Member Since: 11 Apr 2013
Location: Bedworth
Posts: 394
My disco refurb
I bought my discovery 3 in April 2013, although in good condition. The chassis was showing a lot of surface rust and as I am going to keep the car for a while I thought I would give it some TLC. Here are some pictures of the refurbishment.
Car ready for body removal.
First Step to removing the body.
Body Removed
Surface rust.
Chassis after treatment.
Transfer Box and Gear box removal for Clutch replacement.
Transfer box was leaking not from any seals, but from where the two sides of the casing where joined. You can see how thin the sealant was.
Engine strip down for inlet manifold gasket replacement as one side was leaking. Whilst i was in here injectors cleaned and tested. Also replaced all the glow plugs. Managed to remove 5 of them with a vibrating glow plug tool like the one Steve at Advanced factors sells. Unfortunately had to drill one of them out. To reeve all and replace was about 6 hours work.
Inlet manifold removed
New AMK compressor fitted.
Suspension and brakes.
Before
After
I replaced all but 4 bushes that where replaced just before I bought the car. All the shock absorbers where shot, when compressed didn't return to normal position.
Whilst I had the body removed I replaced all the brake pipes from front to back, some them them where rusting quite badly.
Next was to protect the underside of the body as it has some surface rust, particularly along the welds.
Surface rust removed with wire brush ready for paint.
Prepared surface protected with metal paint.
Under body sealed with underseal wax.
There where a lot more jobs completed, rear diff removed and taken apart and inspected, full service including gearbox, diff, and transfer box oils, all drive shafts, wheel bearings, tie rods renewed. The parking brake module was opened and the parking brake cables replaced due to them being all corroded, resealed and touch wood no problems for a few months now. Despite the car having full service history the Parking break mechanisms where rusted and looked as if they hadn't been replaced or cleaned for a good number of years which surprised me for full service history.
All in all took about 8 weeks to complete.
Since the refurb, I have had suspension fault, which was caused by water in the front valve electronics, and a rear calliper stick on, which has required me to rebuild the callipers at a fraction of the cost of replacing.
Heres to a good number of years of hassle free motoring fingers crossed. Now this project is finished looking for the next a Defender 110 Station wagon requiring a rebuild.
6th Feb 2014 9:40 am
Advanced Factors Site Sponsor
Member Since: 27 Nov 2012
Location: Southampton
Posts: 2648
Very impressive Adam, I am certain you get a buzz from such an involved job accomplished.
Paul Redding
+44 (0)23 8052 2774
Order Parts Online at www.advancedfactors.co.uk
6th Feb 2014 10:25 am
brightyuk
Member Since: 11 Apr 2013
Location: Bedworth
Posts: 394
I did enjoy doing the refurb, great when it is back together and with less fault codes than before it was taken apart. Just wish that the parts I hadn't replaced or refurbished would stop failing now.
Pity I don't live closer to SOU make it so much easier getting parts.
Steve do you want to open a branch in the Midlands
6th Feb 2014 10:33 am
Rpp999
Member Since: 31 Aug 2013
Location: Bexleyheath
Posts: 64
Wow, great job. Well done.
6th Feb 2014 10:39 am
simon645
Member Since: 22 Feb 2012
Location: cumbria
Posts: 141
Excellent job ,mate
6th Feb 2014 10:42 am
waterbuoy
Member Since: 26 Oct 2013
Location: Argyll
Posts: 2894
Very smart; hoping to do similar if/when I get my new workshop and lift installed - not in the immediate future though!Currently 2009 Disco 3 SE, 2013 MY D4 HSE and 2016 D4 SE
Previously:
TD5 Defender 110 CSW (230k miles)
300TDi Disco 1 (289k)
4 RR Classics (300-350k each, 2 manual, 2 auto)
110 V8 CSW (220k)
S3 109 hi cap pickup (ex RN)
S2A 88 Safari SW with lpg conversion (bloody lethal)
6th Feb 2014 10:46 am
Dizzykebab
Member Since: 23 Feb 2013
Location: North Yorkshire
Posts: 389
Wowza very impressive work
6th Feb 2014 10:51 am
DSL Keeper of the wheelie bin
Member Since: 11 May 2006
Location: Off again! :-)
Posts: 72979
Respect!!
6th Feb 2014 11:26 am
Iguana
Member Since: 14 Oct 2013
Location: 'Sunny' Zomerset
Posts: 9422
Top job Iggy/Ieuan
Current LR =
2015 RR Sport Autobiography
&
1992 Land Rover Defender Camper
- Gone but not forgotten:
MY10 D4 GS
MY05 Disco 3 'S'
MY14 FL2 HSE manual in Blue
MY15 Disco 4 HSE Lux in Santorini Black
MY08 Disco 3 SE manual in Buck Blue
1960 Series 2 88" (No idea why I sold it!)
6th Feb 2014 11:28 am
Hairy Dan
Member Since: 19 Jan 2011
Location: Co. Durham
Posts: 12319
Excellent job and great write up with the photos Cheers Ian
--------------------
Club N.E.R.D.S
Kielder 4x4 Safari
Discoless
6th Feb 2014 2:30 pm
bigcarpchaser
Member Since: 13 Oct 2007
Location: Camberley
Posts: 2270
Welcome "Lola"
6th Feb 2014 6:36 pm
MarkOne
Member Since: 23 Jul 2011
Location: County Antrim
Posts: 3345
Tidy job she should be good for a few more years
6th Feb 2014 6:39 pm
johnnychainsaw
Member Since: 24 Nov 2009
Location: West Sussex
Posts: 1222
Nice thorough job. Would love to do the same to mine at some point. Respect
6th Feb 2014 6:48 pm
Alan B
Member Since: 12 Feb 2013
Location: Fife
Posts: 6528
Great looking job,
Well impressed
Fancy doing mine next?
D3 57 xs Stornaway grey
D2 02 commercial silver gone but a great servant and won't be forgotten
Iid Bluetooth
6th Feb 2014 7:50 pm
Snow White
Member Since: 16 Aug 2012
Location: Mid Norfolk
Posts: 158
Shame Land Rover don't build it to that spec in the first place RRS HSE 2012 Stage 1 remap, timed heater General Grabbers
Blue D3 with winter pack, xenon lights, Geoff's engine performance upgrade, egr's blanked, mega flushed gearbox, 3 new wishbones, RLD sump guard, V8 brakes front and rear, General Grabbers. Rock/tree sliders. Now gone
Defender 90 tray back, 3 winches (with one or two other subtle mods) Now for sale
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