Another rotten Disco!

[Dusty]

Hey Folks, after many hours of gentle pestering a mate finaly agreed to let me use a corner of his works yard to get to work on my rotten 200tdi Disco.

I had forgoten how hard it is to work on old dirty rotten rusty old motors, my knees and shoulders/neck were complaining at night but, I have the satisfaction of being able to repair it!. no spotty kid saying nah, can't fix that grandad! like in the computer shop. ( i ain't that old! ****** cheeky sod) anyway rain stopped play, so I shall post a couple o pic's to share we you kind folks. My mate was really impressed with the cut 40, and had to play with it, all I could do is watch!

Once we get all the floor out, we'll make some patches for the odd holes and then fit the new floor panel. unlike some PO who had the floor patched previously, lots of patches and effort, then absolutly NO paint/rust prevention, just chuck the inteiror back and get rid.....

BTW The compressor and the cut40 in the pic are both running from the same extention reel ! My friend doesn't use eye protection!!! his choice! I have a grade 5 green full face sheild when cutting, works for me!

Will up date post when the weather/work progresses... Chears All, Dusty.

 

[Chickenjohn]

Those patches look horrible, like the weld is not penetrating but just sitting on top of the lap joints. You are doing absolutely the right thing in cutting the whole floor out and replacing with a new panel.

 

[TurboShed]

Looks like you're off to a good start, keep the pics coming

 

[Sid]

Thanks for showing us your pictures grandad!

 

[Porschemaniac]

Good work - yes, those previous welds do (in my humble opinion) look pretty bad. Sure a whole new panel will be a lot stronger.

It's funny, but the welds on your floor look a lot similar to some that I paid to have done on my beloved 944. Paid a local, so called, 'coachworks' to do the work for me - owing to lack of space and time. Picked the car up and handed over nigh on 400 quid (for a couple of patches). When I got the car home, and finally got around to inspecting the welds, it looked like they had been no more than tack welded in place (badly). Add that to the fact that they had then failed to put ny paint, or sealant on the inside (despite insiting that they would) and suddenly, the equivalent cost of a decent MIG set is not good value for money. In future, I will, as you, be doing all of my own work.

Your mate is a 'brave' man, using the Plasma without eye protection. As you say, his choice - wonder if his eyes often feel gritty at the end of the day!!!

Keep the pictures coming - love to see pictures of ny restoration project and I'll bet that the new floor will be a real contrast.

 

[Dusty]

Thanks fella's for the comments, you hit the nail Porschemaniac, the quote for repairs at a body shop and paint made me realise, I could give in to open wallet surgury or spent the same on some reasonable kit! And then use it for other jobs. Besides, I learnt most of the skill's I'll need at colledge many years ago, ok I might be a bit rusty and slow But, with the help of this forum and you guys/girls I reckon I can fix it. Having a mate in the trade helps of course...that is if'n he can see ok!
Other work permitting I'll get some more done this week and post a few pic's

Dusty, (spellin not my strong point)

 

[bucko]

if people keep repearing there disco's were are the series owners going get there TDI conversions from as its well known the disco's body dies well before the engine has reached the end of its useful life

 

[Robotstar5]

if people keep repearing there disco's were are the series owners going get there TDI conversions from as its well known the disco's body dies well before the engine has reached the end of its useful life

You can always count on Land Rover owners to keep flogging a dead horse!

 

[Paul90]

You can always count on Land Rover owners to keep flogging a dead horse!

Horses I think rather than horse. Most Landrover owners work in the plural so you always have at least one usable vehicle !


I'm half way through replacing my 2nd Discovery floor this year. Pictures of the first are on here somewhere. Lot quicker 2nd time around.

Keep the pictures coming Dusty and good luck. Beware the Paddock flat cross members as they seem to be about 5mm too short. The M&M ones fitted perfectly. Had to "adjust" the paddock ones.

 

[Dusty]

Well, I managed to do a couple of hours today before rain stopped play, brake pipe unions would not come apart with out cutting, but its a good excuse to replace with some new ones. and now i can get to the fuel sedimenter/filter pipe unions, I might just be able to refurbish/service it rather than have to replace it. Anyway rigged up the compressor / Plasma cutter and out with the remains of the floor and crossmembers, remembering to stop before cutting all the rot out.
Helpful Hint for others, MAKE SURE AIR LINE IS AWAY FROM CUTTING SPARKS
Burn hole means a repair to the air line before any more work can be done! Ohh Bugger... off to MM 2mrw!
Trying the britpart floor panel in the hole, I can now work out which edges need what work to be done. I can tryout my (Eblag special) folder to make the sections needed. The cross members all seem at this point to be long enough, thanks Paul, got all the parts from Island4x4, no problems so far. He's a good bloke, took the time to make sure I had the right bits and beat the quote from Paddock/MM.

Hey bucko, I rekon there are still a lot of rotten disco's out there, series owners have no worries for quite a while yet!
And just why would you want a leafsprung landy is beond me.....
still each to their own!
Question, any recomendations for what kind of paint to use on the now exposed chassis? As that's the next job scraping and wirebrushing the crud off. I reckon an old fashioned household gloss (ennamel based?) brushed on generously would work?

Enuff waffle have a look at the latest photos......Dusty.

btw the last one shows load lashing anchor points, I think?

 

[bucko]

if i was you i would clean up and paint them frame rail's before you weld the floor back in

 

[Dusty]

Yup thats the plan....

 

[Iain Westland]

wish i could get to go to that detail i get a few discos in each year, but they only ever want an elastoplast job' (like the patches in the fist set of photos but with welding)

Have fun sir!! btw i am still laughing at those welds, takes me back to my second day on a Mig

looking forward to the updates



Iain

 

[Dusty]

I reckon the orignal weld's were done with a gasless mig or Stick on a roll as my mate calls it.....

 

[Muddi Camel]

Discovery vs most other LR's

This reminds me of one of the many reasons I don't have a Disco. (& the many amusing threads we have on our club forum of Defender vs Disco).

it'll probably be the taildoor frame or the roof to go next

Keep up the good work

 

[bucko]

is that before or after the rear arches

yes i have neva understud that dived between disco owner's and the other owners its just like for god sake we are all fans of the green ovel

 

[Muddi Camel]

Indeed, it's mainly in jest.
Most of the threads seem to be at the expense of Disco owners tho'. I have to say, having a roof rust around the alpine lights isn't something I'd look forward to sorting, so I'm not in the least bit jealous of that one!

 

[Dusty]

wet weekend update

Got a bit more done, still to clean and paint the chasssis rails. Spent ages scraping and wirebrushing, want to blast the remaing crap off with a pressure wash. Then paint with an anti rust primer/ gloss coat. Angle grinder with wire cups are quite scary!

For those who don't understand why a disco, green oval fever affect's some differently to others,......besides both my arms are the same length.
You need odd length arms to drive a series/def or an elbow that is weatherproof, as its always out the window!!!!!!!!!!

Besides the're ferkin cheap at the mo' and mine suit's me!
Need I say more?

some thing to look at.......

 

[bucko]

For those who don't understand why a disco, green oval fever affect's some differently to others,......besides both my arms are the same length.
You need odd length arms to drive a series/def or an elbow that is weatherproof, as its always out the window!!!!!!!!!!QUOTE]

you also forgot the arms like popye and a huge left leg

Nice work
I cant argue with the statement about the arm and the window taking the door top’s off in summer helped (helps to be possitv when owning a 40year old car) o and there that little thing you never have to do until you own a landy o the joys of cleaning ice of both sides of the window

 

[Muddi Camel]

oooh good reposte gents!

You're doing a wonderful job on the Disco. I can only imagine they're so cheap in a bid to prop up sales of welding consumables & steel stock......?

Of course, you could have simply upgraded it with a bit of scaffold pole for a x member & 3mm plate for a floor - it wouldn't rust through for a while

Keep up the good work.