Disco 1 week 3 of my MOT "prep"

ironie · Sep 14, 2018

I have been deep down the rabbit hole for the last several weeks, replacing cills and addressing various rot,
and the endless, "well, while I'm here, I might as well" Today it was the fuel tank bracket

wanna see something scary?

slice bolt and salvage bracket

decide to address chassis rot So far this is the worst I have found.
clean and prepped

drill 4 plug weld holes

nail it on

use cardboard for a heat shield for the fuel tank. I was comfortable, didn't want to get up
put out fire, get up, get a piece of metal to use for heat shield, finish off

Clean up, eat dinner and post on LandyZone. A good days work.
Hope I haven't bored anyone to much.
Present state of Disco, and my ehm.. 'workshop'

Thanks for tuning in. More to come.

kevstar · Sep 14, 2018

Been a busy boy I see it keep at it matey

currymunster · Sep 14, 2018

Looking good chum! I know how you feel. Chin up and do yourself proud

ironie · Sep 15, 2018

Indeed I have Kevstar, and indeed I will.
Big box of work

Thanks currymunster
The day before yesterday was a new rotor and bearing inspection and clean and repack
and of course a new hub seal

fracking caliper bolt will never be a problem again.
Old rotor was a mot advisory on the last three mot's

I suspect it was original equipment.
I haven't quite made up my mind what is on the agenda for today.
Thanks again for looking. Keep the shiny side up mates!

currymunster · Sep 15, 2018

Oh my word - every thing you are doing so far I did last year. My rear discs looked exactly like that. To the point where the pads were lose and rattling around. The caliper had worn away so had to buy two new ones. Did all my bushes as well, hope you got a press. I found it easier to remove with out the press but used the press to fit them. Luckily my local indi garage let'sle use there press no problem. Make sure the holes for the Panhard rod
Aren't worn. Weld a washer on if so.
Happy days

ironie · Sep 16, 2018

yesterday was sort of a bust didn't get much done, dropped the rear prop to replace the doughnut
and didn't much like the look of the locknuts on the brake drum either, so will replace them

something about that rubs me wrong

Today started off with a hour and a half replacing grommets and reinforcing my tarp/workshop.
Then I spent the rest of the day closing out open jobs.

Had a few awkward position welds on floor to finish off.

holes drilled for inner fender skirt (when cars start flying, I will call them wings

)

Truth be told, I feel no pressing need to close this off, but I will get around to it I suppose

A few random welds here and there.

needed a 10mil spacer for the fuel tank strap bracket. I know, my sanity is in doubt, but whatever works.
Waste not, want not. 9.6mm is close enough

Lets see that rotten blankty blank blankblanker rot off now!
I hope I have provided some minor entertainment or usefulness.
Thanks for tuning in.

ironie · Sep 17, 2018

As stated in the title of the thread I was three weeks in when I started posting. I might as well
start from the beginning

So, I ordered a 7.5m length of 120x60x3.6 box section £70 or so
what I have left over might well become a bumper or two. We'll see.
6m each of 50x3 and 20x3 flat @ £10 a length
and a lot of .07 or so sheet from a fridge/freezer I couldn't be assed to
take to the tip in one piece. dumped the plastic and salvaged the sheet steel.
I asked the stockyard to make two 1550mm cuts in the box section and cut the rest in half
and about a meter square of 2 mil sheet from the local scrapyard (for a quid)
with a nice tough industrial epoxy finish that will be fine anywhere I haven't ground or burned it away.
don't overlook the scrapyard, a 4x8 sheet of 2mil would go for around £80 and unless you have a truck plus delivery.

first test fit of sill

decisions made. 1430mm on the long than a 30degree or so angle to match the wheel well
I just eyeballed it and cut both sills to match

start nailing **** together

I framed out the front wheel well with 20x3 flat

and that gave me something decent to weld the inner well patches to as well as providing some true rigidity.

i replaced the flimsy stiffener/mud guard with 20x3 flat (I also later plug welded the new floor plate to it) and tied it into both the sill and the lower inner wing
which I had already added 20x3 flat to replace the lower innerskirt bolt holes which in turn is tied to the 3mil
I plated the lower A pillar with. It all makes a very pleasing note when slammed with my lump hammer

the 50x3 provides a lot of structural integrity than wouldn't otherwise exist even if the floor were pristine

I was going to run a single length of 50x3 all the way back, but decided I was being silly and re-welded the
seat belt bracket back in place.

joining cill, floor and plug welded plate

I made the front bodymount out of a offcut of the box section. That would have been to big for the rear one, so I salvaged the mountseat and rebuilt the rest of the bracket from 3mil

poor planing and a lack of clearance from the A and B pillars forced me to weld them in place
next port of call. The C pillar. I never like the looks of that and wondered what was under it. I had low expectations.

better than expected, still needed seeing to. some people shouldn't be allowed to
use bodyfill.

the other side.

technically this is a MOT fail if they were to see it. For me it is prophecy, pulling the rear quarters is in my future,
but not this time around.

signed sealed, delivered

Being a cheap bastard I used my offcuts. I should have welded them together beforehand instead of caving the well in. poop happens.
inside of "c" pillar. not a pretty sight. one worth noting.

I get a pass on the boot floor this time around. 20x3 flat in the scuzy looking channels and a bit of prettying up and
on to the next job.

Please excuse the lack of brevity, it was a longish post requiring me to remember things which is getting harder as I get older.
Once again. Thanks for tuning in and I hope I have provided some minor entertainment or amusement.
More to come, today was productive day, and tomorrow is a big day for me. I start the other side.
It should go a lot quicker as I won't be figuring things out and it should be in much better shape.
Keep the shiny side up guys!

currymunster · Sep 17, 2018

Cool thread Ironie! Box section sills is on my list for spring/summer. Doing a good job well done

ironie · Sep 19, 2018

Thanks for the kind words Currymunster. and thank you Folk who have liked my posts. I will have to start remembering to hand out likes myself, I in fact owe many. it just never occurred to me.

Guten tag Gentlefolk! The last couple of days have been sort of meh for the Disco. Various real world
concerns interfered with my mission. SWMBO, jobs, parts chasing. bah! The worlds priorities are screwed up.
Back to the important things. Monday was pretty good really. a light day to rest my weary bones but still
feel I had made progress.

Having spent an inordinate amount of time crawling under the front of the Landy, as you do. I have
developed an intense hatred of the front valance.

While this little mess quite offends me, this isn't it's time.

9 inch grinder made short work of the biggest boogers and the sheet metal screws they used to attach the skirt with

another hole, colour me shocked, shocked I say. I did hit the lottery though, at least my version of it
one of my offcuts fit perfectly. touched with the grinder to clean up and nailed it in.

apparently someone owns a grinder but not a drill. this atrocity was no doubt to mount lights on the bullbar.

I suppose I will have to replace the bullbar as I have no rubber to put on the bumper at the moment.
I didn't look at the weather til midnight and saw 15+mph winds, so out I went and took my tarp down.
It has served me well and I can get a bit more use out of it. 10-12 mph winds is about the most it can reasonably
take. Today it is topping out at 40+. Join me in a small wish that my caravan awning makes it though please. It should, but I have lost 2 so far.

I stuffed the bush with lith-moly and slammed it back in. My other minor drama was the search for fine threaded
3/8" ufc locknuts for the prop to brake drum. I failed miserably. Whatever happened to hardware stores with bins of nuts and bolts to pick and match? Gone with the dinosaurs I suppose. I couldn't even get them from screwfix. LRJ can order them for me at like 2 quid a piece. BTW. I thought the mixing of metric and SAE was gone in the mid 80's. I was shocked how many SAE tools I have brought out of mothballs since getting serious with the Disco.

This arrived yesterday, I am now ready to get the trailing arm bushes done. Just need a little better weather.

https://www.ebay.co.uk/itm/HEAVY-DU...182047696391?_trksid=p2385738.m4383.l4275.c10

I had a 2 ton one but I will be stuffed if I can remember where it wound up.
the hammer test
(added short video)

kevstar · Sep 19, 2018

ironie said:
As stated in the title of the thread I was three weeks in when I started posting. I might as well
start from the beginning
View attachment 158796 View attachment 158792 View attachment 158797 View attachment 158798 View attachment 158799 View attachment 158803
View attachment 158804 View attachment 158805 View attachment 158819
So, I ordered a 7.5m length of 120x60x3.6 box section £70 or so
what I have left over might well become a bumper or two. We'll see.
6m each of 50x3 and 20x3 flat @ £10 a length
and a lot of .07 or so sheet from a fridge/freezer I couldn't be assed to
take to the tip in one piece. dumped the plastic and salvaged the sheet steel.
I asked the stockyard to make two 1550mm cuts in the box section and cut the rest in half
and about a meter square of 2 mil sheet from the local scrapyard (for a quid)
with a nice tough industrial epoxy finish that will be fine anywhere I haven't ground or burned it away.
don't overlook the scrapyard, a 4x8 sheet of 2mil would go for around £80 and unless you have a truck plus delivery.
View attachment 158813 View attachment 158821 View attachment 158823 View attachment 158824 View attachment 158826 View attachment 158825 View attachment 158822
first test fit of sill
View attachment 158827 View attachment 158843 View attachment 158874 View attachment 158877
decisions made. 1430mm on the long than a 30degree or so angle to match the wheel well
I just eyeballed it and cut both sills to match

start nailing **** together
View attachment 158879 View attachment 158886 View attachment 158888
I framed out the front wheel well with 20x3 flat
View attachment 158891
and that gave me something decent to weld the inner well patches to as well as providing some true rigidity.
View attachment 158892
i replaced the flimsy stiffener/mud guard with 20x3 flat (I also later plug welded the new floor plate to it) and tied it into both the sill and the lower inner wing
which I had already added 20x3 flat to replace the lower innerskirt bolt holes which in turn is tied to the 3mil
I plated the lower A pillar with. It all makes a very pleasing note when slammed with my lump hammer
View attachment 158906
the 50x3 provides a lot of structural integrity than wouldn't otherwise exist even if the floor were pristine
View attachment 158909 View attachment 158910
I was going to run a single length of 50x3 all the way back, but decided I was being silly and re-welded the
seat belt bracket back in place.
View attachment 158913
joining cill, floor and plug welded plate
View attachment 158914
I made the front bodymount out of a offcut of the box section. That would have been to big for the rear one, so a salvaged the mountseat and rebuilt the rest of the bracket from 3mil
View attachment 158928 View attachment 158929
poor planing and a lack of clearance from the A and B pillars forced me to weld them in place
next port of call. The C pillar. I never like the looks of that and wondered what was under it. I had low expectations.
View attachment 158915 View attachment 158916 better than expected, still needed seeing to. some people shouldn't be allowed to
use bodyfill.
View attachment 158917 View attachment 158918
the other side.
View attachment 158919 View attachment 158920
technically this is a MOT fail if they were to see it. For me it is prophecy, pulling the rear quarters is in my future,
but not this time around.
View attachment 158921
signed sealed, delivered
View attachment 158922
Being a cheap bastard I used my offcuts. I should have welded them together beforehand instead of caving the well in. poop happens.
inside of "c" pillar. not a pretty sight. one worth noting.
View attachment 158924 View attachment 158925 View attachment 158926
I get a pass on the boot floor this time around. 20x3 flat in the scuzy looking channels and a bit of prettying up and
on to the next job.
View attachment 158927
Please excuse the lack of brevity, it was a longish post requiring me to remember things which is getting harder as I get older.
Once again. Thanks for tuning in and I hope I have provided some minor entertainment or amusement.
More to come, today was productive day, and tomorrow is a big day for me. I start the other side.
It should go a lot quicker as I won't be figuring things out and it should be in much better shape.
Keep the shiny side up guys!

Yer corona needs a slice of lime

ironie · Sep 19, 2018

kevstar said:
Yer corona needs a slice of lime

and a shot of mescal

kevstar · Sep 19, 2018

ironie said:
and a shot of mescal

Haha bring on the weekend got some mates coming round doing some repairs & prob get on it

ironie · Sep 19, 2018

kevstar said:
Haha bring on the weekend got some mates coming round doing some repairs & prob get on it

Sounds good. The wife is making me go to Woolacombe next week. but will no doubt buy me a bottle of booze for deserting the Landy.

kevstar · Sep 19, 2018

ironie said:
Sounds good. The wife is making me go to Woolacombe next week. but will no doubt buy me a bottle of booze for deserting the Landy.

Happy wife happy household & all that

Im always out doors my wife has got used to me being outside
playing with my toys

ironie · Sep 19, 2018

kevstar said:
Happy wife happy household & all that Im always out doors my wife has got used to me being outside
playing with my toys

Indeed. No truer words spoken. Mine always has something new for me to fix. So as long as I eventually get around to fixing her things, I can pretty much do as I please.

kevstar · Sep 19, 2018

ironie said:
Indeed. No truer words spoken. Mine always has something new for me to fix. So as long as I eventually get around to fixing her things, I can pretty much do as I please.

Sounds familiar & my wife hates shopping but loves eating out so I mess about with my cars & boats
all week & take her out at the weekend & she's happy, Sunday will be the day of choice this week

ironie · Sep 19, 2018

kevstar said:
Sounds familiar & my wife hates shopping but loves eating out so I mess about with my cars & boats
all week & take her out at the weekend & she's happy, Sunday will be the day of choice this week

I can't complain. She really enjoys Woolacombe, me I am not so impressed by the beach, I grew up by the ocean.
I am just disappointed I couldn't get the Landy finished in time. We really had a lot of fun with it the last time we went.
Next year we will take it. *crosses fingers". You have yourself a fine weekend Kevstar.

currymunster · Sep 19, 2018

Certainly getting on with it - I always it will be a new car by the time I'm done replacing things. Although there is some **** out there. I didn't think a baremach crankcase breather hose would be to bad. How wrong was I - 3 days and it split at the rocker joint. Now leaks worse than the original. Held it up against the original and it was longer so put stress on the 90 degree into rocker. Also the internal diameter seemed to big so it has to be tightened a lot! You gets what you pay for!!

ironie · Oct 7, 2018

GUYS!! Guys! You'll never believe this!
So I woke up around 7, did my morning stuff.
Flushed seven times to get rid of it.
Took the derpwolf for a ride on the bike.
Made a few posts on LandyZone.
drank a 1/5 of vodka, as you do.
Passed out blind drunk, slept eight hours or so, and woke to find
some crazy motherblanker took my tools and cut giant holes in my Disco.

I assume the S.O.B has some sort of a plan, but I'll be damned if I know what it is.
SO I picked up the tools,

came inside and ate a fine steak the wife did up on the gas grill
and hurried here to share my tale of woe.

Edit. I might be lying about some of this.

ironie · Oct 7, 2018

Gave myself a gift today

tacked "welding table to trailer hitch and mounted vice.
The joy of hammering on something that doesn't rob 30% of the blow.
I suspect the work of 'professionals'

welders coffee, cold, extra grind dust

tomorrow we start putting sh|t back together again

Disco 1 week 3 of my MOT "prep"

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