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Flat Bed Disco 2 Project

Discussion in 'Members Vehicles/Projects' started by DefenderPilot, May 19, 2021.

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  1. DefenderPilot

    DefenderPilot Well-Known Member

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    That's the trolley done. I'm seriously short of space now so the plan is to wheel the chassis outside so I can lower the body onto the trolley. The next phase of work is to get the bodywork sorted and the cab kit permanently fitted. The chassis will have to live outside while this is done so I'm going to block all openings on the engine and cover it with a tarp until it's time to do the chassis swap.

    In other news I think my welding is coming along. I can probably call some of these actual welds now. The following picture is one of my better ones.

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  2. Dave2302

    Dave2302 Active Member

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    That's looking better :)
     
  3. DefenderPilot

    DefenderPilot Well-Known Member

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    I have a lot more space in my garage now. The body is completely off and rolling freely around on it's own stand and the chassis is parked outside in it's winter coat. It's going to be out there for a couple of months so I wanted to protect the drive train from the elements as much as possible.

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  4. Dave2302

    Dave2302 Active Member

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    Nice work maestro ;)

    Looking forward to see the Chassis Build :cool:
     
  5. DefenderPilot

    DefenderPilot Well-Known Member

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    Cheers Dave. Lots of work to do on the body first.
     
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  6. Knappster

    Knappster Well-Known Member Full Member

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    Looking good!

    I’ve got garage envy now too!:D
     
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  7. DefenderPilot

    DefenderPilot Well-Known Member

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    The garage would have had a lot more room had it been built as I wanted it. The wall between the new garage and the existing one was supposed to be removed but the costs were just getting crazy. It went a long way over the original quote to the point where I just said "stop when the outside is done". I may well still do that at some point in the future.
     
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  8. DefenderPilot

    DefenderPilot Well-Known Member

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    So, I had to chop more off the body and now it's on the trolley an unforseen problem has cropped up. The sills need replacing as I've previously mentioned but to chop them out will leave the rear body mounts not attached to anything. At the moment it's only the inner sill panels and a little bit of floor holding each one in place. So what I'm going to do is first construct a frame with 40x40x3 steel angle to take new body panels in 1.5mm sheet steel which will conform to the shape required to fill the gap between the Disco body and the fibre glass rear panel. With all this in place and the rear panel temporarily bolted up I should have a rigid enough structure that I can unbolt the rear body mounts and take the weight off them slightly by supporting the body elsewhere. Then the sills can be safely replaced and the body mounts strengthened by welding extra support pieces to the new sill/floor structure. Sounds complicated but pictures should make things clearer.

    I've refitted the rear panel so that I can make up all the frame pieces ready to weld together. As there is no Disco bodywork left at the bottom for it to attach to I'm going to simplify things by cutting out the marked out sections so that I have flat surfaces to work to. All this welding will be done by someone who knows what they're doing by the way. Mine is nowhere near good enough yet.

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  9. DefenderPilot

    DefenderPilot Well-Known Member

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    Just to add to the previous post. I was worried about the condition of the rear body mounts so I've been looking on line and you can get replacements to weld in so I've ordered a pair of those too.

    Clicky linky thing for body mounts.
     
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  10. Dave2302

    Dave2302 Active Member

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    I did wonder that before I saw your latest piccies ;) Will be some weapon when you're finished :cool:

    Not a bad job to do while you're at this stage. Thanks for the link to the Body Mounts, they are good value as they come with the Rubbers / Bolts etc, I'm going to do mine at some point but they will pass MOT this Feb so not urgent, but I like to buy the bits in then if I get a quiet few days I'm good to go :D
     
  11. DefenderPilot

    DefenderPilot Well-Known Member

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    You've been quiet with yours for a while Dave. I presume you're happy with it for now?
     
  12. Dave2302

    Dave2302 Active Member

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    I actually been really busy with mine :D , yes very very happy, but I continued my thread here ....

    http://www.thed2boysclub.co.uk/viewtopic.php?f=3&t=63930

    Thread Title D15KOE in "Members Own Vehicles" ;)

    I also bought a Nanocom, which does a few things that the Lynx didn't.

    Mainly I moved because there are a lot of fellas in the Highlands who frequent D2BC so I have some local buddies one of whom has several D2's for breaking and has been a great help with odd parts, and I have been helping him with repairs and programming etc ;)
    I actually now own another D2 Auto for breaking, so I can build up a Galvy Chassis with those Axles etc etc, to make my Chassis Swap go a lot quicker when the time comes !!
    I also got a set of BFG Mud / Snow Wheels and Tyres and a set of 18" Wheels / Tarmac Tyres, still yet to collect a lot of it when the weather gets a bit better :)
    Yes I am very happy with my D2 now, I have completed a ton of work including Working Key Plips, which required a BCM as usual I had the weird fault no-one else had had ;)

    D15KOE is now running on the correct NNN ECU, 3 track Throttle Pedal, 4 Wire AAP etc which was a huge improvement in performance and smoother running !!
    This ECU also has Stage 1 Re-map, in Discovery 2 terms, and with the Low Stall H/D Torque Converter D15KOE is pretty darned quick now.

    I've just last week completed a full Single DIN Android 10.1 Head Unit, including Active Sub, TPMS, and Reverse Camera as well as all the other standard benefits of a decent Multimedia system :D
    Facelift Instrument Cluster Fitted.

    Many many blue silicone hoses already fitted, just got the Full Coolant set and new Metal Coolant Manifold Pipework to do when I get time, (pro active job). Work has stopped for a couple weeks to get Tax Return finalised :rolleyes:

    I have a nice pair of Facelift Headlamps to fit too, just got to paint the "Hockey Stick" Trims Rioja Red before getting that job done, have also got a pair of Stainless side bars / steps from a D2 Metropolis to pick up :cool:
     
  13. DefenderPilot

    DefenderPilot Well-Known Member

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    Wow, you have been busy. I'll check out that other forum when I get some time for all the detail, probably when I'm on nights. Usually have a lot of spare time then as not much happens at work during the night.
     
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  14. DefenderPilot

    DefenderPilot Well-Known Member

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    Some more parts arrived today, although it was parcel 1 of 2 and no sign of the other parcel. This one contained some new Adrenaline 4x4 HD front suspension turrets. The other one should have a set of solid HD steering bars in it when (if) it arrives.

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  15. Dave2302

    Dave2302 Active Member

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    Lovely jubbly :cool:

    I plan using those Turrets when it's "chassis time" ;)
    Almost a shame to paint 'em really, but I know what they'll look like in 6 months of exposure in our climate :eek:
     
  16. DefenderPilot

    DefenderPilot Well-Known Member

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    I fell foul of the old "measure twice, cut once" adage today and only measured once. So I cut a piece of 40x40 angle 100mm short. Quite annoying as I didn't have another piece long enough to cut to the correct length. On the upside, it did give me some more welding practice. I welded the two pieces back together then cut it to the correct length. This was part of the frame I constructed today to fill in the gap between the Disco body and the rear panel. I've also tack welded in an extra support between the frame and the trolley so when it's panelled I can take the weight off the rear body mounts. I'll have to wait until next week for the panelling to be done though as my welder isn't free right now. I've also trimmed the rear panel and taken it back off for easy access for all the panelling.

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  17. DefenderPilot

    DefenderPilot Well-Known Member

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    Much shininess arrived today.

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  18. Dave2302

    Dave2302 Active Member

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    I am envious ;)

    Looks great :cool:

    I'm a bit drained, just finished my Bookwork / Tax return last 2-3 days, brain is really fried, so to save me reading back please refresh my memory, is that a "Richards" or ?????????????????

    Did you have to go collect it ? Or delivery ?

    How much do I need to save up ?
    Last time I looked was circa £3000 plus (guesstimate) of £2-3 hundred Diesel for me to drive down with a trailer to collect ? :D
     
  19. DefenderPilot

    DefenderPilot Well-Known Member

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    It's Richards Chassis. I managed to get a local courier (Shetland based that is) to collect and deliver to my door for for £480. Given ferry and fuel costs that's actually cheaper than I could have collected it myself.

    The chassis cost £3000 plus £150 extra for the two bolt in cross members.
     
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  20. Dave2302

    Dave2302 Active Member

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    Thanks for that info ...........

    It seems that nothing has changed much since I looked at this around 6 months ago when I first got D15KOE ;)

    I think in my specific case as there's no ferry involved it will cost approx £200 to 300 to go pick one up myself, depending what I use for a towing vehicle ;)
    LOL if I take my mates Touareg V6 it'll cost me about £400 in diesel :eek: My D15KOE likely around £250, or perhaps take a Car with a tow hitch would be the cheapest method depending upon checking weights.
     
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