Steve's disco 2 rebuild

Had a late start today but got a bit more done. Folded some sections up for the roofrack at work during the week and mocked it up today to see what it will look like, need to cut it all to size and then weld it up. Also got the front bumper mounts and winch plate tacked on.

Evening all, been a while since last update. However, I have been busy finishing off the front bumber which will be going for powdercoating next week so hopefully that will be back before next weekend.
Also been making the roof rack which is almost finished, just need to alter the mounting brackets and do a bit more welding then get it powdercoated.
Today I gave the engine an oil/filter change (while the rain was pi55in' down).

Hopefully here's some pics of the bumper (don't have a pic of it finished, has a slot cut in for the winch rope).
Will get a pic of the roofrack tomorrow if I get time

At last, got the bumber back from the powdercoaters and fitted it this afternoon, just need to tighten the bolts up and wire up the lights

Great work mate spot on fabrication

Thanks mate, glad it's finished at long last (didn't get much time in December to work on it).
Next thing on the list is the roofrack, which is almost finished

Looks like a fun project.

Both your bumpers look very professional. The roof rack looks like it'll be just as good. Looking forward to seeing that done and fitted. Finally getting somewhere with my roof rack now after months of inactivity.

DefenderPilot said:

Both your bumpers look very professional. The roof rack looks like it'll be just as good. Looking forward to seeing that done and fitted. Finally getting somewhere with my roof rack now after months of inactivity.

Click to expand...

Thanks, hopefully the roofrack will be strong enough, all a bit of guess work. Need to alter the clamp brackets then I can trial fit it. Will take some pics when I get a chance.
While you're here, did you make new brake pipes that come out of the abs modulator?

steve24v said:

While you're here, did you make new brake pipes that come out of the abs modulator?

Click to expand...

Mostly. All the pipes to each wheel are new. I reused the three that go across the bulkhead to the master cylinder and the drivers side front wheel, with a new section from the joint in that one.

The two lines that go to the back wheels are one run each. I dispensed with the chassis to body flexi sections.

I've made new pipes and have new flexis, but had to use the the steel pipes that come out of the abs modulator to each wheel, as my Fisher Price flaring tool won't do the correct flare that goes into the modulator. Had to cut 3 of these pipes down as they were rotted out on the ends then flared them to join to a flexi, but now have a slight leak. Being steel I'm struggling to get a good join. Didnt know if you made kunifer pipes and flared the ends into the modulator, if so what tool did you use?
Thanks

I'll get a photo of my flaring kit later. Don't think it has any brand name on it but it's probably similar to what you have. It was just a cheap kit I got on ebay.

The new brake pipes are cupro-nickel so quite easy to flare.

Here you go. Once I clamp the pipe up I clamp the clamp in a vise to make it easier to work with. And that's probably the only time in my whole life that I'll ever use the word "clamp" three times in the same sentence.

https://www.ebay.co.uk/itm/36207735...dzkuqnhstm&var=&widget_ver=artemis&media=Copy

This is the same as mine , should invest in a better one really.
So a normal double flare works ok in the modulator then? Looked more like a cone shape I seem to remember which I couldn't replicate

Looking at your kit, looks like you can put a near enough flare using 1 of the 3 bits at the bottom left of the box (unless I'm looking at it wrong)

I just flared both modulator and caliper end the same. The disc shaped pipe inserts allow you to make good flares every time without collapsing the pipe end. I'll set one up tomorrow on a bit of waste brake pipe and take some pictures so you can see how it works and the flare produced.

Thank you, that would be great. My set might be worn out a bit, sometimes the flare doesn't stay central to the pipe unless you get lucky (either that or it's just crap lol)

Oops. I seem to have forgotten something today. Sorry about that. I'll try again tomorrow.

DefenderPilot said:

Oops. I seem to have forgotten something today. Sorry about that. I'll try again tomorrow.

Click to expand...

No problem mate, have many other things to get on with, so whenever you have time, thanks again.

Here's a sneak peek at the roofrack, still have some welding to do on it and trial fit it onto the disco

Looks really good. How will it mount? You making mounts yourself or will it bolt to roof bars?