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Rusty boot floor / Body removal
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Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 134

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3
Rusty boot floor / Body removal

Thought I would post up my attempt at sorting some pretty poor paintwork under the rear 1/2 of my body on my 08 plate manual Disco 3.

Ideally wanted another 90, but the boss vetoed that and stated that it must have family car potential. So I bought the most cost effective manual, non sunroof Disco 3 I could find. I knew it could have been a bit better underneath but the budget didn't stretch to a better car. I have had the car for 3 years now and its been pretty reliable and I do all my own maintenance.

Apart from family holidays, carting kids about, commuting to Aberdeen, etc, the car gets used at the local LR club for tyros. I also did Mudmaster competing against the army in it. It now has nice tree scratches down either side.... It goes surprisingly well off road. Until it doesn't, then the immense weight of the thing is immediately obvious.






So the master plan was to lift the body off and tackle the boot floor rust so that it doesn't end up as scrap in a couple of years.

After some asking around it became clear that lifting off the body was the only way to go. It also became clear that this was a DIY job as to pay some one to this properly would be ruinous in terms of time.

So I spent quite a while thinking up a plan while driving to work (Falkirk to Aberdeen on a Monday morning). Along came corona virus and I decided that is was a superb lock down project. So while the idiots were buying loo roll on the last Friday before lockdown I bought steel.

I've actually now got the body off, but though that writing up how I did it would be of potential interest.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #21595797th Jul 2020 11:53 pm
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PROFSR G
 


Member Since: 06 Mar 2017
Location: IN A HOME FOR THE BEWILDERED🙄
Posts: 2870

Ireland 2009 Discovery 3 TDV6 Commercial XS Auto Stornoway GreyDiscovery 3

Everyone loves a good story, especially one with pictures Whistle

As for the repairs, and since you have the body separated, now is a good time to look at those other potential issues which may need attention in the near future . For example, how's the clutch and suspension components? Engine rear hpfp belt, Exhaust system, Turbo hoses and oil feed pipe, Inner sills, etc,etc.

Like you, and as a result of lockdown, I have just had my own one divorced from the chassis and the parts list grew exponentially to a tad over £3,500 Big Cry

In my case a complete new clutch and ancillary components, new cam chains, tensioners and all seals. New oil & water pumps, timing belt kits, glow plugs, crankcase breather, all gaskets except heads, and exhaust fasteners. New front and rear upper and lower suspension arms and all bolts, Calipers, discs, brake pipes, and on and on it went with chassis & U/body clean up and paint before I reacquired a brain Rolling Eyes

There comes a point where you have to say STOP! and that point is different for everyone, but I hope this gives you an idea of what you might consider if it doesn't scare you first Laughing
 Be yourself, everyone else is already taken.  
Post #21595868th Jul 2020 12:57 am
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Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 134

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

So the plan was:

1/. release body
2/. jack up body with 4 x transit van scissor jacks with wooden chocks until beam could be passed between the chassis and body
3/. Jack beams up.

Really just a fancier version of a friends Disco 2 chassis swop that involved big wooden beams, oil barrels and a small hydraulic jack.

So lots of steel chopping, drilling and a little bit of milling:

Click image to enlarge








Gave me:







Only thing left to do was park the disco in the middle of it and start jacking!

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #21598259th Jul 2020 12:04 am
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PROFSR G
 


Member Since: 06 Mar 2017
Location: IN A HOME FOR THE BEWILDERED🙄
Posts: 2870

Ireland 2009 Discovery 3 TDV6 Commercial XS Auto Stornoway GreyDiscovery 3

What the f@xk Shocked You're a brave man, are you addicted to Iron Brew? Laughing

Edit: Have you actually used this set up yet? If you don't mind I would advise against it especially on grass. If it buckles while you are working on it you're dead!
 Be yourself, everyone else is already taken.  
Post #21598349th Jul 2020 12:31 am
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Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 134

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

PROFSR G,

Yes I have used it! Not on the grass - that was just a test build. Caused some consternation with the neighbors - 'what is it?'.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #21598709th Jul 2020 8:14 am
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Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 134

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

PROFSR G wrote:
Everyone loves a good story, especially one with pictures Whistle

As for the repairs, and since you have the body separated, now is a good time to look at those other potential issues which may need attention in the near future . For example, how's the clutch and suspension components? Engine rear hpfp belt, Exhaust system, Turbo hoses and oil feed pipe, Inner sills, etc,etc.

Like you, and as a result of lockdown, I have just had my own one divorced from the chassis and the parts list grew exponentially to a tad over £3,500 Big Cry

In my case a complete new clutch and ancillary components, new cam chains, tensioners and all seals. New oil & water pumps, timing belt kits, glow plugs, crankcase breather, all gaskets except heads, and exhaust fasteners. New front and rear upper and lower suspension arms and all bolts, Calipers, discs, brake pipes, and on and on it went with chassis & U/body clean up and paint before I reacquired a brain Rolling Eyes

There comes a point where you have to say STOP! and that point is different for everyone, but I hope this gives you an idea of what you might consider if it doesn't scare you first Laughing


Time will tell what my costs are. Hoping that doing it all my self I will keep costs down.
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #21601179th Jul 2020 11:27 pm
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Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 134

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

So lifting the body step one - release everything. So my sources of data were:

1/. Disco Mikey's write up
2/. the LR 'how to lift the body section TOPIC

After a while I realised that Disco Mikeys write up is detailed in some area's, not so in others. The body removal LR write up was clearly for a left hand drive auto, I have right hand drive manual. Not insurmountable, but I spent some time on it, took pictures and did a write up to follow in reverse.

Jacking:

4 of transit van jacks at each sill and off I went using chunks of sleepers as chocks/safety backup. Discovered that to do this with jacks you need to remove the air reservoir and compressor. Then found the transit jacks fouled with the front chassis outriggers, so swopped to 2 x disco 1 bottle jacks at the front. Some how seem to have lost these pictures. But once I could get the beams under the body it easily lifted up.










Then pulled the chassis out using a chain blocks against the wife car:


Click image to enlarge


Mind the handbrake isn't still on, other wise you will pull the car towards the Disco 3 .....

Finally I ended up with:




Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #21601239th Jul 2020 11:51 pm
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Russell
 


Member Since: 24 Aug 2007
Location: Kent
Posts: 10384

United Kingdom 

Looking good, well done but stay safe with that
 MY17 D5 1st Edition Namib Orange
MY15 D4 HSE Kaikoura Stone
MY12 D4 HSE Nara Bronze Sold and gone
MY11 D4 HSE Stornaway Grey Sold and gone
D3 S spec Silver Sold and gone
Tow bar, full length roof bars, side steps, tow bar storage unit, surround camers.
D4 camera club 
 
Post #216013110th Jul 2020 12:51 am
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PROFSR G
 


Member Since: 06 Mar 2017
Location: IN A HOME FOR THE BEWILDERED🙄
Posts: 2870

Ireland 2009 Discovery 3 TDV6 Commercial XS Auto Stornoway GreyDiscovery 3

Breg90 wrote:
So lifting the body step one - release everything. So my sources of data were:

1/. Disco Mikey's write up
2/. the LR 'how to lift the body section TOPIC

After a while I realised that Disco Mikeys write up is detailed in some area's, not so in others. The body removal LR write up was clearly for a left hand drive auto, I have right hand drive manual. Not insurmountable, but I spent some time on it, took pictures and did a write up to follow in reverse.

Jacking:

4 of transit van jacks at each sill and off I went using chunks of sleepers as chocks/safety backup. Discovered that to do this with jacks you need to remove the air reservoir and compressor. Then found the transit jacks fouled with the front chassis outriggers, so swopped to 2 x disco 1 bottle jacks at the front. Some how seem to have lost these pictures. But once I could get the beams under the body it easily lifted up.










Then pulled the chassis out using a chain blocks against the wife car:


Click image to enlarge


Mind the handbrake isn't still on, other wise you will pull the car towards the Disco 3 .....

Finally I ended up with:




Adrian


I do admire your determination and the work / skill you put in to building the rig, though I still harbour some safety concerns. So now you're well on the way to an overhaul of just about anything you could want. I changed the chains and tensioners and pulled out those damn manifold flaps which allowed a thorough clean up inside.

There is a lot you can do very easily now which will not be the case once the body is back on. Use this time wisely! Best of luck with it, be careful!! And, enjoy the realignment Smile
 Be yourself, everyone else is already taken.  
Post #216013210th Jul 2020 2:21 am
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nigethecat
 


Member Since: 11 Sep 2016
Location: Kessingland
Posts: 1527

United Kingdom 2015 Discovery 4 3.0 SDV6 HSE Auto Indus SilverDiscovery 4

Most impressive! The only part I don’t believe is that you are in Falkirk as it's not raining in three of the photos! Rolling with laughter

An excellent job although I share the Profs safety concerns... look at the brake pipes as well if this hasn’t been mentioned... and also deal with any rust on the rear chassis

More photos as you progress please Thumbs Up
 I want to see the sweets before I get into your windowless van... I'm not stupid!

Back in a D4 😎
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Post #216015810th Jul 2020 8:22 am
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rowlejohn
 


Member Since: 15 Sep 2017
Location: Montmorillon, Vienne (86)
Posts: 183

France 2008 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

Good topic Thumbs Up Thumbs Up Thumbs Up Bow down
 Relocated to Mid France from N. Wales March 2021
Rovacomlite and IDD/ SSD diagnostics user
Previous Landies
3.9 SE Classic
3.5 V8 Disco
4.6 P38 HSE
L322 Vogue HSE
TD4 ES Freelander 1 
 
Post #216022710th Jul 2020 12:09 pm
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Moo
D3 Decade 


Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 10242

United Kingdom 2005 Discovery 3 TDV6 S Manual Zambezi SilverDiscovery 3

Best new topic in a while. Thumbs Up
 New Volvo XC90 R-Design (known as Basil)

Sold - D4 HSE (Known as Gerty)

No longer the Old Buses original owner Sad
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
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BAS Remap, Allisport Intercooler and deCat
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Prospeed ladder
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Post #216025710th Jul 2020 1:26 pm
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LT
 


Member Since: 31 Dec 2005
Location: South West
Posts: 16968

United Kingdom 2016 Discovery 4 3.0 TDV6 Landmark LE Auto Santorini BlackDiscovery 4

Ingenious and impressive. Thumbs Up
 2006 D3 HSE (Original & still the best)-GONE
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2014 D4 HSE (Almost too bling)-GONE
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Post #216026510th Jul 2020 1:58 pm
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adam
 


Member Since: 20 Sep 2005
Location: Home and Happy
Posts: 6917

United Kingdom 

Amazing and interesting
 Now Golf GTI PP, 7 speed DSG.
Ex D3 and D4 
 
Post #216026610th Jul 2020 2:08 pm
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Pete K
 


Member Since: 15 Jan 2016
Location: GL
Posts: 7274

England 2005 Discovery 3 TDV6 HSE Auto Rimini RedDiscovery 3

Thumbs Up

I think if I were doing that on a model with electric seats, I would remove the front elec seats first, as they are very heavy (to lighten the load a bit)
  
Post #216028210th Jul 2020 4:31 pm
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