Project Roverkill D2a [Archive] - Australian Land Rover Owners

DieSchnelleKafer

8th May 2016, 04:45 PM

Hi Folks,

My name is Blair and i am relatively new to this forum but have been lurking for a few years. I am currently studying in Perth W.A, and i plan to document a new project that i will be working on, a newly acquired 2004 D2a discovery classic. Shes a manual v8 and 131,000k on her. I searched my local gumtree website and car sales website for 6 months looking for my new dream rig, but unfortunately the exact combination that i wanted did not turn up.

After realizing that maybe i was being too picky as nothing was presenting itself, i purchased this D2a in question. This car was everything i wanted; low kays, D2a, v8, priced well, good condition, black interior etc. The only issue being it is a manual, i much prefer an auto, and not LPG.

I have owned a 93 disco v8, and a 95 2 door disco v8 and loved the cars. only reason to sell them was of moving cities, life changes etc. So this new project has been well anticipated, i have always wanted a D2, and being a d2a is just the icing on the cake.

The plan for now:
1. Give the car a really good service, bearings, ball joints, brakes, engine service components, and everything to get the car up to factory spec again.

2. LPG conversion. Research shows that the OMVL XXI dream kit is the way to go, i have found a good place online to get the kit. The conversion will be put on this thread.

3. auto conversion. Yes i know, ridiculous.. but research is leading me towards a comp-shift controller from Ashcroft in the UK, coupled with a 4hp22eh from another d2. full control on shift points and pressures will be a real win.

After all this work gets done, the goodies can start going on! I already have an ARB locker to go in, more lift, tyres, roof rack, lights, exhaust.. you know how it goes. https://www.aulro.com/afvb/images/imported/2016/05/698.jpg

Homestar

8th May 2016, 07:49 PM

Will follow this with interest - looks like you scored a nice example to as a base to start with. :)

DieSchnelleKafer

3rd July 2016, 09:15 PM

Hey guys so it has been all go with the disco project, i got a 4 week break from uni so i have had some real time to do some work. So i replaced the headliner:
https://www.aulro.com/afvb/images/imported/2016/07/1027.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160522_170409_800x450_zpskjzjhppf.jpg.html)

I also fitted some cool canvas seat covers, maybe not to everyones taste but i love them!

https://www.aulro.com/afvb/images/imported/2016/07/1028.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160522_170355_800x450_zpsnet4yb3h.jpg.html)

I restored the gators on the hand brake, shifter and difflock lever:

https://www.aulro.com/afvb/images/imported/2016/07/1029.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3787_800x533_zpsw03opggg.jpg.html)

I rebuilt both front an rear shafts with new u-Joints and centering bearing on the front and a new rotoflex coupling and new u-joints at the rear

https://www.aulro.com/afvb/images/imported/2016/07/1030.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3809_800x533_zpshgh3cupx.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/1031.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3795_800x533_zpsglvnmbay.jpg.html)

I also replaced the shuttle valve and bypassed the plug wiring to the modulator. This mod was actually really easy, i hope this solves those pesky Mexicans coming back.

https://www.aulro.com/afvb/images/imported/2016/07/1032.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3803_800x533_zpspcwijikj.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/1033.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3796_800x533_zpsyimt7u7y.jpg.html)

I fitted a light holster as well, in the holster sits a super bright LED battery torch. Easy access :)https://www.aulro.com/afvb/images/imported/2016/07/1034.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3790_800x533_zpsnq0zfzrx.jpg.html)

The sequential LPG kit rocked up a few weeks back as well, it is OMVL, and as far as i can see, built quite well. I also started to drill the nozzle holes on a spare intake plenum that i had in the shed. Tomorrow i will start the LPG conversion properly and get into it, there is a fair bit to do! https://www.aulro.com/afvb/images/imported/2016/07/1035.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3805_800x533_zpsbydgbznc.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/1036.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3807_800x533_zpsx5mzo7mx.jpg.html)

And to top this post off, i started to manufacture a switch cluster with two seperate volt gauges for the starting battery and a deep cycle. https://www.aulro.com/afvb/images/imported/2016/07/1037.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3792_800x533_zpspywegq1d.jpg.html)

DieSchnelleKafer

5th July 2016, 11:13 PM

Another busy day in the shed. Today i turned my attention to the removal of the intake manifold and stripping the engine bay. Once the manifold was removed i then proceeded to finalize how the LPG injectors injector tubes were to be routed. This is not as straight forward as i was assuming. I have done many hours research into the best way to fit the injectors and how to run the hoses. What i believe to be the best solution is shown in the photos below. Research and my own intuition lead me to These desirable criteria that i needed to achieve:

1. the gas nozzles that enter the intake runner need to be in close proximity to the petrol injector outlets. It is my understanding that the petrol ecm is programmed to spray fuel right before the intake valve opens, therefore if the LPG injectors were to deliver a charge of lpg further up stream of the petrol injectors, the correct fueling charge inside the runners would be delayed per cycle, not a desirable operating outcome. Playing to this theory, the gas nozzles were located right before the petrol injector.

2. the lpg injector tubing length must be kept as short as possible. This is an interesting one.. i believe that the length of the tube that runs from each individual lpg injector to the intake plenum is desirably kept to a minimum, so this is what i have done. The only downside i have researched is that changeover time from petrol to lpg will be delayed (if the tubes are too long), not a huge disadvantage. The most important thing however is that they are all of equal length for the 8 cylinders. As the length increases, the magnitude of flow restriction increases. what this means is that if the tubes are all of varying length, each cylinder will be given different volumes of lpg with each combustion cycle.

3. metal-rubber abrasion must be dealt with accordingly. There is a potential that fretting corrosion can occur between the rubber injector hosing and the cast alloy intake plenum/intake parts. An effort should be made to de-burr all surfaces and use insulating materials.

After all this was considered it then took some thinking and tinkering to get the desired outcome. I struggled to find a suitable injector hose, it needed to be 6mm O.D, but also heat resistant and flexible enough to duck and weave through all the metal parts, i used a vacuum hose that i picked up from coventrys auto supplies.

https://www.aulro.com/afvb/images/imported/2016/07/947.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3815_800x533_zps0zawaibh.jpg.html)
https://www.aulro.com/afvb/images/imported/2016/07/948.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3821_800x533_zpsol5hlu10.jpg.html)
https://www.aulro.com/afvb/images/imported/2016/07/949.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3824_800x533_zpszaihgaix.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/950.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3827_800x533_zpszuv8wgie.jpg.html)

Because of the location of the passenger side injector rail, I relocated the IAV intake hosetail. the IAV will be replumbed down the track to accept this new position.

https://www.aulro.com/afvb/images/imported/2016/07/951.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3828_800x533_zpsbux8bloh.jpg.html)

bee utey

7th July 2016, 12:12 AM

This is how I did my first Thor injection install. Without a body lift your bonnet clearance is limited.

http://www.aulro.com/afvb/attachments/lpg/18247d1251366055-lpg-pics-injection1.jpg

Proper 6mm LPG injection hose isn't hard to find, even ebay has it. About double what I pay for it but small change in the grand scheme of things..

Brand NEW LPG GAS Vapour Injection Hose 6mm X 1 Meter | eBay (http://www.ebay.com.au/itm/Brand-New-LPG-Gas-Vapour-Injection-Hose-6mm-x-1-meter-/321660371588?hash=item4ae473c284:g:n34AAOSwa39U0rQ 9)

As for change over time, I had no problems with 300mm hoses. Some software allows you to to add a small amount of overlap. Sequential changeover means it swaps over one injector at a time anyway, makes it very smooth.

Cannon

8th July 2016, 09:57 AM

I believe you can get some sort of spacer plate to go under the manifold.

That's what I've got I think :)

https://www.aulro.com/afvb/images/imported/2016/07/908.jpg

DieSchnelleKafer

31st July 2016, 08:38 PM

Hey folks so here is another update. I had 4 weeks off uni so it has been a productive time.
1. managed to get the UHF working (installed the missing aerial)
2. fit 2 VDO gauges, Water temp and oil pressure. (see photo of pressure sensor)
3. get the LPG full installed and signed off. This turned out to be a real task to get someone to fit the high pressure gas line and sign it all off, I dont blame anybody for turning the work down, but i received a very rude response from a shop that frankly, left me feeling a bit bruised. never the less i met a bloke more than happy to help me out and teach me many things along the way.
4. replaced the LH engine mount
5. fit an ARB air locker in the rear.
https://www.aulro.com/afvb/images/imported/2016/07/21.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160711_153428_zpsnsigvpzk.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/22.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173826_LLS_zpsr8p9se2i.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/23.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173644_LLS_zps71xxvwmp.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/24.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173624_LLS_zpsoggij0tf.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/25.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173545_LLS_zpsfnyymafa.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/25.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173545_LLS_zpsfnyymafa.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/26.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173608_LLS_zpsjeledulv.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/27.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160729_105909_zps04y4teid.jpg.html)

Here is a photo of the spaghetti under the dash. I managed to fit the AEB lpg computer directly on top of the bosch m5.2.1 unit. i then proceeded to splice and solder all the necessary wires together, lots of coffee and lots of double checking!
https://www.aulro.com/afvb/images/imported/2016/07/28.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160715_122649_zpstld1nur8.jpg.html)

And here is the difflock install:
https://www.aulro.com/afvb/images/imported/2016/07/29.jpg (http://s50.photobucket.com/user/BlairWhittle/media/FB_IMG_14691663585921_zps45hheqso.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/30.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160722_1342231_zpseecdmovc.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/07/31.jpg (http://s50.photobucket.com/user/BlairWhittle/media/4f6f2552-0f71-4443-9629-83d4c1d0b333_zpsie0vktrn.jpg.html)

DieSchnelleKafer

31st July 2016, 08:59 PM

https://www.aulro.com/afvb/images/imported/2016/07/19.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160731_173917_LLS_zps5p7apovt.jpg.html)

So how does it run on LPG?

the answer is great. As soon as my lpg man switched it to lpg the first time it ran great. i was shocked. we did an automatic calibration and then took it for a drive, no dead spots, no rough running etc. Now that was a week ago, and tests have come back with 20l/100km. Bare in mind that this is only with a rough auto calibration.

Before we embark on a full tune (driving while adjusting) i need to carry out the following:
1. new leads
2. new iridium plugs
3. fix the exhaust leaks that are forward of the O2 sensor.

I actually want to install 2 fuel/air gauges one for each bank). I intend on tapping into the m5.2.1 wiring to take advantage of the sensors that are already in place. Has anybody had experience with items such as below:
Black 2inch 52mm CAR Motor Digital 20LED AIR Fuel Ratio Gauge AU Stock | eBay (http://www.ebay.com.au/itm/like/BLACK-2Inch-52mm-CAR-MOTOR-DIGITAL-20LED-AIR-FUEL-RATIO-GAUGE-AU-STOCK/231344383626?hlpht=true&ops=true&viphx=1&_trksid=p2050601.c100103.m2451&_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1% 26asc%3D20140211150826%26meid%3Dc45e244b8d134e4998 0e9f9a9b12f28f%26pid%3D100103%26rk%3D3%26rkt%3D4%2 6sd%3D111474747205%26clkid%3D7208475709163910686&_qi=RTM2010742)

Homestar

1st August 2016, 10:46 AM

Looks good. :)

What sort of grief did they give you about the LPG? I don't understand why someone would turn down the work - or was it a 'Land Rover' thing?:confused:

DieSchnelleKafer

1st August 2016, 07:21 PM

Looks good. :)

What sort of grief did they give you about the LPG? I don't understand why someone would turn down the work - or was it a 'Land Rover' thing?:confused:

When i had completed as much work as i felt i could do safely, i started to look for someone who could finnish the job off. I went down to our local LPG vehicle shop (the last one in town i might add, all of them had closed down in recent years). From what i can gather, the bloke was offended that i had not just come straight to him to do the whole job. Once i realised he wasnt interested in the work i asked if i could at least buy some of the low pressure gas line that connected the converter to the injector rails, he was even less happier about this and began to pay out on me for that fact that i needed to have a fitters licence to buy the tubing. He then proceded to tell me how i looked like i had little experience with anything mechanical/electrical and how i should bugger off.

Damn.

Luck would have it that i got given the phone number of a gentleman who was prepared to help me out by a freind. We organised a day to do all the remaining work and then got down to it. He was also an absolute rover nutter and we got along well. It was an absolute win.

As someone who does every little bit of work on their cars, i believe anything can be accomplished with research and coffee, this mind set doesnt change in regards to an LPG conversion.

DieSchnelleKafer

31st August 2016, 10:50 PM

So a few updates on the build thread. a few bits and pieces have been done since the last update:
-Replaced leads with NGK units with convoluted tubing on all of them
-Fitted Iridium BKR6EIX NGK plugs gapped to 0.7mm for LPG
-fitted a new passenger side rear hub as the old one was leaking axle housing oil
-fitted a full length aluminum roof rack
-installed a new Alpine IDE178BT head unit, steering wheel controls work!:)
-fitted new toyo a25 255/75 r16's
-fitted new britpart fender flares to replace the old sun damaged units

So the car has gotten a lot of love lately, probably to much. But ehh, keeps me busy. The new tyres have really transformed the vehicle. Before i had a mis-match of tyres and they were all 10 years old, so they were hard as a rock. These new fellas have really softened the ride and improved the road holding.

The new plugs and leads have also smoothed out the engine running. i feel as if it runs at higher revs much nicer as well as improved idling smoothness.

here are a few pics that show the finnishing off of the fuel tank mount:
https://www.aulro.com/afvb/images/imported/2016/08/1.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3829_zpsjjz94fby.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/08/2.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3830_zpsuv1wgzii.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/08/3.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3832_zps21sjhf7h.jpg.html)

Here is the new tred (dont have any photos of them installed) Toyo a25's

https://www.aulro.com/afvb/images/imported/2016/08/4.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3833_zps6nxstxan.jpg.html)

and more photos:

https://www.aulro.com/afvb/images/imported/2016/08/5.jpg (http://s50.photobucket.com/user/BlairWhittle/media/506b783d-2e32-40f8-8195-b88752a2cde0_zpsgpwngiql.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/09/1057.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160828_144508_zpsfzjmwiqz.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/08/6.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160823_141331_zpsltkzw4cz.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/08/7.jpg (http://s50.photobucket.com/user/BlairWhittle/media/20160817_140954_zpslny6j0u2.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/08/8.jpg (http://s50.photobucket.com/user/BlairWhittle/media/IMG_3859_zpstkf10fel.jpg.html)

cuppabillytea

31st August 2016, 11:54 PM

Some good things happening here. :thumbsup:

Homestar

1st September 2016, 06:16 AM

Looking good. :)

DieSchnelleKafer

2nd September 2016, 11:27 AM

Thanks cuppabillytea and Homestar, just wait until all the suspension work starts happening:cool:

If anybody knows anything about diagnostic tools and BCU's, please please see my help thread http://www.aulro.com/afvb/electronic-diagnostic-systems/240241-d2-connection-issue-between-lynx-bcu.html

I am having a real hard time talking to the BCU module with my lynx diagnostics tool

rangieman

2nd September 2016, 05:07 PM

DieSchnelleKafer

13th November 2016, 03:56 PM

https://www.aulro.com/afvb/images/imported/2016/11/466.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2031_zps6aywvid5.jpg.html)

Righteo so whats been happening? I have been busy with work/assingments for the past fed months and hence there has not been to much progress on the build. I have however racked up 11,000km on the car with the LPG system fitted and i cant be happier.

I am now about to enter into a free period for myself, and hence you will see a fair bit of progress on the build in the next few weeks.

One modification i have been able to conduct is converting the discovery to an "in-line" thermostat system. There are plenty of people who have done this, generally for the same reason. I have used an 80 degree chevy based thermostat for this mod. before the car was sitting at around 94-97 degrees, on the highway, on the 4x4 trails, sitting in traffic.

Now that i have the 80 degree thermostat in, i see temperatures between 82 and 85 degrees. Again this is for all types of conditions, highway, 4x4 trails or sitting in traffic.

I am still using the standard viscous unit.
https://www.aulro.com/afvb/images/imported/2016/11/467.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2038_zpsfvdf3ohs.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/11/468.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2039_zps68ak5w2x.jpg.html)

https://www.aulro.com/afvb/images/imported/2017/01/871.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2040_zpsjreu0luk.jpg.html)

And just to finnish on an exciting note, here is some parts i have been gathering for when i get free time. I am going to get this truck sounding how it should, but with a twist.. the second photo is a vacuum operated exhaust butterfy. The plan is to conduct the exhaust system in a manor that has it quiet as a stock vehicle when this valve is closed, but nice and aggressive when it is opened. The valve will be actuated manually in the cabin, as well as by a micro switch at a certain amount of throttle. >:D

https://www.aulro.com/afvb/images/imported/2016/11/469.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2036_zpsuj0ovdfi.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/11/470.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2037_zpscn6kazhg.jpg.html)

DieSchnelleKafer

14th December 2016, 11:46 PM

A little bit of work has happened since last update.

enjoy a nice little photo of us camping:
https://www.aulro.com/afvb/images/imported/2016/12/511.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2051_zpsgoslwoty.jpg.html)

After being warned about how my previous oil pressure line to the sender was routed, i replaced the nylon hose and mounting position i previously employed, with a hard lined, bracketed system. The concern here was that the nylon tube would be fatigued around the olive of the compression fittings.
https://www.aulro.com/afvb/images/imported/2016/12/512.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2080_zps44x5utxu.jpg.html)

i added a permanently supplied cigarette socket to the center console to charge phones. Note the usb socket is for the stereo.
https://www.aulro.com/afvb/images/imported/2016/12/513.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2079_zps4cn6btre.jpg.html)

The roof rack brackets were rusting and were too high after i removed the stock roof bars. I shortened them by 50mm and hammertone coated them.
https://www.aulro.com/afvb/images/imported/2016/12/514.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2086_zpsvgdukzue.jpg.html)

The plan was always to get rid of those ageing ARB side steps. so i custom fabbed some sliders using the arb chassis brackets. they are made of 3mm box section and 3mm wall tubing. enjoy :)
https://www.aulro.com/afvb/images/imported/2016/12/515.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2057_zpsiguytegh.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/12/516.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2060_zpsgqqbmerm.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/12/517.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2062_zpsrgtgjmh8.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/12/518.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2085_zpsqonfti8b.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/12/519.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2083_zpsasv1quya.jpg.html)

so thats where i'll leave it for now. watch this space.

https://www.aulro.com/afvb/images/imported/2016/12/520.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2084_zpsuswozssi.jpg.html)

DieSchnelleKafer

2nd January 2017, 01:37 AM

Clutch!

The clutch began to "judder", or fiercely shake the engine soon after i bought the car. Unfortunately due to free time constraints i had to put up with it until last week.

The cause of the judder could be put down to oil contamination on the clutch faces. the source of the oil turned out to be the rear main seal. Replacing the clutch was a 3 day job, only because i was very picky about reassembly (everything cleaned of dirt and oil and all wiring re-sheathed etc). I also replaced the v8 valley gasket in the process of having the engine out. I suspected that it had formed a leak after i did the LPG install.

https://www.aulro.com/afvb/images/imported/2017/01/1087.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2112_zpsjifmt4an.jpg.html)

https://www.aulro.com/afvb/images/imported/2017/01/1088.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2113_zpsa9efoggh.jpg.html)

https://www.aulro.com/afvb/images/imported/2017/01/1089.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2115_zpsuokl0ixt.jpg.html)

The clock was ticking to get the clutch back in and the car driving. This was because we had a major music/camping festival to get to down south, Southbound 2016. The engine was back in and running at 7:00pm the night before the festival, leaving me to pack for a 4 day event with little time :eek:

https://www.aulro.com/afvb/images/imported/2017/01/1090.jpg (http://s50.photobucket.com/user/BlairWhittle/media/DSCN2127_zpsoagyripf.jpg.html)

worane

2nd January 2018, 09:38 PM

What has happened to that poor little Alfa Spyder in the shed. It looks a little the worse for wear. I owned one in the seventies.
Regards, Nick.

Tombie

3rd January 2018, 12:34 AM

Slider looks good.
Are you not worried about hooking up in ruts in that back section though?

AK83

3rd January 2018, 06:44 AM

What has happened to that poor little Alfa Spyder in the shed. It looks a little the worse for wear. I owned one in the seventies.
Regards, Nick.

I thought it was a Karmann Ghia(going by the volksy engine under the bench too).

worane

3rd January 2018, 11:22 PM

You may well have a good point there.

Archangel007

8th January 2018, 08:39 AM

I thought it was a Karmann Ghia(going by the volksy engine under the bench too).

Engines everywhere!!

DieSchnelleKafer

10th January 2018, 04:52 AM

I thought it was a Karmann Ghia(going by the volksy engine under the bench too).

Hey guys, yes its a 1967 Karmann Ghia (volkswagen) :) the intention is to fix it up. I have already restored a 1956 volkswagen Beetle so the Karmann ghia shouldnt be that bad. The project is for my mother.

Quick update guys. There has actually been a lot of progress on the disco. It has had a whole new exhaust system and custom rear swing away setup installed. oh plus it has received some new mud tyres :) currently studying abroad in the U.S so i have not been able to post any new pictures but i will soon. Before i left we went on some really awesome road trips/camping adventures so i will add some photos of that in as well.

On another note, can anyone recommend a good image hosting website? i am not afraid to pay a fee.. i have just been left scarred and bruised after the photobucket disaster/sham. also, can everyone still see the photos on this thread? I need to know. thanks.

Bluetoes

10th January 2018, 06:31 AM

Yep photos still there

Hunt family

21st January 2018, 09:23 PM

What an incredibly interesting adventure...

Very committed, talented individual..

I must ask, what are you studying?

DieSchnelleKafer

19th February 2018, 07:30 AM

What an incredibly interesting adventure...

Very committed, talented individual..

I must ask, what are you studying?

Hi, Thanks very much! I am in my third year of Mechanical engineering at Curtin University in W.A. Currently doing 6 months abroad at Colorado School Of Mines, there will be some photos about that in a second. Building things is my passion so I want to follow that path.

DieSchnelleKafer

19th February 2018, 08:02 AM

Hey Guys, so here is what has been happening.

Below you will see the new rear bar I fabricated. originally it was a second hand bar, but that was it.. just a metal 100x100mm box tub section, I forgot to get a photo of it when it was purchased. Many many hours of grinding/welding and painting down in the shed got it to what you see below. It has a neat little latch mechanism that attaches the right swing arm to the disco rear door, hence it only takes one action to get into the rear cargo area. It is sprayed with 2 litres of raptor liner for durability. Some cheapie ebay special LED lights finnish it off. With the amount of driving I do in Perth I really wanted some bright rear lights, and these LED's do the trick.. they are super bright.

https://www.aulro.com/afvb/images/imported/2018/02/467.jpg (https://imageshack.com/i/pmXkHikBj)

https://www.aulro.com/afvb/images/imported/2018/02/468.jpg (https://imageshack.com/i/pm6owrETj)

https://www.aulro.com/afvb/images/imported/2018/02/469.jpg (https://imageshack.com/i/pnJMdFlaj)

New tom woods shaft so I don't blow a hole into the side of my gearbox:

https://www.aulro.com/afvb/images/imported/2018/02/470.jpg (https://imageshack.com/i/poVJXIV7j)

in December 2017 we took the time to head down south for a getaway, We went down to Denmark, Margaret river etc. We stayed at a beautiful camp site called Alexandra bridge, off the blackwood river.

https://www.aulro.com/afvb/images/imported/2018/02/542.jpg (https://imageshack.com/i/pnfE0pMzj)

https://www.aulro.com/afvb/images/imported/2018/02/472.jpg (https://imageshack.com/i/poXB2P03j)

Also, here are some photos of the trip I did in CO with the Colorado land rover owners club. Enjoy.

https://www.aulro.com/afvb/images/imported/2018/02/473.jpg (https://imageshack.com/i/po29SkvNj)

https://www.aulro.com/afvb/images/imported/2018/02/474.jpg (https://imageshack.com/i/pnNisdNUj)

https://www.aulro.com/afvb/images/imported/2018/02/475.jpg (https://imageshack.com/i/pnbMWWIzj)

https://www.aulro.com/afvb/images/imported/2018/02/476.jpg (https://imageshack.com/i/podDkxe6j)

https://www.aulro.com/afvb/images/imported/2018/02/477.jpg (https://imageshack.com/i/pnKfvysFj)

https://www.aulro.com/afvb/images/imported/2018/02/478.jpg (https://imageshack.com/i/pnAfYq81j)

More to come.

DieSchnelleKafer

19th February 2018, 01:04 PM

I just found an image before the bar was remade. Both swing arms were scrapped and built again, I remade the chassis supports as well due to the fact the old mounts had cracked and bent from what I believe to be corrugation damage.

https://www.aulro.com/afvb/images/imported/2018/02/539.jpg (https://imageshack.com/i/polNNldhj)

The headman headers have also been installed, it sure feels like the v8 has more capacity to rev now. I have also installed a flow master 80 series 1 into 2 muffler. It replaces the stock centre silencer. one exit goes to the rear of the vehicle (like normal) however the second goes to a 2-1/2 inch stainless steel butterfly valve that exits right under the disco. This valve is vacuum controlled, a vacuum line runs up into the engine bay and meets a solenoid that feeds of the intake manifold. I have a small switch next to the gear shifter that controls the exhaust valve.

I only open the valve up on private land where there isn't anybody around though of course ... .. ;)

https://www.aulro.com/afvb/images/imported/2018/02/540.jpg (https://imageshack.com/i/pnppZR0Vj)

https://www.aulro.com/afvb/images/imported/2018/02/541.jpg (https://imageshack.com/i/pnx5HKNKj)

DieSchnelleKafer

20th February 2018, 05:16 AM

Slider looks good.
Are you not worried about hooking up in ruts in that back section though?

Hey mate thanks, Not really. I had the rover on a knarly angle where most of the weight of the vehicle was on the sliders in a deep rut, I had to reverse. The Sliders took all the brunt and I could see them hooking up at all.

turtle

22nd February 2018, 08:17 PM

bee utey

22nd February 2018, 11:14 PM

"This valve is vacuum controlled, a vacuum line runs up into the engine bay and meets a solenoid that feeds of the intake manifold. I have a small switch next to the gear shifter that controls the exhaust valve."

Just a question re controlling the exhaust valve. If you are accelerating heavily and your foot is to the floor, won't your vacuum drop to 'very little' in the manifold and then you would lose the control signal? This would then close the valve and you would lose the benefit of having a 'free flowing' exhaust.

Foxy

A small vacuum reservoir and a non return valve on the vacuum line fixes that. No different to a brake booster.

DieSchnelleKafer

23rd February 2018, 02:13 PM

"This valve is vacuum controlled, a vacuum line runs up into the engine bay and meets a solenoid that feeds of the intake manifold. I have a small switch next to the gear shifter that controls the exhaust valve."

Just a question re controlling the exhaust valve. If you are accelerating heavily and your foot is to the floor, won't your vacuum drop to 'very little' in the manifold and then you would lose the control signal? This would then close the valve and you would lose the benefit of having a 'free flowing' exhaust.

Foxy

Hi, Yes you raise a good point. I failed to mention i have a check valve between the manifold and the solenoid for this reason. The valve is just off a Japanese 4wd, i believe a Toyota surf (those cars have a gazillion vacuum lines).

D2_TD5

5th April 2018, 09:18 PM

Nice Build! Good to see custom fab on a D2 [bigrolf]

Where did you get your headman headers from?

DieSchnelleKafer

9th April 2018, 04:06 AM

Nice Build! Good to see custom fab on a D2 [bigrolf]

Where did you get your headman headers from?

Hey thanks mate. Yes i enjoy doing some handy work with the welder etc. I am deciding whether or not to sell the ARB bar and custom build a front winch bumper or just modify the ARB unit... I i like the idea of a custom built unit, we will see.

Hedman headers were from JEGS in the States. Hedman 39800: Standard Duty Uncoated Headers | JEGS (http://www.jegs.com/i/Hedman/500/39800/10002/-1) part number 39800

unfortunately they are not a direct bolt on. Test fit the headers and then you will likely find that each runner (just after the exhaust port on the head) needs to be pie cut and welded a small amount as to pull the bottom of the header away from the chassis rail. Once you test fit/modify them then i would recommend to have them ceramic coated like i did. I recommend getting the "sandwiched" type of header-exhaust port gasket, these gaskets are the best for this header. Do not use the gaskets that come from the box.

Pros of these headers:
-i could feel a power increase in the top of the rev range, the car is happy as Larry to sit up in the 5000rpm range, good for sand driving.
-because of the 4 into 1 configuration the car now sounds like it has a small, small block chev in it [wink11].

- i could not feel a loss in low down torque (everyone said i would).

Cons:

-mediocre build quality, light wall tubing.

- after you factor in the ceramic coating, they cost as much as any other Australian header on the market. (although the Aussie headers are not 4 into 1).

- added engine noise. The light wall tubing transmits a lot of exhaust sound.

Hope that helped.
-Blair

below you will see the relief cuts and welds that i did to make the headers fit. I only realized it needed to be modified after the ceramic coating.

https://www.aulro.com/afvb/images/imported/2018/04/320.jpg (https://imageshack.com/i/pngcIXmRj)

D2_TD5

9th April 2018, 08:43 AM

DieSchnelleKafer

9th April 2018, 10:24 AM

Cool, thanks for all the details! Cant wait to get stuck into the Rover V8, I rekon with the right mods and tune it could make some decent grunt and be some what economical, for what it is anyway.

Are you planning to get a tune?

Being honest mate these engines seam like a dead end, hate to burst your bubble. Have your fun however don't bury to much money in to one haha. The max i would do to one is some headers and a camshaft... that is about all i have planned for this engine. If i want more power/reliability then it will be engine conversion time

From my research it appears that the Bosch m5.2.1 ECM is not able to be tuned easily. Its not all bad news however because the stock tune already has a considerable amount of leniency when it comes to air fuel ratios. The closed oxygen sensor system will cater for camshafts, exhausts etc. You may be able to get away with a few mods and the ECM will adapt to the new engine parameters (with more fuel). I have known a few blokes who have put a 4.6 crankshaft into their d2's and the stock ECM caters for the increased need for fuel just fine.

cheers,

D2_TD5

9th April 2018, 10:59 AM

cool, be keen to see the graph if you ever put yours on a dyno.

I guess that's probably the reason I couldn't find much on modding the Rover V8 unlike the GM LSx engines! Should have a bit of an idea in the next few months what I can get out of it. Gotta sort a dead MAF issue first [bighmmm]

ozscott

9th April 2018, 02:37 PM

DieSchnelleKafer

11th April 2018, 04:19 AM

I have a 4.6 high compression in my D2 manual with stock Bosch EM and injectors and it goes very well and with good economy.

Mate what a great thread - your build up is something to be proud of. I did an inline thermostat and it has been excellent. Yours looks neater than mine. Would you mind posting up the component details including hose numbers and types and joiner that appears to have the bleeder in it. I have a TEFBA Filter that complicates my set up (maybe mine cannot run like your set up due to filter). Mine works well and had been there for quite some time and a hell of a lot of corrugated roads so I should leave it alone... Cheers

If a 4.6 crankshaft comes up easily i may toy with such things however i am really liking the look of the mercedes om606 six cylinder turbo diesel conversion, we can all dream!

Thanks Mate, projects always take longer than anticipated but its getting there.

Okay these are the parts i used:

1. Gates bottom hose part number 22639 (from a bmw)

2. Gates top hose part number 21719 (GM part)

3. "meziere" inline thermostat housing part number 680-WN0071 (suits chevy thermostats) Meziere WN0071: Inline Thermostat Housing 1-1/4" Slip-On Hose Inlet | JEGS (http://www.jegs.com/i/Meziere/680/WN0071/10002/-1)

4. chevy 170 degree F thermostat part number 680-WN0070170 http://www.jegs.com/i/Meziere/680/WN0070170/10002/-1

5. inline bleeder with added sight glass and temperature sender hole: Coolant Sight Glass – JTR Stealth (https://jagsthatrun.com/products/coolant-sight-glass)

One of the best mods i have done.

mrapocalypse

12th April 2018, 06:53 PM

Hi,

Great thread, where'd you get the alloy roof rack.

Cheers

I.

DieSchnelleKafer

16th April 2018, 04:36 AM

Hi,

Great thread, where'd you get the alloy roof rack.

Cheers

I.

Gumtree special mate. If you need a simple rack then this style will do however i would not recommend one if you plan on doing lots of gravel roads/currugations etc. The tall legs required to clear the roof have already cracked in a few places from fatigue.

mrapocalypse

18th April 2018, 06:45 PM

Good call... thanks.

I.

DieSchnelleKafer

2nd July 2018, 06:57 PM

So i always wanted to do away with the ARB bar. Don't get me wrong, i like the way they are built however i wanted to build something of my own and while doing it create provisions for a winch. The first job was to sell the ARB unit. A nice fellow from down south picked it up to install it on his d2 after the front was wrecked by a prang. So the car was left looking like this. Unfortunately while 4wding in the Harvey hills with my mates, i broke off the drivers side headlight finisher :/

https://imagizer.imageshack.com/v2/xq90/924/6vLfFu.jpg (https://imageshack.com/i/po6vLfFuj)

I started off by making all the beefy brackets in 5mm flat plate. Lots of 1mm cutting discs and lots of sparks.

https://imagizer.imageshack.com/v2/xq90/921/mCNGPE.jpg (https://imageshack.com/i/plmCNGPEj)

https://imagizer.imageshack.com/v2/xq90/921/k7qTdD.jpg (https://imageshack.com/i/plk7qTdDj)

https://imagizer.imageshack.com/v2/xq90/922/BdUt65.jpg (https://imageshack.com/i/pmBdUt65j)

https://imagizer.imageshack.com/v2/xq90/922/iFs1zc.jpg (https://imageshack.com/i/pmiFs1zcj)

DieSchnelleKafer

2nd July 2018, 07:01 PM

All the way through this i used a laser level to get all the angles correct before tacking the steel together.

https://imagizer.imageshack.com/v2/xq90/921/tQuhT0.jpg (https://imageshack.com/i/pltQuhT0j)

I used a hole in the engine bar sheet metal each side as a datum to level the vehicle. Getting the vehicle level turned out to be a hassle, i suspect the land rover factory reserved discovery building to only early Monday mornings.

https://imagizer.imageshack.com/v2/xq90/921/Fm4ANc.jpg (https://imageshack.com/i/plFm4ANcj)

A few more bits welded in. My mate has since been hired by a 4x4 accessory shop and he was able to bring back a Warn winch for all the mocking up.

https://imagizer.imageshack.com/v2/xq90/924/gOPImT.jpg (https://imageshack.com/i/pogOPImTj)

https://imagizer.imageshack.com/v2/xq90/922/RFD0ky.jpg (https://imageshack.com/i/pmRFD0kyj)

After most of the beefy internal mounting was taken care of i focused my attention on the outer sheet metal.
https://imagizer.imageshack.com/v2/xq90/922/EE4iGy.jpg (https://imageshack.com/i/pmEE4iGyj)

https://imagizer.imageshack.com/v2/xq90/924/6Ssu29.jpg (https://imageshack.com/i/po6Ssu29j)

https://imagizer.imageshack.com/v2/xq90/922/EsyAd7.jpg (https://imageshack.com/i/pmEsyAd7j)

https://imagizer.imageshack.com/v2/xq90/921/yZ2bmp.jpg (https://imageshack.com/i/plyZ2bmpj)

The process of filling in the blanks was quite simple really.

1. Cut cardboard to size
2. trace cardboard on steel
3. cut steel
4. weld that sucker in

https://imagizer.imageshack.com/v2/xq90/922/3dlnzN.jpg (https://imageshack.com/i/pm3dlnzNj)

https://imagizer.imageshack.com/v2/xq90/924/wbEOvJ.jpg (https://imageshack.com/i/powbEOvJj)

https://imagizer.imageshack.com/v2/xq90/923/nkXDoC.jpg (https://imageshack.com/i/pnnkXDoCj)

Once the sheet metal was done i braced the inside. This is not the most recent photo, there is even more bracing now.

https://imagizer.imageshack.com/v2/xq90/923/H4tdVD.jpg (https://imageshack.com/i/pnH4tdVDj)

DieSchnelleKafer

2nd July 2018, 07:11 PM

I always wanted to add a nice big hoop to the front of the vehicle. I didn't want to cover the headlights in any way, i think the headlights on this model are one of its best attributes therefore there were no hoops added to the side.

https://imagizer.imageshack.com/v2/xq90/922/ZYRz9J.jpg (https://imageshack.com/i/pmZYRz9Jj)

Here was my method of cutting the pipe perfectly. I leveled the hoop and positioned it in the correct orientation/angle. Out came the white marker pen and then later the grinder.

https://imagizer.imageshack.com/v2/xq90/922/dn9L6c.jpg (https://imageshack.com/i/pmdn9L6cj)

https://imagizer.imageshack.com/v2/xq90/924/ZYNL1H.jpg (https://imageshack.com/i/poZYNL1Hj)

outcome of this method:

https://imagizer.imageshack.com/v2/xq90/921/QejxpS.jpg (https://imageshack.com/i/plQejxpSj)

Its amazing what some thick enamel matt black can do!

https://imagizer.imageshack.com/v2/xq90/921/BQqnMe.jpg (https://imageshack.com/i/plBQqnMej)

https://imagizer.imageshack.com/v2/xq90/922/FC7X2i.jpg (https://imageshack.com/i/pmFC7X2ij)

https://imagizer.imageshack.com/v2/xq90/923/MXB3xZ.jpg (https://imageshack.com/i/pnMXB3xZj)

https://imagizer.imageshack.com/v2/xq90/921/pWgUQZ.jpg (https://imageshack.com/i/plpWgUQZj)

There is still plenty to do on this bar. I intend to throw some spotlights and some replacement fog lights. I would also like to put some body filler on the hoop weld lines then respray that section again.

Cheers everyone

Tombie

2nd July 2018, 07:17 PM

Nice fab work; very nice.

Rather concerning though that the SRS system is no longer compliant.

You could end up seriously injured because of something you’ve designed to protect you!

DieSchnelleKafer

2nd July 2018, 07:21 PM

Nice fab work; very nice.

Rather concerning though that the SRS system is no longer compliant.

You could end up seriously injured because of something you’ve designed to protect you!

Cheers mate,

I gave all that area some thought and i am happy with how i have done it. I don't want to start this conversation on this thread in order to minimize clutter.

Rok_Dr

2nd July 2018, 07:29 PM

DieSchnelleKafer

2nd July 2018, 07:56 PM

Agree with Tombie

Lovely metal work I’m impressed.... but you if are in an accident and survive your insurance company will walk away and the other party’s insurer will come directly at you.

And I suspect the forward angled hoop will also result in a canary if the police pull you over.

Cheers

Steve

Thanks Rok,

Like stated previously i am not going to enter in to this discussion. I have seen it before and i dont want this thread to turn in to an argument on hypothetical scenarios. There are so many variables, and so much conjecture surrounding this topic.

I appreciate your concern however my energy for this topic is not there.

speleomike

2nd July 2018, 08:23 PM

Hi

You are doing a great job documenting this project. Keeping this thread on-topic and with the really excellent pictures will means others who wish to do some of these mods will have some great examples to get ideas from. You clearly have some really ace mechanical and engineering skills :-) Most people that do mods will need to check for themselves what is OK or not in their own state.

Keep up this great documentation project.

Mike

LRJim

2nd July 2018, 08:55 PM

Nice fab work; very nice.

Rather concerning though that the SRS system is no longer compliant.

You could end up seriously injured because of something you’ve designed to protect you!Unless he's changed his airbags in the last 10 years it probably wasn't anyway [emoji1]

Unplug the fuse if it concerns you otherwise homemade bull bars ftw just don't ram up someone's bum!
Not a fan of the hoop but that's my opinion (maybe coz I see it on a lot of mall jeeps)

But I really love your work no one would know it's "homemade" there's a difference between DIY and Done it myself and you nailed it[emoji106]

DieSchnelleKafer

2nd July 2018, 09:06 PM

Unless he's changed his airbags in the last 10 years it probably wasn't anyway [emoji1]

Unplug the fuse if it concerns you otherwise homemade bull bars ftw just don't ram up someone's bum!
Not a fan of the hoop but that's my opinion (maybe coz I see it on a lot of mall jeeps)

But I really love your work no one would know it's "homemade" there's a difference between DIY and Done it myself and you nailed it[emoji106]

Thanks for the compliments mate. Yeah like i said, there is just so many variables that can be disputed when this conversation comes up its just crazy!

Funny about the hoop. I might chop it off and go with this one instead... what do you think? [wink11]

https://imagizer.imageshack.com/v2/xq90/923/fUmTT6.jpg (https://imageshack.com/i/pnfUmTT6j)

LRJim

2nd July 2018, 09:12 PM

Thanks for the compliments mate. Yeah like i said, there is just so many variables that can be disputed when this conversation comes up its just crazy!

Funny about the hoop. I might chop it off and go with this one instead... what do you think? [wink11]

https://imagizer.imageshack.com/v2/xq90/923/fUmTT6.jpg (https://imageshack.com/i/pnfUmTT6j)Bahahahhaha yeah that's the one I love!!
Don't get me wrong I like hoops but they just overkill it, they do help with a rollover though I'll give them that. Cheers

Tombie

2nd July 2018, 10:05 PM

That’s not referred to as a Hoop, that’s a Stinger [emoji41]

Tombie

2nd July 2018, 10:06 PM

Unless he's changed his airbags in the last 10 years it probably wasn't anyway [emoji1]

Unplug the fuse if it concerns you otherwise homemade bull bars ftw just don't ram up someone's bum!
Not a fan of the hoop but that's my opinion (maybe coz I see it on a lot of mall jeeps)

But I really love your work no one would know it's "homemade" there's a difference between DIY and Done it myself and you nailed it[emoji106]

It’s Not 10 years anymore [emoji41] they extended that ages ago.

Feel free to join in the thread in Tech chat about Dangerous behaviours / Mods..

DieSchnelleKafer

8th July 2018, 05:10 PM

So i took the chance to do a bit of a working holiday down south at a beautiful place called Bremer Bay. We used to go down to this area as kids for camping holidays. To see it has not changed in however many years is nice - how i remember it. Its a Sunday and there isn't anything to do here so i thought i may as well update the build thread.

I have completed a number of small modifications to the disco. I replaced the diff drain plugs with some alloy replacements. Anyone who has dealt with the plastic stock units will know why i did this!

https://imagizer.imageshack.com/v2/800x600q90/923/fhr656.jpg (https://imageshack.com/i/pnfhr656j)

I pressed up some aluminum sheet metal and fixed a table for the rear door. It has two strong magnets at the top to secure it in the upright position. I have already used this thing a million times, its a great addition for camping and lunch stops etc.

https://imagizer.imageshack.com/v2/800x600q90/924/e4vlJ2.jpg (https://imageshack.com/i/poe4vlJ2j)

https://imagizer.imageshack.com/v2/800x600q90/921/0E9FOV.jpg (https://imageshack.com/i/pl0E9FOVj)

and to finish this post off some beauty shots of the vehicle. (Don't mind the missing headlight plastics!)

https://imagizer.imageshack.com/v2/800x600q90/924/kZ7e4X.jpg (https://imageshack.com/i/pokZ7e4Xj)

https://imagizer.imageshack.com/v2/800x600q90/923/saY1qK.jpg (https://imageshack.com/i/pnsaY1qKj)

https://imagizer.imageshack.com/v2/800x600q90/921/VI69OZ.jpg (https://imageshack.com/i/plVI69OZj)

Cheers

rangieman

8th July 2018, 05:35 PM

Looking good [thumbsupbig]

I enjoy following your thread [wink11]

DieSchnelleKafer

8th July 2018, 09:03 PM

Spent the afternoon exploring the dunes at Dillon Bay. A few weird looks were given by on lookers as i spent a good 10 minutes getting the right shot.

https://imagizer.imageshack.com/v2/800x600q90/922/r8NDCH.jpg (https://imageshack.com/i/pmr8NDCHj)

https://imagizer.imageshack.com/v2/800x600q90/923/17aoYY.jpg (https://imageshack.com/i/pn17aoYYj)

cjc_td5

8th July 2018, 10:38 PM

DieSchnelleKafer

19th July 2018, 09:36 PM

A great beach and great shots. We spent a day looking around on that beach in April.
We struck some very very soft sand over on the eastern side of Bremer Bay near Gordon Inlet. The only time I have got our D4 bogged.[bigsad]
Have fun.

Thanks mate

Yeah i was warned by a few locals that the softness of the sand can be unpredictable at certain areas. The further i headed along the beach past the inlet, the softer it got!

DieSchnelleKafer

24th October 2018, 07:41 PM

A little bit of work has been completed on the vehicle in the past few months. I was able to get it very bogged up in Harvey whilst on a camping trip:

https://imagizer.imageshack.com/v2/xq90/924/vVFkQ6.jpg (https://imageshack.com/i/povVFkQ6j)

https://imagizer.imageshack.com/v2/xq90/924/0Nh1gh.jpg (https://imageshack.com/i/po0Nh1ghj)

The front ball joints were worn so they got replaced, what a bugger of a job. Upon removal of the hub carrier assembly it was interesting to see how much play the bottom drivers ball joint had, a tad alarming. Whilst i was there, the front axle seals and front pinion seal were replaced.

https://imagizer.imageshack.com/v2/xq90/923/7m1v7O.jpg (https://imageshack.com/i/pn7m1v7Oj)

https://imagizer.imageshack.com/v2/xq90/921/WGtPqM.jpg (https://imageshack.com/i/plWGtPqMj)

https://imagizer.imageshack.com/v2/xq90/921/rXWLGY.jpg (https://imageshack.com/i/plrXWLGYj)

The front bar got some love. I filled the areas around where the front hoop was welded to the elbows as well as a few divets in the bar caused by the welding process. The bar received another thick coat of flat black enamel.

https://imagizer.imageshack.com/v2/xq90/921/iw47TP.jpg (https://imageshack.com/i/pliw47TPj)

On went a "Great White" 18 inch light bar. These things are bright!

https://imagizer.imageshack.com/v2/xq90/924/Qc9awd.jpg (https://imageshack.com/i/poQc9awdj)

https://imagizer.imageshack.com/v2/xq90/924/FQVeiN.jpg (https://imageshack.com/i/poFQVeiNj)

Whilst i was in the painting mood, the sliders were stripped and painted with a good quality epoxy primer and then several coats of Dulux enamel flat black. All those 4wding trips and boot scuffs had taken their toll on the paint. My thinking with this is that its super easy to touch up scratches and marks along the way, just whip the dulux spray can out and go to town!

https://imagizer.imageshack.com/v2/xq90/923/awiRWy.jpg (https://imageshack.com/i/pnawiRWyj)

rangieman

24th October 2018, 08:18 PM

Looking good [thumbsupbig]

DieSchnelleKafer

26th October 2018, 02:41 PM

Looking good [thumbsupbig]

Thanks Mate [biggrin]

igaitcho

30th October 2018, 09:39 PM

"I pressed up some aluminum sheet metal and fixed a table for the rear door. It has two strong magnets at the top to secure it in the upright position. I have already used this thing a million times, its a great addition for camping and lunch stops etc."

I am in the process of doing something similar to my back door... I see you used the original holes for securing the sheet to the door. I was just wondering what you secured it with and what additional work you may have had to do to the door?

Great feed too!!

DieSchnelleKafer

2nd November 2018, 04:31 PM

igaitcho

3rd November 2018, 07:14 AM

DieSchnelleKafer

6th November 2018, 05:08 PM

I considered using some aviation rivnuts my old man had sitting around but to install them i needed access to both sides of the panel. I shall do a bit of research on newer ones etc. I was going to try using the Xmas tree plastic fittings but thought they might be a bit weak. Thanks again

Yes the ones i am talking about can go into a blind hole, thats why i really love the things.

https://imagizer.imageshack.com/v2/xq90/922/bLmI3h.jpg (https://imageshack.com/i/pmbLmI3hj)

CU55TM Disco

13th November 2018, 10:32 PM

That Swing Away Carrier looks interesting, tell me more!

DieSchnelleKafer

13th November 2018, 11:49 PM

That Swing Away Carrier looks interesting, tell me more!

https://imagizer.imageshack.com/v2/800x600q90/924/UssVTR.jpg (https://imageshack.com/i/poUssVTRj)

I suppose you are talking about the convoluted way that the above arrangement has been built. There are two swing away arms on the rear, left and right. The right has an arm that connects to the rear door so that it swings with the door, the arm is rubber insulated to the right arm to deal with body/chassis relative movement.

the right arm has a rubber stopper that sits behind that 6mm head (1 of two in above photo).

Behind the other hex head bolt lies another rubber stopper that sandwiches the right arm to the bar when latched.

The over-centre latch pulls the left arm nice and tight, binding the whole assembly together.

Basically, it was done so that it only requires the user to pull away the left swing away.

There are a few things i would do differently if i made one again. Its quite a heavy assembly because of the thickness of the steel used, some areas need beefing up as well.... I also have plans on redoing the left swing away to carry a small LPG bottle as well as a 20l jerry. I would also like to change the rear lights to something more aesthetically pleasing.

igaitcho

15th November 2018, 11:34 PM

Yes the ones i am talking about can go into a blind hole, thats why i really love the things.

https://imagizer.imageshack.com/v2/xq90/922/bLmI3h.jpg (https://imageshack.com/i/pmbLmI3hj)[/QUOTE]
Awesome, thanks! Do you recall what size rivnut you used?

DieSchnelleKafer

17th November 2018, 10:58 PM

Yes the ones i am talking about can go into a blind hole, thats why i really love the things.

Awesome, thanks! Do you recall what size rivnut you used?[/QUOTE]

No worries mate, 6mm threaded nutserts, best of luck with your project. Use 6mm dome head allen bolts, or counter sunk allen head bolts to make your project more aesthetically pleasing. I had normal allen head bolts on it for a while but my mates kept yelling at me to change them because they looked "discusting"... (i have good, honest mates).

DieSchnelleKafer

30th May 2023, 12:03 AM

Hi Folks, long time no see!

This car has been in storage for 2 years whilst I let life get in the way - but now I’m back at it.

Cue the OM606 – I found this in 2018 and mothballed it, couldn’t believe my luck really (probably less than 100 in Australia). The plan since then has been to put it in my Disco, using the following bits and pieces:

OM606 turbo motor with HX35 holset
Mercedes 722.6 transmission from an ML270 (includes bolt pattern at rear)
Red winches 722.6 to LT230 adaptor plate and spud shaft
Either a compushift or “Ofgear” gearbox controller, undecided currently
Baldur systems DSL1 engine controller
Custom programmed crankshaft signal emulator to retain the standard rover V8 ECU / traction control etc, I have a working prototype

Note: The HX35 is unlikely to be a responsible choice of turbo for this application, however I’m going to do it for the meme.

https://imagizer.imageshack.com/v2/800x600q70/923/Ajtn9W.jpg (https://imageshack.com/i/pnAjtn9Wj)

https://imagizer.imageshack.com/v2/800x600q70/924/ntHtsb.jpg (https://imageshack.com/i/pontHtsbj)

May as well dive right in.

The first two jobs have been small ones. I mounted up the Mercedes 722.6 shifter module into the center console. I’m currently getting a shroud / cover 3D printed, the aim is to have it look relatively stock.

https://imagizer.imageshack.com/v2/800x600q70/923/62QbQs.jpg (https://imageshack.com/i/pn62QbQsj)

https://imagizer.imageshack.com/v2/800x600q70/924/88bZBX.jpg (https://imageshack.com/i/po88bZBXj)

https://imagizer.imageshack.com/v2/800x600q70/923/AHA6GG.jpg (https://imageshack.com/i/pnAHA6GGj)

The other small job was to utilise the Mercedes throttle position sensor. This sensor will feed into the DSL1 ECU, there will be no mechanical connection to the motor. For anyone curious, the DSL1 will take care of the cruise control duties.

https://imagizer.imageshack.com/v2/800x600q70/923/Dt9INO.jpg (https://imageshack.com/i/pnDt9INOj)

https://imagizer.imageshack.com/v2/800x600q70/923/Mb0s4v.jpg (https://imageshack.com/i/pnMb0s4vj)

Will keep you all posted.

DieSchnelleKafer

11th June 2023, 09:30 PM

This weekends work.

I 3D modelled a surround for the gearbox shifter unit which blends it into the centre console. It took one or two test prints to make it right, but the end result is great. Expect to see more 3D printed parts in this conversion, the process is just to easy. Please excuse the lighting - I am working under flood lights at the moment as the shed has just been built and I havent completed the electrical fitout.

https://imagizer.imageshack.com/v2/800x600q70/922/i9HveI.jpg (https://imageshack.com/i/pmi9HveIj)

I have begun to tackle the wiring side of the conversion too. See below image showing the original V8 ECU relocated to the passenger side glovebox compartment, together with the new Baldur DSL1 unit strapped on it's back. As you can see, the plastic structure of the glovebox was cutout to make room for the ECU's.

The idea was always to relocate the original Bosch unit to a higher location than stock - I was never comofrtable with the standard position, granted things would need to go seriously pear shaped in order to have water up that high. Anyway, there will peace of mind now.

If anyone is curious, you can read up on the DSL1 controller here: DSL1 controller (https://controls.is/dsl1.html)

https://imagizer.imageshack.com/v2/800x600q70/924/4iy9Gs.jpg (https://imageshack.com/i/po4iy9Gsj)

86mud

20th July 2023, 11:11 AM

Nice work, keep the pics coming

DieSchnelleKafer

24th November 2024, 03:56 PM

Hi Everyone.

So, things changed a little bit whilst you’ve been away lol. After some careful consideration I sold the OM606 and purchased it’s bigger and more modern brother, the OM648. For those that don’t know anything about these engines, they are a 3.2 litre inline 6 common rail diesel which were supplied in the mid 2000’s E class estates and sedans. As normal, the euro guys have found ways to make massive power from (no surprise there). My understanding is that these engines were never supplied in Australia, my particular engine was imported from Europe.
The reasons that I went for this engine are as follows:

The torque placement is lower in the rev range than the 606. 606’s are known for having little torque until on boost.
They create less heat when in large vehicles. A lot of guys seem to be having issues with keeping the 606’s cool in 4WD. This could be especially challenging in Australia.
You can include a “popcorn” rev limiter in the tune, sometimes also called “hard cut”. It’s going to sound fully sick in the dunes.
These engines were released until around 2007/8. Meaning that they post date the vehicle. This may prove to be a big help when it comes time for the final engineering signoff.
It’s different. As far as I can tell this will be the first OM648 discovery 2 in the world.

Further to that, I have also swapped the 722.6 Mercedes box in favour of an 8HP70 unit (8 speed auto from a BMW X5). The gearbox will be controlled by a “TurboLamik” TCU – Google for details. I have a friend who has an 8HP / Barra discovery 1 who gave me a demonstration of the 8HP + TurboLamik combination, It’s truly awesome.
As you can imagine this change took a lot of thought, but I am already happy with my decision. I would be regretting my decisions if I didn’t make this call when I did. This engine and gearbox combo is expected to perform very well and will likely serve as a modern and respectable retrofit to the classic D2.

Here is the engine when it arrived to Perth.

https://imagizer.imageshack.com/v2/800x600q70/923/BMuzdd.jpg (https://imageshack.com/i/pnBMuzddj)

https://imagizer.imageshack.com/v2/800x600q70/924/7KpdAs.jpg (https://imageshack.com/i/po7KpdAsj)

https://imagizer.imageshack.com/v2/800x600q70/923/mT9a3F.jpg (https://imageshack.com/i/pnmT9a3Fj)

TurboLamik transmission controller to manage the 8HP70. Also seen is the DCT sequential style shift to be used to run through gears which will be mounted in the factory gearshift location.

https://imagizer.imageshack.com/v2/800x600q70/924/g1g4SJ.jpg (https://imageshack.com/i/pog1g4SJj)

https://imagizer.imageshack.com/v2/800x600q70/923/J9Yr5P.jpg (https://imageshack.com/i/pnJ9Yr5Pj)

Treated myself to a hoist in the meanwhile. Never realised how much I needed one lol.

https://imagizer.imageshack.com/v2/800x600q70/923/ZIyvIv.jpg (https://imageshack.com/i/pnZIyvIvj)

https://imagizer.imageshack.com/v2/800x600q70/922/2ntG2A.jpg (https://imageshack.com/i/pm2ntG2Aj)

https://imagizer.imageshack.com/v2/800x600q70/923/hzjkb4.jpg (https://imageshack.com/i/pnhzjkb4j)

https://imagizer.imageshack.com/v2/800x600q70/924/uE0wPl.jpg (https://imageshack.com/i/pouE0wPlj)

Foreshadowing…

https://imagizer.imageshack.com/v2/800x600q70/922/9XTL7G.jpg (https://imageshack.com/i/pm9XTL7Gj)

Started to mockup all of the mounts. Transfer case mounts had to move back approx 60 mm.

https://imagizer.imageshack.com/v2/800x600q70/922/Uou457.jpg (https://imageshack.com/i/pmUou457j)

https://imagizer.imageshack.com/v2/800x600q70/923/43kaHM.jpg (https://imageshack.com/i/pn43kaHMj)

https://imagizer.imageshack.com/v2/800x600q70/922/1vrrjj.jpg (https://imageshack.com/i/pm1vrrjjj)

https://imagizer.imageshack.com/v2/800x600q70/923/FzPLvV.jpg (https://imageshack.com/i/pnFzPLvVj)

https://imagizer.imageshack.com/v2/800x600q70/924/uE0wPl.jpg (https://imageshack.com/i/pouE0wPlj)

https://imagizer.imageshack.com/v2/800x600q70/924/BELPna.jpg (https://imageshack.com/i/poBELPnaj)

https://imagizer.imageshack.com/v2/800x600q70/924/gNo93X.jpg (https://imageshack.com/i/pogNo93Xj)

https://imagizer.imageshack.com/v2/800x600q70/923/jRQ8hr.jpg (https://imageshack.com/i/pnjRQ8hrj)

https://imagizer.imageshack.com/v2/800x600q70/924/QzjnJl.jpg (https://imageshack.com/i/poQzjnJlj)

https://imagizer.imageshack.com/v2/800x600q70/924/ziyiGU.jpg (https://imageshack.com/i/poziyiGUj)

I’m this deep already. May as well just restore the chassis too eh?

https://imagizer.imageshack.com/v2/800x600q70/923/Hl4pme.jpg (https://imageshack.com/i/pnHl4pmej)

https://imagizer.imageshack.com/v2/800x600q70/923/9Q0C9I.jpg (https://imageshack.com/i/pn9Q0C9Ij)

https://imagizer.imageshack.com/v2/800x600q70/923/6NCgQj.jpg (https://imageshack.com/i/pn6NCgQjj)

https://imagizer.imageshack.com/v2/800x600q70/923/F9Hdjy.jpg (https://imageshack.com/i/pnF9Hdjyj)

https://imagizer.imageshack.com/v2/800x600q70/924/F9ssXr.jpg (https://imageshack.com/i/poF9ssXrj)

https://imagizer.imageshack.com/v2/800x600q70/923/ux9uY1.jpg (https://imageshack.com/i/pnux9uY1j)

https://imagizer.imageshack.com/v2/800x600q70/922/98YXnC.jpg (https://imageshack.com/i/pm98YXnCj)

https://imagizer.imageshack.com/v2/800x600q70/924/ZbJUuM.jpg (https://imageshack.com/i/poZbJUuMj)

https://imagizer.imageshack.com/v2/800x600q70/923/NPGo0D.jpg (https://imageshack.com/i/pnNPGo0Dj)

https://imagizer.imageshack.com/v2/800x600q70/922/hS6y7j.jpg (https://imageshack.com/i/pmhS6y7jj)

Chassis painted and re-assembly begins.

https://imagizer.imageshack.com/v2/800x600q70/923/1fa9DS.jpg (https://imageshack.com/i/pn1fa9DSj)

https://imagizer.imageshack.com/v2/800x600q70/923/Pjk6zo.jpg (https://imageshack.com/i/pnPjk6zoj)

https://imagizer.imageshack.com/v2/800x600q70/923/IhMbt8.jpg (https://imageshack.com/i/pnIhMbt8j)

https://imagizer.imageshack.com/v2/800x600q70/922/aPITGr.jpg (https://imageshack.com/i/pmaPITGrj)

https://imagizer.imageshack.com/v2/800x600q70/923/FO7Mgp.jpg (https://imageshack.com/i/pnFO7Mgpj)

DieSchnelleKafer

24th November 2024, 04:17 PM

Engine mounts welded in for the final time.

https://imagizer.imageshack.com/v2/800x600q70/922/MGF0wJ.jpg (https://imageshack.com/i/pmMGF0wJj)

https://imagizer.imageshack.com/v2/800x600q70/923/SL4H08.jpg (https://imageshack.com/i/pnSL4H08j)

https://imagizer.imageshack.com/v2/800x600q70/924/PzQpLu.jpg (https://imageshack.com/i/poPzQpLuj)

https://imagizer.imageshack.com/v2/800x600q70/923/lkGbje.jpg (https://imageshack.com/i/pnlkGbjej)

Mock fit-up with the body. Looking good.

https://imagizer.imageshack.com/v2/800x600q70/924/9ma1C7.jpg (https://imageshack.com/i/po9ma1C7j)

https://imagizer.imageshack.com/v2/800x600q70/924/9yAxVI.jpg (https://imageshack.com/i/po9yAxVIj)

Got a chance to begin the exhaust. 3” from turbo back. Turns into 3.5” just after the transfer case. No, it does not need to be that big. Yes, I did it anyway.

https://imagizer.imageshack.com/v2/800x600q70/922/qrGuZn.jpg (https://imageshack.com/i/pmqrGuZnj)

https://imagizer.imageshack.com/v2/800x600q70/924/4KNLf0.jpg (https://imageshack.com/i/po4KNLf0j)

https://imagizer.imageshack.com/v2/800x600q70/923/duCgh6.jpg (https://imageshack.com/i/pnduCgh6j)

Fuel supply sorted. The stock tank supplies an aluminium surge tank. A Bosch 200 series pump collects from the bottom of the surge tank and supplies it to the high pressure common rail pump.
I also mounted an oil cooler for the transmission. It’s not in the most favourable position I know. We will see if it needs a guard or to be relocated entirely down the track – time will tell.

https://imagizer.imageshack.com/v2/800x600q70/922/7NIL0P.jpg (https://imageshack.com/i/pm7NIL0Pj)

https://imagizer.imageshack.com/v2/800x600q70/923/9qxVif.jpg (https://imageshack.com/i/pn9qxVifj)

https://imagizer.imageshack.com/v2/800x600q70/923/FMjwPH.jpg (https://imageshack.com/i/pnFMjwPHj)

https://imagizer.imageshack.com/v2/800x600q70/923/3W5pog.jpg (https://imageshack.com/i/pn3W5pogj)

At this point it would be rude not to also paint the engine bay…

https://imagizer.imageshack.com/v2/800x600q70/923/ivRtWh.jpg (https://imageshack.com/i/pnivRtWhj)

https://imagizer.imageshack.com/v2/800x600q70/923/ML23rr.jpg (https://imageshack.com/i/pnML23rrj)

https://imagizer.imageshack.com/v2/800x600q70/923/1DM7ya.jpg (https://imageshack.com/i/pn1DM7yaj)

https://imagizer.imageshack.com/v2/800x600q70/922/SgbKZn.jpg (https://imageshack.com/i/pmSgbKZnj)

https://imagizer.imageshack.com/v2/800x600q70/924/ZjlpCT.jpg (https://imageshack.com/i/poZjlpCTj)

https://imagizer.imageshack.com/v2/800x600q70/923/uuG0hT.jpg (https://imageshack.com/i/pnuuG0hTj)

https://imagizer.imageshack.com/v2/800x600q70/923/AmUVZ9.jpg (https://imageshack.com/i/pnAmUVZ9j)

https://imagizer.imageshack.com/v2/800x600q70/922/YVSRoF.jpg (https://imageshack.com/i/pmYVSRoFj)

So that’s where I’m at. Here is what’s left:

Hookup transmission cooler
Finish power steering plumbing
Mount body on chassis
Coolant hoses
Mount water to air intercooler + front radiator
Aircon lines
Turbo oil feed / drain
Propshafts
Wiring

Currently aiming to have this vehicle on the road by middle of January 2025, we’ll see if I can pull it off!