it’s over advanced, managed to get the correct adapter to screw in the back of the ve pump to then fit a DTi to measure the timing accurately.
Finally got the paperwork back from the DVLA, took 4 Months but they changed all the details with no additional stuff needed so I’m happy!
I’ve been using the disco daily for the past few weeks to commute to work and back as it’s mainly back lanes and only around 8 miles so if anything did go wrong I’m not too far from home or work.
things on the whole have been good, I’ve turned the injector pump up a bit and turned the boost pin which has livened things up nicely.
I’ve fitted an air tank and regulator, piped it up to enable me to use the air assist clutch which is superb I must say.
Finished the exhaust off, although I’m going to change the tip to 4” angle cut I think.
Also made a cover for where the turbo and air filter stuck through the bonnet, not 100% happy with it though and want to re draw and make it full width of the bonnet and match the curve to the swage line.
Just bought a second hand bonnet too in the same colour as mine has a nasty dent in the front and is bent along length where my father in law accidentally removed a 12” gate post!
Other bits I will be doing in the coming weeks are,
Transfer box ratio change - got a 1.003 gearset on the way from Ashcrofts as it’s a low revving engine it’s too low geared currently for my liking.
3200 RPM Pump Govener spring - current one in the pump limits me to 2500rpm and starts to de-fuel around 2100. Coupled with the higher ratio transfer box should be good.
Injectors - got a set of +50hp injectors on the way from the states, not that I want the extra 50hp but it gives me headroom and The current injectors are rather tired and I have a little more diesel knock than I should.
Also going to retime the diese pump when I fit the injectors as I think it’s over advanced, managed to get the correct adapter to screw in the back of the ve pump to then fit a DTi to measure the timing accurately.
Alex458
Member
Well even thought the wife collared me to do jobs today I still managed a few hours on the disco!
Took the top off the diesel pump and changed the governer spring to the 3200rpm one
This has transformed the way the engine behaves, throttle response is faster and it really does pick it’s feet up now being able to rev higher and having more fuel up top. Sounds flipping awesome too!
Checked the diesel pump timing and it was quite advanced so I’ve pulled it back a bit and things sound much better diesel knock wise but will still change the injectors when they show up I think.
Fitted a boost gauge and EGT gauge too now I’m starting to play with things a bit more just so I know things are safe
Cut the stainless pipe ready to modify the exhaust too.
Might attempt to remove and rebuild the transfer box tomorrow as all the bits from Ashcroft have arrived now, although that depends on how many things the wife insists I do instead!
Took the top off the diesel pump and changed the governer spring to the 3200rpm one
This has transformed the way the engine behaves, throttle response is faster and it really does pick it’s feet up now being able to rev higher and having more fuel up top. Sounds flipping awesome too!
Checked the diesel pump timing and it was quite advanced so I’ve pulled it back a bit and things sound much better diesel knock wise but will still change the injectors when they show up I think.
Fitted a boost gauge and EGT gauge too now I’m starting to play with things a bit more just so I know things are safe
Cut the stainless pipe ready to modify the exhaust too.
Might attempt to remove and rebuild the transfer box tomorrow as all the bits from Ashcroft have arrived now, although that depends on how many things the wife insists I do instead!
Alex458
Member
Well not yet delved into the transfer box, decided to do that next weekend now.
I did however get a few other bits done, managed to get the original Rev gauge working, it’s not smack on accurate but close enough that I’m happy.
Was really frustrating it not working at all, Even though the alternator I’m using off a TD5 had no provision for a tach I managed to take the back off and tap into one of the windings before the regulator which is AC voltage which is what the original V8 Rev gauge would have used.
Fitted the bigger tip to the exhaust which I’m really happy how it looks now, has the added bonus of sounding slightly deeper too.
Slowly starting to tackle the list of jobs still to do, I’m sure it will never be truly finished but that’s all part of the fun!
I did however get a few other bits done, managed to get the original Rev gauge working, it’s not smack on accurate but close enough that I’m happy.
Was really frustrating it not working at all, Even though the alternator I’m using off a TD5 had no provision for a tach I managed to take the back off and tap into one of the windings before the regulator which is AC voltage which is what the original V8 Rev gauge would have used.
Fitted the bigger tip to the exhaust which I’m really happy how it looks now, has the added bonus of sounding slightly deeper too.
Slowly starting to tackle the list of jobs still to do, I’m sure it will never be truly finished but that’s all part of the fun!
ifloochies
Well-Known Member
Amazing stuff...
Don't know how I missed this thread, but sure glad I found it now
Don't know how I missed this thread, but sure glad I found it now
Alex458
Member
To be fair I’ve changed the thread title, a few years ago when I first started the thread, I wouldn’t have ever imagined I would have done this conversion so the original title did not give you any clues!
More jobs on the cards this weekend,
The transfer box is coming out to do the ratio change, Change the gearbox oil, measure up for an intercooler and pipe work finally, wire up the reverse lights to the gearbox.
Once I’ve got an intercooler in and the new injectors in I’ll be tweaking it some more.
Currently runs about 16psi of boost and EGT hasn’t broken 500degC uphill under full load, it goes rather well at the moment but there’s more to be had I think.
Will be looking into what to do axle wise shortly too I would imagine, not sure how much the standard diffs will take if I upgrade the halfshafts?
More jobs on the cards this weekend,
The transfer box is coming out to do the ratio change, Change the gearbox oil, measure up for an intercooler and pipe work finally, wire up the reverse lights to the gearbox.
Once I’ve got an intercooler in and the new injectors in I’ll be tweaking it some more.
Currently runs about 16psi of boost and EGT hasn’t broken 500degC uphill under full load, it goes rather well at the moment but there’s more to be had I think.
Will be looking into what to do axle wise shortly too I would imagine, not sure how much the standard diffs will take if I upgrade the halfshafts?
Colmhd1955
Member
My Gawd!! Epic work! I can almost smell the oil. A fantastic thread, how the hell did I miss this one?
Alex458
Member
Well I’ve had an interesting weekend!
Started to remove the transfer box to change the ratio and just thought I would check that my input gear would work with the 1.003 gearset...
Turns out it won’t and I need a 28 tooth input gear not the 32 I currently have
Not to worry I thought, I’ll order one from ashcrofts when i finish for the day.
I then carried on and changed the gearbox oil as it’s been quite noisy in neutral with the clutch up, I’d put this down to me having quite thin oil in it.
When I pulled the drain plug I think more metal came out than oil! The gearbox has always been a tad on the noisy side but this has proved it’s got internal issues.
I could get another or rebuild this one but it just so happens I have a leyland roadrunner here due to be scrapped that has the T5x spicer box in!
I’ve read this is a much stronger box than the zf5 and has better ratios, although it Will mean another adapter plate has to be made along with a few changes as the gearbox is free I think it would be stupid not to do it.
may have found a billet input gear for the lt230 for the spicer too
Started to remove the transfer box to change the ratio and just thought I would check that my input gear would work with the 1.003 gearset...
Turns out it won’t and I need a 28 tooth input gear not the 32 I currently have
Not to worry I thought, I’ll order one from ashcrofts when i finish for the day.
I then carried on and changed the gearbox oil as it’s been quite noisy in neutral with the clutch up, I’d put this down to me having quite thin oil in it.
When I pulled the drain plug I think more metal came out than oil! The gearbox has always been a tad on the noisy side but this has proved it’s got internal issues.
I could get another or rebuild this one but it just so happens I have a leyland roadrunner here due to be scrapped that has the T5x spicer box in!
I’ve read this is a much stronger box than the zf5 and has better ratios, although it Will mean another adapter plate has to be made along with a few changes as the gearbox is free I think it would be stupid not to do it.
may have found a billet input gear for the lt230 for the spicer too
