Land Rover Club Holland - Forum

Re: Brought my Project Discovery 1 over here

2015-01-31T15:01:39+01:00

Ik ben zo heel veel blij, de Belgische kenteken was hem terug na 6 maand geleden en sinds dat punt ik hebben en stuk of tien tot de RDW kunnen hulpen verder. Maar nu ik hebben mijn eigen Nederlands kenteken, twee geele platje op de Discovery gezetten en terug op de baan.

Statistieken: Geplaatst door Nigelw — 31 Jan 2015, 15:01

Re: Brought my Project Discovery 1 over here

2014-10-08T20:30:05+01:00

So this now brings us pleasantly up to date.

I started off with a €3,500 budget to get a Discovery and get it on the road in a tidy order, kind of went a bit over the top.

€1200 Discovery.

€860 tyres

€750 winch and bumper

€375 repair panels

€160 replacement blower motor

€480 power steering box

€450 new shocks all round

€85 steering damper

€300 Discs and pads all round

€40 HD drive flanges (to stop oil leaking from front stub shafts)

€145 replacement oils, fluids and filters

€165 polybush kit

€80 genuine part headlamps (old stock from an independent supplier)

€130 seals, gaskets and sealants(hylomar and silicones for engineering purposes)

€80 miscellaneous second hand trims and interior parts

€320 new batteries(main starter and second aux battery)

€125 various electrical parts, components and cables

€200 welding wire and gas

€75 cutting and grinding consumables

€240 primers, paints, stone chip etc.

€100 on vinyl to re-trim dash

€140 complete new exhaust system

Think I'm up to date there.

total €6180

+ another €450 in tests and garage fees to enable getting to the test as it had to go on special trade plates and I cannot take it on those, €85 to get the new plates on and certified at the keuring station.

Oh my!!!

Not even started the mods and upgrades yet

Shocking hey.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:30

Re: Brought my Project Discovery 1 over here

2014-10-08T20:25:56+01:00

The good bits and bad bits update.

Bad bits first, well, I, erm broke the indicator stalk off in my hand after getting a little heavy handed whilst trying to turn left, looked a bit like.....

This..............

I can still use the turn signals and turn the lights on and off, but the horn, flash and high beam are currently unavailable until I get a new switch.

Now some good new and an improvement. Anyone who owned a car in the 80s and 90s will be able to recall how woefully inadequate the interior courtesy lighting was, now I had already addressed the front lighting with the LED panel replacement of the tube lamp and wanted to get another to fit in the middle light unit but they had sold out, time to get creative!!!

Went from....

To this.....

Left the back still dark and seedy, much like a hookers den not the back of my working truck!!!

NOW this is a vast improvement over that pesky little 5W tube lamp.......

Getting there slowly...............

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:25

Re: Brought my Project Discovery 1 over here

2014-10-08T20:24:13+01:00

Found some LED lighting to brighten up the interior a little at night when I need to see what I am searching for.

Before.

After.

Not bad hey

Then came the fun bit I have been putting off for the last few weeks, finding a good way to wire the winch in that does not make it look like a complete after thought, came up with this idea, cable tie cables to the radiator valance panel and then drill some holes through into the engine compartment to connect up, was going to re-locate the solenoid pack but it is very well sealed as I discovered when I opened up the housing so just brushed every terminal and connection over with vaseline to stop corrosion and water immersed contacting.

Test fit over and happy, get it done

Used a small piece of hose pipe with a slit in it to sheath the slam panel stay and then cable tied the two cables to that.

Really want to get the split charging sorted but not 100% on how I want to do it!

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:24

Re: Brought my Project Discovery 1 over here

2014-10-08T20:21:17+01:00

So after each roll of the dice I scored an own goal at the keuring, how random that they can actually miss things and then add them on to the next test

But yes, spatlappen!!!!!

Decided to make my own.

Trip to the shops yielded some goodies

This was my take on takling the mud flaps.

Take one piece of old conveyor belting, an old card board box to make a template and a sharp stanley knife.

Make template to suit, cut belting to size.

I used a hole punch for the bolt holes but an over sized drill bit works fine too.

Fit and forget.

This last picture demonstrates the width of the new flaps too.

Very happy now, but not for long!!! I had it suddenly dawn on me that with my new flaps being so long that they will get ripped off if I just bump a curb, so, on the bottom of the new flaps there is now a piece of flat bar rivetted on with a link from an old chain welded to it as to enableme to hang them up out of harms way when on an off road situation and to ensure that they do not get dragged under when reversing over a curb LOL.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:21

Re: Brought my Project Discovery 1 over here

2014-10-08T20:19:53+01:00

Here are some pics of the winch being fitted, not planning on getting stuck anytime soon

Trim grille to fit and done.

Looks quite good now

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:19

Re: Brought my Project Discovery 1 over here

2014-10-08T20:17:28+01:00

Should the transmission fluid come out looking like this?

Found me a Christmas tree on the sump plug too.

Here's a look at how the fluid that came out compares to new ATF.

Found a few chunks and flakes in the filter but hope there is nothing much to worry about.

Oh the joys of refilling it, best advice I could ever give is to buy a good quality oil syringe, the one I bought was expensive by my standards but it was still rubbish, will invest in a better one or maybe a pressurized filler for the future.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:17

Re: Brought my Project Discovery 1 over here

2014-10-08T20:16:13+01:00

Time for some picture goodness in this thread

I fitted new brakes front and rear, and while the front hibs were apart I changed the 4 short studs in the diff housing and all new hub seals all round, happy I did the fronts especially as they didn't look so good.

Good to see the drive shafts are barely showing any signs of wear.

Using correct box spanner for the hub nuts not a cold chisel

This picture shows a method of removing the old disc from the hub, you can do it this way but you "will" require a new hub seal as the block needs some mighty bashing to free the disc from the hub, I just put it in my vice and vented my frustrations upon it

Always be sure to clean off the old thread lock and rust, either by wire brush, or by the appropriate tap and die.

New discs on and torqued up with thread lock.

New Corteco seals

Although the new seals are pre-lubed, I like to add a bit more and add a good smear of grease on the stub axle too.

Locking washers are pennies, fit new ones, your life depends on it!

Finished article

Repeat times 4 and jobs a good un, unless the calipers stick

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 21:16

Re: Brought my Project Discovery 1 over here

2014-10-08T18:57:47+01:00

Brake pipe being freshly formed using the old one as a template and a some tape to hold it all in place while I formed the rest.

Then thanks to outside help the ends were flared for me.

Once fitted, time to get busy......

Next installment is the last of the fun bits.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:57

Re: Brought my Project Discovery 1 over here

2014-10-08T18:53:13+01:00

After the weld-a-thon was over I decided to do a bit of tidying up and as my brake pipe tools are still not here I had to do some of the other jobs, oh yes, wire in the new relays for the head lamps.

Very pleased with this little job and although it took me ages to do I think that I did a good job

You can see the nice little bracket that I made to mount the relays onto, even painted it with 3 coats of paint too

As I forgot to take my pictures and had completed the other side I was sure to get some progress shots of the drivers side.

On this side you can see I have opened up the split conduit and threaded some new wires through to connect to the new relays, but why?

Simply because I had the wiring still from my 300Tdi shape V8 and the wires to the head lamps are thicker on the later model, so to me it made sense that as I was ensuring the highest possible currents going to the lamps I needed to make sure the cables were strong enough to handle the loads and also because the newer connectors were in much better condition too.

As there is no bracket to mount them to this side I will mount the bracket onto the inner wing panel at the back here and it will still look very tidy compared to what it was.

There are future plans afoot that will most likely see a whole new under bonnet fuse board and relay board, but this is proficient enough to give me the best light output for normal driving, and when SWMBO allows me some more tokens I have my eye on some very nice LED light bars that will go on the modified winch bumper, but that is for another day.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:53

Re: Brought my Project Discovery 1 over here

2014-10-08T18:51:14+01:00

So time to bring this up to speed.....

Inside the new door post bottom you can just see the extra support I fitted to help brace the pillar and add strength.

Now this being a new second hand repair section it had a small amount of rot that needed addressing, think I did a better job than the last guy who attacked this door post with his welder.

Time to sort the floor out....

There is a support strut that goes in to the door post that has a brake pipe run through it and had to make a new one and also mangled the brake line when disassembling it as it was so rotten.

All seam sealed over the welds and stone chipped, looks much tidier.

Will get round to the brake line when flaring tools eventually turn up, bloomin Christmas holidays

But the rear sill body mount next, it was not actually attached to anything it was little more than a rusty pile of, well rust and bushes.

So still some fettling to do.

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:51

Re: Brought my Project Discovery 1 over here

2014-10-08T18:34:47+01:00

To add some more pictures of what has been going on these past few sessions.....

We all love a bit of rot, but time to investigate how much more I have to deal with and it turns out a lot more than I had realized :blush:

As I had just finished the passenger side inner wing it seemed fitting to carry on and sort out the door post and foot well......

So first bit of trauma to start me off was the sheering off of the brake line as I attempted to remove the union that holds it all together and passes through the door post and floor support strut.

So trim out a bit of the rotten floor and get the door post braced with my make shift iron work.

I used this on the other side when I did that too, it works, fashioned in a way as to allow you to cut right through the door post and it won't move anywhere.

Then start cutting......

I hate this bit, it is not until you actually cut it open that you find the full extent of what you are dealing with, and you can guess how it goes, poorly executed previous repairs to the sill, door post and the support really showed how incompetent the previous owners were!!!

Only one solution, chop it all out and start again....

First repair piece going in but loads more to go.

Rear passenger side sill body mount, and yes this really is only being held on by a little bit of tin, as you can see the rest has rotted away.....

The last bit to be attacked...

Could be busy a while longer....

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:34

Re: Brought my Project Discovery 1 over here

2014-10-08T18:30:25+01:00

Some more pictures

Thought I had better grace the thread with some pictures now that I have fitted the shiny new steering damper, also managed to locate some more from the inner wing saga too

After test fitting the washer bottle and the expansion tank I could drill the holes for them and the body earth from the battery, after the paint had dried I did sand back the paint and the eye of the earth lead to ensure a good contact was made and after fitting the nut and exposed bolt end were painted an the bolt head and eye were smeared in vaseline to try and prevent future corossion.

And the steering damper

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:30

Re: Brought my Project Discovery 1 over here

2014-10-08T18:27:46+01:00

Found some more pictures so you can see how much better it all looked once it was finished and how bad the other side was too.

And that was the drivers side all done and complete, loads of stone chip spray on it inside and out along with a good thick smear of seam sealer along the joins, inside the arches will be done with body schutz to give it longevity against the elements and then Dinitrol all round.

I got lucky for a change with finding a supplier for the P clips to secure the cables with and the brake pipe clips are genuine parts too as he had them in the stores, need to find the right size/part number for the bigger single clip that holds the speedo cable in place now though as I lost/can't find the one that came off, put it in the box but as usual it vanished.

So this is how bad the other side was, not an uncommon sight on a truck as old as this.

Also found a good sized hole in the bulkhead too.

Right,now start digging around under the under seal and see how bad it gets.

Remove brake pipes and start cutting.....

Nice hey.

More to come........

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:27

Re: Brought my Project Discovery 1 over here

2014-10-08T18:25:49+01:00

Thought there were more pictures on my camera of how it was going with the drivers side inner wing build but here you go.

More to come

Statistieken: Geplaatst door Nigelw — 08 Okt 2014, 19:25