1997 discovery 1 300tdi complete build

So last June I bought a 300tdi only 87k miles on the clock from New in need of a lot of welding work started stripping it out then the typical Welsh rain hit project stopped. Now the ground has dried out and we are on lock down I thought it was time to start getting it done, so chucked a battery on and she fired straight up drove her round on to to drive where she is now in the resting place ready for the body to be lifted off. Pictures shall start to follow as of tomorrow bear with me as doing it all from my phone. My first question is what is the best way to lift body off sills are none existent and I only have an engine crane and a trolley jack

Following!

Well today the body was off and seen how bad it really was pictures of chassis shall follow tomorrow

So a bit more done today but run out of welding gas

So another bit welded in today before the wind picked up and a bit of rain appeared so all on stop may look into some sort of gazebo so wind and rain won't be an issue

So had better weather today over cast but no wind so got a little more done, now run out of sanding discs for the grinder so no more welding time for a cuppa and then may strip the rear axle off the chassis

This is far too familiar! Good luck

It's by far the worst d1 chassis I've seen just struggling to find replacement chassis parts like the rear cross member may have to make one and working out what's meant to be where and there's 2 rods on bushes that come down from body to chassis which I'm struggling to find

I can match it lol

the rods coming down from body to chassis on your rear cross member are seat belt anchors. If you were to replace rear cross member, you’d need to weld in new brackets to bolt them into.
Have a look at my build thread ‘steep learning curve’ from say 10 pages in.
few things:

• if welding around that rear crossmember that on main chassis rails, you’ll need to reinforce with strengtheners. The strengtheners are 90 degree crescents welded in about a foot long. I skinned inside with 3mm then 2mm ontop here. Then welded h sections in on the span (again have a look on thread)
• I wouldn’t bother trying to weld inside spring seats if they’re shot. The rot will be eating inside out so chop them off n put in the new rail.
• Wire brush then get plus gas on your a frame nut and soak for a week before going for it. Your impact socket won’t fit but I bought a standard smaller silver line hex that did.
• You won’t be able to do full inspection on that cross member and fix properly with axle on way and you’ll also need to drop cradle and tank

You can see part of strengtheners here

I know the ones for the rear seat belt but there are 2 further forward under the front seats the last repair you see I have put strengtheners in to it the rear cross member I mean is the one the towbar bolts through will have a look at your thread when I get the laptop out

It’s the trans cross member under front seat which I think it bolt in? Atleast is on a fender

theres some rust there
keep up the good work
I've wondered what my 200 D1's are like in similar places

Rich.

It sits behind the gearbox crossmember it's basically the back fof the front seats on the inside of the chassis rails

Cheers zed yes a fair bit of rust but as you know the typical Ammanford weather has not been fair so only getting started now really

Sorry! I was reading it as it was a cross member and know where you mean!

Ahh I see well when I lifted the body off both of these sheared have hunted high and low and can't find them finding chassis parts it's either superceded or no longer available joy of an old car I suppose

When I see brave souls re-joining specks of rust in a sea of thin-air back together I am filled with awe and admiration.
It would always gnaw at me that the larger pieces are just waiting their chance to dissolve as well. The urge for a replacement chassis would eat at me like road-salt on a Disco Chassis.
All I can say is "Bravo!" and watch in wonder at the skills and dedication displayed. Thanks for sharing.

I would love to buy a new chassis for it but funds just don't allow so for now it will all be taken back to bare shiny (sort of) metal red oxide primer and then 2 coats of chassis black hoping to have the chassis complete by end of the summer