Had a bit of a trial fit up of the radiator and the intercooler

I had to re drill and tap some stud holes so the lt77 gearbox mated up with the 200tdi And here is the 200tdi all bolted up to the gearbox Also took the turbo off and "clocked" it so the outlet pointed in a better direction

Have managed to win on eBay at a bargain price a box of various 2 1/4" stainless steel bends, custom side exit exhaust I think ?

I decided to use black smooth hammerite, done lots of research and decided that was the best for me. I wire brushed it all down first. This is the original engine, a 5 main bearing 2.25l petrol And this is the hole it left Lifting out the 200tdi out of the donor discovery, it was easier...

Don't think my axle pics uploaded so hopefully here they are

Original drum brake back axle removed And disco disc brake back axle fitted Decided to overhaul the calipers whilst I had it all apart

Hi David Welcome, I'm only 10min from Colchester if you ever need any help or advice :-) Owen

I would be interested to know if it could go next to the battery under the passenger seat too, I have a Eberspacer D2 to put in mine and was considering putting it behind the rear bulkhead with exhaust etc going out the floor..... Next to the battery would use a dead space nicely ?

Next I gave the chassis a coat of paint and fitted rear relocation cones I also ordered a set of QT radius and trailing arms as the previous owner had done a 2" lift on the original ones

The rear part of the chassis wasn't too bad, had a new quarter chassis at some point in the past, just had to patch up a few bits including the rear tub supports

Yes plan is to do away with the back windows and to re spray it a different colour ( which is yet undecided which colour ) this is when I got it into the workshop and started stripping the body off And taken the rear tub off

Hi Been looking at everybody's rebuild threads and thought it was time I posted up some pictures, I bought this 1985 90 back in the summer with a view of doing a Tdi conversion and various other jobs to it, this is how I bought it complete with original 2.25 petrol engine. Hopefully pic will...

Hi I have converted my 90 from a 2.25 petrol to a 200tdi. I removed the studs that didn't line up, removed the locating dowels then drilled and tapped new holes to fit

I've just done mine on my 90, I bought a selection off eBay but think they were all 10mm metric, and I used 3/16 kunifer pipe

In my old house the neighbours either side painted (yes painted !!) there tarmac driveways, there was mine in the middle covered in oil, diesel and piles of mud where it used to fall off my truck.........they used to love me :-)

Ditto above, find a local engineering company. I use a local family run company, I can buy off cuts for next to nothing for beer tokens

Ditto !!!! Didn't learn from it though as have now bought another one to restore

Think it's dual lines, 2 pipes from master cylinder go down to each caliper, if I can put the original 90 calipers onto the disco axle it will be much easier. I'm working on the back part of chassis at the moment ( I'm planning ahead ) I have stripped it down to a bare chassis to weld, prep and...

Hi Just had a look at my donor disco now that it is here, front calipers have dual brake lines going into them, where as my 90 calipers have single feed going to them. How do I get round this ? Do I need to use the disco master cylinder ? Cheers Osp

The disco is being delivered tonight so will have a quick look at the calipers, would be easier to use the original 90 axle, but guess its not much to change them over. Think all brake lines will be renewed anyway, just to be on the safe side.