Just a few pics from the repair work I'm doing (nearly done) on the disco after this.

So new parts bought have been:

• Paddock performance vented front brake discs
• Bearmach Defender calipers (SEB500460 & 470)
• Mintex pads
• Encompass 4x4 Steering bars, TR ends and damper relocator
• Britpart SuperGaz steering damper
• Some more synthetic diff oil (diff pan leak got worse!) and power steeering fluid.
• New to me, second hand steering box - a local ebay bargain which resulted in me gaining some Fallow Deer stalking too!
• 1Ltr Fertan with a cavity spray attachment
• 2.5L of Bonda zinc resin primer

I also bought a few new tools to, as I didn't want to be trying to do the job and struggling, so a new 1000W Clarke impact wrench and a few sockets, spanners, grindy things and general workshop cleaners/lubes/degreasers were added to the shopping list too.


There was no particular order to the way I've done the work, so I started with the brakes first, by painting up the BM brake calipers with some high temp silver aluminium paint - 2 coats should keep them from crumbling for a couple of years.


Then I fitted the Discs and made a couple of new brake lines for the new calipers - I was hoping that Clive (pressbrake) was going to be able to sell me some braided brake lines too, but apparently his machine has been

stolen and he's not getting another one as it's not worth it?!


With brake discs and calipers I put the pads in, except one of the four pads wouldn't fit - turns out the inside of that half of the caliper wasn't accurately machined, so I took the grinder to the pad backing and made it fit!! I'll see if I can get it replaced.


Then I got onto the inner sill body mount - I was going to get a replacement from froggats (easyon panel) but they couldn't get it to me for the weekend, so I made my own instead - I had some 2mm steel for the mount and a bit of 3mm for the reinforced top of the mount.


Here's the old:




A bit of cutting after a project binky style CAD template, a bit of bashing with a BFH and a form, and a vice later and I had the basic shape.


Then I cut out a bit of 3mm mild, cleaned it up and zinc/ali painted before gluing it on top of the new mount with the melty thing.


Before I could get the remnants of the old one off, I had to make some big holes in the floor to get in there with the bleedin grinder. :Cry:


I remember the old mount now - it's about 2.5 years old! That was a froggatts easyon mount, and it really hasn't lasted very well. The reason for that of course is that I was in a bit of a hurry when it went together, so didn't do any proper rust prevention! oops... Looks like I'll need to do the other side too at some point this summer, along with the bottom of the door posts. Feck.


So, back to the mount: I clamped it in place, and marked with a drill the place for the new hole to go. Plenty of cutting oil needed to get through the now 5mm thick steel with me little 32mm hole saw!


No room for all the pics in this post...!

So, then I welded the mount in alongside the new closing plate that sat in front of it.


Bet you can't guess what I do for a living?
That's right, I'm a hairdresser.




I find old PC cases are very good for this kind of thing - I've got quite a lot of pentium 2 & 3 vintage PC steel in this disco!


I cut a lump of the inner sill away as it wasn't doing a great deal, so I just put the new mount directly on the box section and welded up the rest of the edges.



Time for copious amounts of fertan before closing up and painting with Bonda. I'll seal over the under side with Tigerseal (inner sill area) and stone chip, unless I can get hold of some Bilt hamber underseal first, or dinitrol if not.


Then I got onto the steering box which is when all the fun started. Considering it was the first of fecking june, I could be convinced it was actually mid november last night! 40-50mph winds and rain dumping down made for a really long night. I gave up at 11pm, as I couldn't really feel my hands anymore, the rain was dripping directly into my ear and I was wet through. Ontop of that, using greasy tools with cold, wet hands is a really stupid idea!


I got the old steering box off with a bit of messing around, and got the new one on after trying to undo the lower bolt on the arm infront of it - I wanted to fit my 'new' steering guard (had it about a year now!). After nearly twisting the head off the bolt, I gave up on that idea to attack it on another day.


So anyway, I got the Encompass 4x4 30mm mild steel steering arms on - they are SERIOUSLY impressive, and then gave in and went indoors for a hot bath!

Did you use the SIP?

Hey Rich! No, not this time, but I did get it working again - Thanks again bud!

This was all welded with a SnapOn 185 mig, as that had the gas bottle connected up!

Well I'm pleased it's working for you. Good luck with the repairs.

Yeah the little SIP is good after a few new parts, though it did throw a bit of a wobbler on the trailer rebuild I did recently! It may have been asking a bit much of it though now I think about it