Station-MotorSport

Hi. Estimate on cost... thats a difficult one. If it was to the level I'm doing this one then I really honestly dont think it would be worth it, unless of course you have some particular reason to want to keep the Discovery in question, such as heavily modified, with loads of expensive goodies etc. At a guess I would think that you would be talking around the £4-£5000 mark for the strip down, repair work and rebuild. But that wouldnt include all the bodywork and respray. To do that would probably be another £2000 to do it properly - all seals, trims, rubbers etc removed, painting door shuts, engine bay etc.

Hi. Lol, if it wasnt for the fact the engine has had a new head and injection pump I really would have thrown it away. The engine starts and runs like a dream, no smoke / nasty noises or anything. Ive decided its going to end up a different colour now. Ive seen a few of the 3dr commercial disco's in white with black bumpers that look good and as I really like the combination (hence our 205GTi and Defender too!) it will be white all over, black door surrounds and black steel bumper conversion. Once the bodywork is sorted Im going to lift the shell clear of the chassis and give that a quick going over, basic sand blast and repaint along with all new brake lines etc, will run them along the chassis rather than under the floors, where ever a brake line clip goes through the floor it has rotten through which makes me think they drilled them after it was painted! Watch this space!

Hey again. Managed to grab a few hours on the Disco the other day. Basically spent the time with the plasma cutter, heres the results: Resulting in this: Going to spend a few hours with the angle grinder and clean it all up then start making the new metal.

Hi. Unfortunately not. Had a few customer jobs to get done and now dad has a skip lorry in the workshop with the gearbox out so I cant get anything in or out at the moment.

Managed to have today on the Disco as well. Slight change of plan! After spending the morning with the Plasma cutter taking away the rot, I wasnt left with much metal! I figured that whilst I was doing the rear arch I might as well cut out the boot floor and the other arch, but.... after removing both rear quarter panels (exterior) I realised that if I was to cut it all out there isnt anything actually holding the roof in place, so instead of cutting away more metal I measured all the critical measurements to ensure the sill is in the right place and promptly tacked (very large tacks) in place. So, my plan is to sort the front quarter out on the drivers side, only thing is theres a lot more to do than the passenger side: Found a few more genuine Land Rover bodges too: It seems instead of making sure that each panel is joined to the other, they get the close enough and then fill the gaps with putty, same as my earlier post about the windscreens! It also amazes me with the floors, they are made from 3 different panels overlapped on each side. I guess because the floorpan was original Range Rover they cut away the bits they didnt want and then just spot welded the new bits over the top! Oh, and there is only primer on the insides of the inner arches at the back, no closure panels etc and they just happily rust away hidden from view. How any manufacturer can deem this acceptable I dont know. Was chatting to a mate of mine who owns a windscreen replacement company and he has commented the Disco 3 is manufactured the same way too!

Hello All! Been ages since I've been on here, yet again! Finally managed to grab a couple of days work on the Disco after weeks of it being tucked away! Got the front inner wing all welded back together and looking right. The sill is ready to go on, but I decided to repair the rear wheel arch first so it goes where its meant to be! Pulled the rear quarter panel off and found a whole lot more rot and grot behind it. At least after I'm done I will no there is no rust on it anywhere!! Hopefully next week I can get the rear arch done and then the sill on!

My totally and utterly rotten disco1 is also non sunroof! You wont see it with the wing off mate, its behind the windscreen rubber. If you have the 4 part rubbers and bonded screen be seriously careful! I destroyed my rubbers getting them out and they are nearly £300 for the set The other way to spot it, is unfortunately with the dash out! I would be almost certain this is the fault you are describing as you could see water marks down the side of the A-post on mine. I have since removed all the corking, cut away the rusty rotten muck and welded in new metal and fully welded the hole shut, problem gone (I hope)! As Im giving mine a full resto all these little holes that they filled with cork are gradually going to be cleaned up, repaired and fully welded shut! Good luck!

Hi. After pulling my disco1 apart for a resto I found this hole that is factory made and full of corking gunk, obviously it had cracked and was leaking: its behind the dash at the top of the bulkhead / bottom of screen - same both sides, lol!

Hi. Managed a bit more work. We got all the bottoms of the A & B posts remanufactured, the outriggers, seat braces and end panels are ready to go on. Heres a few more photos of the 'so far' work. Hoping to get the sill on tomorrow and then we can get the floor and inner wing finished! Keep watching!

LOL. Now I'm a mechanic and on the odd occasion we get stumped by something that we havent seen before, so when all else fails we grab a H****s manual and then look at the description and diagrams, look at the car, then remark 'What the hell, that aint right?' Sometimes I really wonder why we bothered. Prime example is on the Jaguar XJ6 manual, its electronic timed ignition, but use a distributor to just distribute the spark, no timing etc envolved. The manual clearly states that after refitting the distributor the car must be return to the dealer for retiming of the distributor!!

I think the OP has realised its a faulty sensor, however I think he is trying to work out which fuse, if it blew, would cause the ABS to stop working.

Hello, Long time no post. Managed to get a fair bit more work done yesterday and today. Got the passenger side sill and floor cut away to nice clean non rotten metal. Ive decided to replace the sills with box section, gives it a bit more strength and works out so much cheaper. A pair of inner and outers LR design works out at over £240. The box section was £80 for a 7m length, I only need 1.4m per sill so it works out at £32 for the pair! The next step in the plan is to repair the bottoms of the A and B posts, tack the new box section to them and then fabricate some new outriggers and then get the floor and door seal lips sorted. Ive had to buy a new boot floor and a pair of rear wheel arches, so I think I have everything I need now to finish it! Ok, pictures below: (I cut a bit more metal out after this photo as I wasnt happy with it, prefer to take it back a bit further and be sure theres no rot in anything anywhere!!) Cheers Jonathan

Managed to get the inner wing welded in today. Sourced a pair of new battery trays from our local land rover agent. Bizarely, they are identical, but handed, the passenger side is £5 but the drivers was £45?? Never mind as I needed both it work out at £25 each so wont grumble! Hoping to get the side section of the inner wing sorted and then everything back together, then its on to the sills! I think I'm going to go down the box section route as a number of people do, I'm going to fabricate a steel winch bumper for it too.

Hey. If your going to be using it as an off-roader (etc) and its as badly rotten as mine then I would suggest building a new body! Managed to get a bit more work done on the Disco today. Ive made the new inner wing today and am hoping to get it welded in tomorrow.

Hi. Done a bit more work today. Got most of the passenger inner wing, footwell and windscreen scuttle area cut away in prep for welding. After spending a couple of minutes with a chisel I have come to realise that LR made a total cock up building these Discos' The inner wing, scuttle panel, bulkhead and A-posts do not actually meet each other completely, instead of welding/brazing it together at the gap they simply bodged it with putty!! Hence why mine is rotten as the putty has become old hard and cracked! (This hole is not rot, but is the genuine way its held together after the putty is removed!!) Then cutting out the rest of the rot: New piece to stitch into the Disco: New piece tacked into place: Update over! Think I can get the rest of tomorrow morning on the Disco, then its probably going to have to come out the shop again as weve got more customers vehicles to get on with