Discovery Rebuild Thread

[solihull-mick]

As a few of you may know that lensters old 3 door discovery is well past its prime in life, so time to replace the said vehicle, with what i hear you cry, maybee a D2 or a 110, no another disco 1, a bargain was found on Eblag, money swopped hands, and here we have the results, ok so its a a tad rusty in places , but no where near as bad as his 3 door , few pics to whet your whistles.......

[wrecker]

well good luck with this build mate,

love what you have done in the past so will be keeping a close eye on this thread :dance:

[muddydisco]

Same here love you're project threads but you need to work quicker and post more piccys  :lol: :lol:

[solihull-mick]

Few more pics just after boot floor was removed, found a few more holes 













More to come today as more gets cut off  :dance:

[stuntman]

Mick, can you let us know roughly how many hours to do each job etc, it'll be handy for some of us to use as a guide for our home tinkering  ;) although we'd have to factor in manual tools and extra time  :P

[solihull-mick]

Well time does have a few factors, tools used, and how rotten the disco is your doing, but i can give a rough guide,

Boot floor replacement including cross beams and remove and install trim approx 10 hours, included in that rust treatment and body coating, and paint,

Inner wing replacement one side, including remove and install outer wing and wiring, approx 6 hours, bit more for drivers side if servo has to be removed

Inner and outer cill one side, including remove and install trim and seats, doors etc, approx 8 hours,

These would be a fair bit more if working at home with no air tools, but you get the drift of time invloved,

Once the main strip has been done and rust removed its not that bad a job, make sure everything fits as i should before any weldings done, and if possable make sure the motor is standing on its wheels, as body shells do twist if jacked up while cills and things are removed,last thing you want is to weld a cill in place then find out the door wont shut,  allways if you can cut and remove the rust area and sink in a new piece of steel,this can be done using a joddle tool, makes a great repair which can be double welded, you will find the end jobs looks better and will last a damm site longer with the right coating,

 ive seen to many customers come in with mot fail sheets with rot in the same places as they had patched 12months before,i know cost is a factor in any repair, worth spending a little more to make it last more than 12 months,

Will try and post pics as i go along to show repairs as they happen, good luck to you guys doing this at home, and remember disconect the battery and alternator or any other ecus in the car, they dont like big welding current up them !!!!

[Frankie-Boy]

Mine's going in to Mick's soon for the same treatment, It'll be good to see a progress report about it on here.  ;)

[lenster]

Why did i choose a disco 1? I searched everywhere for a decent vehicle to become my new ride, but either they were too far gone already or people were asking silly money. I looked at the series II but it has a bigger overhang behing the rear wheels and far too many electrics. My current disco has tide marks right up to the inner door handles, I love the deep water and have a tendency to put the vehicle on its side quite a lot. No amount of sealer can protect wiring that well, so i've gone for an older model. Once Mick has worked his magic I will be assimilating both vehicles. (one for the trekies)

[solihull-mick]

Few more pics to add as i go


Rear cross member gone to far, new one been ordered














Santas has come early loads of new steel !!!!

[kiteman0]

looking good mick
i need to do the same to my inner wings
cut them completely out  :roll:

[muddydisco]

So when we seeing some more progress on the disco mick  :lol: :lol: :lol:

[stuntman]

Seconded, come on mick!

[solihull-mick]

Will post more when i get chance to touch it ,,,,

[lenster]

don't forget me, i'm the lonely disco tucked in the corner!

[solihull-mick]

I havent forgot you len, take a chill pill baby 

[lee celtic]

I think he's practicing on frankie boys Before doing his own  ;)

 :lol: :lol: :lol:

[solihull-mick]

I think he's practicing on frankie boys Before doing his own  ;)

 :lol: :lol: :lol:

lol, if only i needed a bit of practice, the disco is lensters not mine, got more rotton disco`s than i know what to do with  think there is four on site awaiting the MRM touch, and another 3 that are about to fail the mot big style top design from landrover !!!!