Steve's disco 2 rebuild

Made the brake lines today, ended up using the britpart flexi hoses on the back as they should be ok.
Had to make some Ali brackets for the flexi pipe to mount onto as I didn't realise i could unbolt them from the old chassis (probably rotted out anyway).
Left the front end long so I can attach when the body is fitted to chassis.
Anyway here's some pics-

Just need to get some clips to fix to the chassis, old chassis didn't have any, pipe was just resting on the chassis rail.
Nice bodge

Made some progress today, fitted the clips for the brake lines so they are now properly secured to the chassis.
Also fitted a new valeo dmf and clutch kit, replaced the crank seal while I could too.
View attachment 253892gearbox out

don't have a flywheel locking tool so used a strap to hold it while torquing the bolts up

new clutch fitted, lined the friction plate up by eye as I don't have a clutch allignment tool, gearbox went straight on job done,
next job is to make a new fuel tank cradle so I can fit the tank. Hopefully won't be too long for the next update

Got round to making the fuel tank guard,


Will be sending it to the powder coaters along with some other stuff, hopefully will get it back before Christmas.
Bought some HD steering bars and some flexi brake lines to replace the pipes that come off the abs modulator as they are corroded. Nearly ready to put back under the body after I've welded the inner arches up and probably some other areas.

Also managed to get some non ace anti roll bars, so will need to get some links for them, is it best to get the HD ones like this

Managed to do a bit more today, finally got the stuff back from powder coaters, got the tank fitted and piped up, found out I'm going to need a filter housing as it's seen better days, plus one of the wires to the fuel pump is corroded and broke.
Fitted the non ace anti roll bars and the HD Terrafirma steering arms.

Need to save the pennies now for some shock absorbers, will either be old man emu, fox or bilstein haven't decided yet.
Next job will probably be to repair the inner wings as they are rotted out and to make new brake lines out of the abs modulator, all good fun

Did a bit more today, sorted the brake lines from the abs modulator

Then started to remove bits off of the inner wings to get to the holes that I need to repair (after I cut out the previous bodge)

Now that I've sold my 90, I have some money to start buying parts like the gas for the welder, shocks, engine bits and eventually tyres once the body is back on.

Gutted to see it go, had its quirks but never let me down

Didnt get alot done today, tidied all the cr4p up under the body, slapped some primer on the gearbox tunnel and cut a bit of rust out of the o/s inner wing. Isn't too bad, hopefully won't burn the wiring loom when I weld it up.


Might get some gas for the welder if I get a chance this week, if I do that will be next weekends fun job. Also will have to look at the sills as the front body mounts need sorting and the back end of the sills near the rear wheels are rotted, rest of the sill looks alright. Might replace the whole thing with box section and make some new body mounts.
Still un-decided on shock absorbers, swaying towards old man emu, I want to keep it at standard height, will the HD rear springs give it a hard ride? I've removed the 2 seats in the boot area and will be making a metal rear bumper eventually so unsure if medium or heavy duty springs would be better.
Cheers

Got a delivery today :


Went for these in the end, got them from flatdog uk. Will be keeping the standard springs for the moment, if they need to be changed I will do that later on once I've finished the build, (whenever that will be)

Almost finished the inner wing repair until the gas ran out, will be getting some more next week. Also fitted the steering damper and the rear shocks

Quick update, finished the inner wings last weekend

Bought a new fuel filter housing as the old one was rotted, fitted the new one today

Now doing the boring task of painting the underside of the body, yawn

Also fitted the raised rear spring seats I made

steve24v said:

View attachment 250602
Put new cv's on today, couldn't get them off with a hammer so ended up disc cutting them off.
View attachment 250603
View attachment 250604
Front axle all complete now, with new bearings. I will do the hub nut later once I've robbed a big enough torque wrench.
Got the brake lines to do next

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Hi bud! Nice build thread!

What springs and radius arms did you go for? I'm struggling to find decent springs for my 90, and don't want the usual britpart/terra/bearmach offerings as I've had bearmach and they are now going saggy on the rear! Cheers!

Hi mate, thanks. Using standard radius arms and the springs that were on the disco when I bought it. They will probably need changing once I've got it back on the road but I will sort that when the time comes.
There is someone on Facebook that does springs, think it's full flex springs, haven't used them personally but people recommend them.
My brother has Terrafirma springs on his 110 which have lasted ages, but I think Terrafirma have gone 'downhill' since.

Good work and nice to see investment in a D2

ronsealdeath said:

Good work and nice to see investment in a D2

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Thanks mate. Certainly is an investment, I didn't realise how expensive parts were for a d2 compared to the 90 I used to have

steve24v said:

Also managed to get some non ace anti roll bars, so will need to get some links for them, is it best to get the HD ones like this
View attachment 254917

Click to expand...

I have the Meyle HD links which are great. Meyle Heavy Duty for a Disco 2 is part #RBM100223HD (Front) / #RGD100682HD (Rear).
For better articulation on a D2 with +2” lift, move the Disco 2’s longer front links to the rear and install longer Disco 3’s front links to the front of the D2.

JUKE179r said:

I have the Meyle HD links which are great. Meyle Heavy Duty for a Disco 2 is part #RBM100223HD (Front) / #RGD100682HD (Rear).
For better articulation on a D2 with +2” lift, move the Disco 2’s longer front links to the rear and install longer Disco 3’s front links to the front of the D2.

Click to expand...

I got the meyle HD ones in the end, not fussed about articulation at the moment just want to get it back together. Thanks for the info about the disco 3 links, will change them if I get problems with articulation

Hi mate just want to say great thread watching with interest, love to see people doing this type of thing at home good luck TY