Corkys New Motor

After my intro thread
https://www.landyzone.co.uk/land-rover/willing-to-learn-with-10-thumbs.289406/

time to start a project thread

50th Anniversary Discovery 300 in Atlantis blue with leather interior.
Interior needs very little to bring it up to scratch.
The exterior needs quite a bit of fettling.

So far I've

Changed the ignition barrel as the old one hada snapped key in it and started with a screwdriver

Rear windows wouldn't work and with the help of a thread on this forum located a dry joint in the window ecu


Joint resoldered and all good again.

Loads of work to do but thats a start

Both passenger door locks had problems but again using the search facility was able to diagnose faulty lock springs.
Rear door spring was broken was broken and took about 20 mins to repair.
The front door spring looked ok but eventually managed to strip out the lock and replace the spring and door now works as it should.

Had a few hours to spare
Mnaged to remove front bumper and both front wings to assess how bad or good the inner wings are.
On closer inspection both have some rust issues but only at this stage require patching which should see it through for a few years.
The battery tray is shot to pieces.
The hammer test revealed a hole at the top and bottom of the inner drivers side, top patched and treated so far



Having a few hours today also managed to strip out the centre console as the handbrake felt 'wooly' found a plastic nut which would appear to have came from the set up.
Dropped the front prop and removed the hand brake drum for a look, looks like the seal to the transfer box has a slight weep, so stripped the gubbins out and new seal ordered.
Handbrake lever inside cabin rebuilt and plastic nut put in its rightful place and all seems to be correct now.
So the weekend can begin.

Jobs for next week (hopefully)

1. Finish drivers inner wing and battery tray.
2. Fit new rear seal at trasfer box and reassemble handbrake drum.
3. Work out a strategy to replace the sills as both shot.
4. Replace rear bumper lights as one lens has been melted at some point and both have lost the factory fitted connectors.

Like to alternate between welding and mechanical jobs so as to keep interested.

Transfer box seal replaced. Removed the brake shoes to clean up the backplate and dropped one of the bloody pins that hold the shoes on. Cant find it anywhere.
Anyone have just a single pin going spare, save me having to buy a whole fitting kit!

Been chopping out the drivers side sill and so far have been left with



Removed the front and back seats to give me better access


and also the doors to get at the spot welds


Dont think I've finished chopping but getting there - I hope



Propshaft and brake drum still off as still can't find the bloody shoe pin!

Anyway onwards and upwards

120 x 60 x 3.2 x 1500 (2no.) Box section ordered £42 in total pick up tomorrow

Its been a while but a bit of an update
Patched Inner front offside wing
Fabricated new battery tray
Offside Sill replaced with Box section
Bottom of A pillar replaced
Fuel Tank cradle fabricated after dropping fuel tank (which helped with a few bits of welding)
Offside front and rear floor sections cut out and sections replaced
Rear offside Inner wing patched
Offside chassis rail required a few patches
New brake caliper and disc and brake line replaced on the offside.
New Trailing arm bushes fitted
Replaced the Rear seat belt as existing belt frayed.
Surprisingly the boot floor was in very good condition and was original.
After completing the offside was able to start the Discovery to allow me to turn it around in the garage to work on the nearside.
Will try and upload some photos of the offside repairs.

Have been beasting in over the past few weeks and sorting out some dodgy electrics and bodge jobs in readiness for the MOT.
Someone in the past has fitted a switch marked on/off and ran two wires from it up behind the steering wheel
Removed the instrument cluster today for a look see and found this shambles

Bit of a head scratcher this one,the right hand plug looks to have been completely cut off and all wiring rejoined using connector blocks.
The anomaly being the two wires from the on off switch have been joined to either end of the black/red wire marked number 2 on the plug.
Spent the afternoon soldering and heat shrinking all the wiring back together again.

Another view of the mess



Before I rejoin the black/red wire can anyone shed any light on this bodge?

Suppose on the plus side, I've now got a pile of connector blocks

Update time MOT Pass
Another Land Rover saved from the Scrap yard and a 50th Anniversary one at that.

The rebuild consisted of
welding to front inner wings
Constructing and welding a new battery tray
Welding to rear inner wings
New Sills
Welding to chassis
2 body mounts replaced

New bonnet release cable
New anti roll bar bushes front and back
New Ignition switch
Rear window electrical fault rectified
New rear brake discs, calipers, pads a pipes
New fuel pump
New oil cooler pipes
New Power Steering box
New rear Trailing arm bushes
New exhaust
New front nearside stub axle
Front nearside swivel and wheel bearings
New track rod ends
New fuel filler hose
New rear screen washer return valve and Nozzle
New battery
Full service including gearbox transfer box and axle oils all replaced.
Timing belt replaced.
and loads of other small repairs carried out that didn't require any parts.

Vehicle was MOT'd this morning and passed with flying colours with no advisories.
I will post the remaining build pictures when I have a chance but for now too busy enjoying my new Discovery