Steve's disco 2 rebuild

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steve24v

Well-Known Member
Posts
540
Location
Romsey Hampshire
Started rebuilding my disco td5 back in May due to the usual rust issues. Owned it for about a year and a half now. Drove it daily until the mot ran out without any problems. When I bought it the front prop needed new ujs and I fitted a new headlining.
As of now I have taken the body off the chassis as the back end is completely shot. I have a new galv richards chassis which I'm building back up and replacing with new parts where needed.
progress is slow as I can only work on it at weekends. Will post some pics once I've figured out how
Cheers
Steve
 
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Front bumper was a pain to remove with all the screws rusted solid, all the body mount bolts came undone fine apart from the outrigger ones which just snapped.
 
Had a go at doing the steering joints, made my own press tool to do the job as I'm too tight to buy one. Worked well with the use of a lump hammer
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Put the new ones in the freezer before fitting to make it easier. Job went easier than I thought it would
 
So this is where I am at the moment
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Engine and gearbox is on the chassis now, waiting for new cv joints to arrive so I can finish the front axle. Will have new wheel bearings fitted all round.
Need to make a new fuel tank undertray to fit the tank, will be making it out of Aluminum.
Fixed the wiring loom onto chassis and removed any unwanted wires such as the ace and air suspension as they have been deleted from a previous owner.
Waiting for some new brake pipe to arrive so I can make some new ones as the old ones were just resting on the chassis rails without any clips holding it in place
 
Good job. I'm going to be getting a new chassis for mine soon. How long did it take for you to get yours?

Took just over 3 months, they welded a bracket on wrong and noticed it after it was galvanised so had to wait for them to sort that out.
IN case you don't know you don't get the gearbox crossmembers included, and I've had to ream some holes out to get the suspension bolts through
 
Took just over 3 months, they welded a bracket on wrong and noticed it after it was galvanised so had to wait for them to sort that out.
IN case you don't know you don't get the gearbox crossmembers included, and I've had to ream some holes out to get the suspension bolts through

Cheers. I know you have to pay extra for the cross members. I'll be ordering those with it. If it takes that long I should get my order in sooner I suppose. I'm hoping to have mine finished and on the road by the 1st weekend of June next year. That's when the Shetland Classic Car Show is. I usually go along with the Shetland Land Rover Club to help out and put my car on their stand.
 
I phoned them to order mine, he told me it would be 3 months wait, as they were busy. Might be different for you, I would order it sooner though as you will only be waiting for it when you need it, like I was
 
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Put new cv's on today, couldn't get them off with a hammer so ended up disc cutting them off.
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Front axle all complete now, with new bearings. I will do the hub nut later once I've robbed a big enough torque wrench.
Got the brake lines to do next
 
Will be looking at replacing the brake lines this weekend, has anyone used 5hitpart braided flexi hoses? They don't have the locking lug that is next to the banjo bolt that stops the pipe from turning on the caliper. Are the goodridge hoses the same if not I will pay the extra and get them (or just get standard ones)
 
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