andy2986

Hi Yes, all info helps. My Disco is also having a bit of light renovation. (its been off the road 4 years now and Think it will be at least another year as work keeps getting in the way !) This is my plan at the moment re the roll cage. The previous owner has wielded on some extra "bits" so will remove them then have it blasted to get all the old paint off it. Im thinking of cutting the feet off of it (they look pretty manky anyway and replace them with some thicker new plate with matching pieces underneath the floor. (I might have some issues there as I fitted box section sills when I started the rebuild.. we will see.) I might lower the whole cage by 1.5cm's as that would make the fit better..... Like Andyb im going to dispense with the rear seats and continue my storage system to the back of the front seats... I haven't spoken to Safety Devices as yet. Im out on tour at the moment and won't be back till August so thought it better to call them when im in front of the cage so I could answer any questions they might have.

thanks for the reply Dave, I was going to make some second plates for underneath and weld them in..... Im away from the disco for a while (probably a good thing as I was going to set fire to it out of frustration !!) Ive had a look at the camel rebuild on this site and also found quite a helpful write up (in polish!) on the www. I think the next thing will be to get in touch with safety devices as there is supposed to be a unique number stamped on one of the front legs. they might be able to help me out as to wether its a go through the vents in the dash model or a sit behind the vents and block the glove box model !! Thanks all for your replies so far Andy

Hi Thanks any pics would be good.

Ahh !!! didn't think that ! will give it a go, thanks

A couple of photos !!

Hi All, Does anyone have any pictures of a 300 Disco with an internal roll cage fitted ? Ive tried google but it's not all that helpfull. Or does anyone have any experience they could share in fitting one ? Ive managed to get hold of a Safety Devices internal Cage for my disco. Tried a quick "dry fit" today. Bugger me it's a pain to fit. The car before me had it in-front of the dash air vents but I thought they fitted through the side vents in the dash (I would have to take off the mounting plates to do this) I know these are (were) supplied as a bolt in no weilding cage but I think its all a little too tight so may well cut the feet off and start again. I will give Safety Devices a ring on Monday to see if they can offer any advice but thought I would ask here first. Andy

I tend to use Island 4x4 first. Ive found them helpful in the past. That being said I haven't bought anything from them for 6 months or so. I did have to swap out a wrong part a while ago (over 18months) and I dont remember it being a pain. They sent a replacement part and collected the wrong part. Andy

A while back I converted some KC daylighters to run on HID. I know its not a projector lamp but you can get a choice of lenses and the bowel at the back of the light was big enough to hold one of the smaller HID ballasts so it was a simple 2 wire installation (just +ve and ground ) out of the fitting. The light output was very good and you get a choice of colour temperature. Andy

I have a set of 4 push on schrader valves that I keep in the glove box. eBay ! You just put them straight on to the airlines that go directly to the bags. There really good for helping track down air leaks and invaluable as a get yo home bodge.

Right then, a quick update. I had a rare day off from my tour and managed to get to the workshop and have a poke around The bumpstops themselves fit easily into the top hat of the X-spring As do the brackets that hold the bumpstops in place What I am concerned about is how the axle rotates as it travels down, my worry is that when the springs compress, the angle of the springs due to rotation might make the bumpstop miss the hole ( hope you understand what I mean ) for now I have removed the X-spring just so I can move on with the project This is how it stands at the mo, large remote shocks and bumpstops are not an easy fit in a Disco but slowly its getting there. When I get further on in the project I will try and fit the X-springs but for now im back on tour again so it will have to wait for a while Andy

Hi Guys, Thanks for all your ideas so far. I couldn't get to the workshop today unfortunately, so i haven't had a chance yet to see whats what.. as soon as I can get down there I will let you know how its looking Andy

Off the top of my head I think the bump stops are 50mm dia will check tomorrow Andy

Hi Simon, Umm, didn't think of that ! Im at the workshop tomorrow so will have a look... cheers !! I think the spring bit of the x-spring will be big enough might have to make the hole in the top hat bigger ? Would that be an issue ? will whip off a spring tomorrow and have a look Andy

Hiya all.. Decided to re-do some of the suspension on the Disco. I am fitting Terrafirma mega sport long travel shocks all round and also thought I would fit hydraulic bump stops at the same time. Thing is I have X springs in the rear (!!!) and they live where the bumps stops want to go.. So, I was thinking of fitting the rear bump stops in the Chassis instead, kind of where the original rubber bump stops are. What are peoples thoughts If I drilled through the chassis and welded the bump stop mounting tubes in place so the new bump stops are fitted in the axle and acted on the original rubber bump stop axle plates ? Of course I could always ditch the X springs and make my life easier but where is the fun in that ?? Cheers Andy

Don't ever work out what you have spent on it !!

What helmet are you using ?

Arrrrgggghhh OK OK you all win !! Im buying a Speedglas 9100 xx Think ive found one from a UK supplier for about £270 Will let you all know how i get on going now to try and repair my poor old wallet..... Andy

Hi, Thanks for your recommendations so far, Looks like the Speedglas is the way to go. To be honest I wasn't thinking of paying that much. Although when my helmet failed me yesterday I would have paid a lot more just to get the job done. Will have a poke around and see whats on offer. Andy

Hiya all, Need to buy a new welding helmet. Mine just broke, might have something to do with me hurling it across the workshop out of frustration. Im after an automatic dimming type that isn't solar powered . My current ( ex ) helmet was a solar powered job but my workshop is very dark and I don't weld every day so when today I go to do some welding the bloody thing wouldn't darken. So I what do you all use ? Andy

Thought I would post an up date. Seems to fit a bit better with the exhaust fitted as it should be rather than a quick mock up.. Here is the exhaust side of the X-Deflex system And here with the exhaust Its a bit tight I think the answer is to rotate the Arm anti clock wise on the splines so its got room to move when the suspension compresses. I ran out of time to do any more tests but I think its going to fit...

Brilliant ! thanks Andy

Hiya, Been rebuilding this **** heap of a Disco for two years now It has bitten me and fought me every sodding inch and every pigging second of the two years ive been working on it.. Anyway I think I need a little help with this. Ive fitted an X-DeFlex kit. loverly bit of kit as it goes, its been on the shelf for over a year now waiting to be fitted. ( I thought the rebuild would be finished a long time ago ) With that on I thought I would test fit the exhaust, it's a Griffin side exit stainless job (also been on a shelf for over a year now) It all seems very tight after the axle, My question…. Does anyone have any pictures of the exhaust side of a X-DeFlex system with a side exit exhaust fitted ? Or any issues with fitting one with a large bore exhaust system? Just trying to work out how much space I need. Its looking as though the large bore exhaust might me to big for it and the X-DeFlex system to work together. Admittedly ive only fitted the exhaust with cable ties as a temp dry fix, I need to get new exhaust mounts as mine have disappeared ! Will post some pics when I get home from the workshop later. Andy

Hi, The continuing fight of rebuilding my Disco from the ground up has hit a snag, its been two years since ive started im on the exhaust now and my hangers are lost, think the spiders in the lock up have them… So Im trying to find out the part numbers for a 1997 300tdi Discovery Front exhaust mount/hanger intermediate exhaust mount / hanger rear exhaust mount / hanger Also if it's not a to bigger ask, are they the same as a 300tdi defender ? YRM have galvanised ones that look identical but there listed for defenders…. Thanks in advance Andy

Yup No worries, will let him know.. Andy

Im sending off the gasket to him today (he uses that as a template) wouldn't have thought it would be more than a tenner Andy