Disco ute

[Disco_ute84]

I've been meaning to start this thread for a while now, but here it is at last.
A few years ago I was in the market for a 4wd. I wasn't really all that impressed by what was on the market, I wanted live axles, coil suspention, turbo diesel that didn't drink 12-15lts/100 and a few creature comforts (air con, abs, airbags).

On a filght home from working up in Bundaberg I was reading a copy of Overlander. In it featured an article on a custom disco tray back (a fellow aulro member), the article got me thinking.

So in late 2007 I bought a 2003 2a discovery.

http://photos-snc1.facebook.com/v375/74/120/612654116/n612654116_1084813_9819.jpg

It is a Td5 manual. 44000km on the clock. When i bought it, it had a broken passanger side mirror (I think because the disco was laying on it :))
I believe the disco came from up near brisbane somewhere. Does anyone on here now this vehcile in its past life.

Once I got it home I stripped the back had the body striaghtend out. That my father in the background.
http://photos-snc1.facebook.com/v375/74/120/612654116/n612654116_1084894_4291.jpg

After the body was back inline I preped the two chassis. I bought a second chassi so that there was only one join (one was cut forward and the other cut back) Unfortuantly the disco now has a new chassi number (they are stamped on the back rhs, just below the inlet to the fuel tank for those that dont know)

http://photos-snc1.facebook.com/v375/74/120/612654116/n612654116_1084896_4856.jpg

I then made a cut the chassis (see picture for cut profile) and joined them together.

http://photos-snc1.facebook.com/v375/74/120/612654116/n612654116_1084810_8929.jpg

The driveline was lengthened buy using a center bearing. I could of lenghtened it by making a one piece tailshaft, however I did not want the tailshaft hanging down at an angle.
Fuel lines were lenghtened buy using truck air brake line (8mm).
I had to make new brake lines from the abs module to the rear.
I was lucky with the wiring to the back (including abs sensors). Originaly they ran along the rhs chassi rail, across the 3" pipe above the diff, along the lhs chassi rail, then back across to the other side. I simply ran them all the way along the rhs chassi rail and only cross over once. This means that the plug for the lhs abs sensor is now the rhs and vise versa.

http://photos-snc1.facebook.com/v375/74/120/612654116/n612654116_1084811_9221.jpg

When I started I didn't want the back of the cab to look like a piece of sheet metal had been traced to the profile of the cab and welded on, mainly because I think that this is what makes a converted wagon look like a converted wagon. I want the disco to look like it is a factory job. After going around local car yards with a cardboard cut out of the profile, I got a back pannel from an 02 ford courrier. It had to be widened 116mm in the middle. The side profiles are close enough to work with.
http://photos-b.ll.facebook.com/photos-ll-snc1/v375/74/120/612654116/n612654116_1084793_2190.jpg

The last month or so i have been working on basicaly from the top of the rear window up.

http://photos-c.ak.fbcdn.net/photos-ak-snc1/v926/74/120/612654116/n612654116_1196354_6513.jpg

http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v650/74/120/612654116/n612654116_1535971_2155340.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v650/74/120/612654116/n612654116_1536119_715187.jpg

I was busy making these pannels on the weekend. I made the verticle curve in them by running the tig over it every 20mm and quenching the heated area. It follows the curve of the B pillar perfectly.

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v650/74/120/612654116/n612654116_1536120_1753335.jpg

http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v650/74/120/612654116/n612654116_1535972_5548645.jpg

I'll continue to post pics as the work progresses. I'm out to the shed now to do some more.

Tim

[Grover-98]

Very nice! keep the pics coming in!

I wouldn't mind doing this to my old rangy!

James.

[101RRS]

Nice work - are you going to make this into a ute :) or a tray back like Roversmith's.
http://www.aulro.com/afvb/members-rides/33722-discovery-2a-ute.html

Keep up the good work:).

Garry

[long stroke]

Very, very nice:cool:
Can't wait to see it finnished:D

[V8Landy]

Nice a lot fun ahead:D

[2_door]

thats absolutely awesome. cant wait for the updates, will watch with great interest.

wish I had the balls/cash/time/room/tools to do the same thing :eek:

well done

[Gaz69]

Good work mate,
Keep the updates coming. Always liked the disco utes.

Cheers Gaz

[4wd4fun]

Thats nice work and should look factory when finished.:D:D

[roversmith]

Tim you have very good taste in automobiles :D:D

[discowhite]

disco ute84 and roversmith,
how much in length did you add to your wheel base's?

cheers phil

[roversmith]

disco ute84 and roversmith,
how much in length did you add to your wheel base's?

cheers phil


500 mm, makes it a 120'' I was about to ask Tim the same question.

[Disco_ute84]

I added 600mm. So I guess that makes it 124" wheel base.

With the small extra cab it has, hopefully it will look balanced with an decent size tray.

[disco_ute]

I am very interested in the chassis extension. When i did mine my engineer said i couldn't extend the chassis let alone weld to it. I wanted to weld some mounts for the tray to it and he said i had to produce a document from the the manufacture stating the make up of the steel used ie high tensile or mild steel.

Mick

[discowhite]

think you need a better engineer! the series 1 disco utes ive seen have all had chassis extensions, and a lengthened wheel base.

is yourse series 1?

cheers phil

[disco_ute]

think you need a better engineer! the series 1 disco utes ive seen have all had chassis extensions, and a lengthened wheel base.

is yourse series 1?

cheers phil
Yeah it a D1 sorta I could have done anything i like i just needed a document stating the makeup of the chassis to be able told to weld to it. Some chassis are High tensile steel and can't be welled to let alone have holes drilled in to them (big trucks for example) and i had to prove it wasn't and didn't need to in the end as i could weld to the outriggers so i didn't chase it. That's why I am interested.

I have seen 4x4's with holes drilled in chassis rails for rock sliders etc if they were in a crash and push came to shove insurance could be void unfortunately that's what everything come down to 'Are you Covered'????

Just because they are extended doesn't mean they are engineered.

I have seen some dodgy **** that the owner claims to be engineered and they are far from.

Don't get me wrong what these guys have done to the D2 is very impressive and i know how much work is involved and if i had the chance i would do it to a d2 also!

[discowhite]

the one ive seen the engineers report for has had a whole new rear clip(chassis) folded up the same as the OE piece, but instead of having the chassis dip back down after the diff its all horizontal. really neat job. it's engineered with longer tailshaft and trailing arms also. i know the engineer if you want to have a chat to him?

cheers phil

[disco_ute]

the one ive seen the engineers report for has had a whole new rear clip(chassis) folded up the same as the OE piece, but instead of having the chassis dip back down after the diff its all horizontal. really neat job. it's engineered with longer tailshaft and trailing arms also. i know the engineer if you want to have a chat to him?

cheers phil

no thanks not changing any more now :o

[Disco_ute84]

I called maybe 7 or more engineers before i found one that gave me all the right answers.
Before i started i basicaly new what i wanted to do, i just had to find an engineer that would let me do what i wanted to.
Alot of them wont touch a vehcile if it has SRS airbags, one wanted an internal roll cag (i dont think the phone call went much longer after he said that:p).
When my Grandfather bought a new hj45 landcruiser, (back in the late 70's i guess) dad picked it up from the dealership and took it straight back to the workshop and put 2' in the chassi. We used to put the bulls in the stock crate, and if they dont bend a chassi nothing will. 30 years latter and its still going. The speedo stoped working 10 years ago with over 500000k/m on the clock.
I have noticed that Land rover make the Defender rails in 3 sections. Dad has a 130, and i have noticed they have a front (curved above diff), middle (staight), rear (curved above rear diff). Each section is joined by a verticle weld and the top and bottom flange is reinforced by what looks like 50x3 flat that is fully welded all the way along. I guess the 90, 110 and 130's all share the same chassi ends and the mid section is made depending on the wheel base.

[disco_ute]

I called maybe 7 or more engineers before i found one that gave me all the right answers.
Before i started i basicaly new what i wanted to do, i just had to find an engineer that would let me do what i wanted to.
Alot of them wont touch a vehcile if it has SRS airbags, one wanted an internal roll cag (i dont think the phone call went much longer after he said that:p).
When my Grandfather bought a new hj45 landcruiser, (back in the late 70's i guess) dad picked it up from the dealership and took it straight back to the workshop and put 2' in the chassi. We used to put the bulls in the stock crate, and if they dont bend a chassi nothing will. 30 years latter and its still going. The speedo stoped working 10 years ago with over 500000k/m on the clock.
I have noticed that Land rover make the Defender rails in 3 sections. Dad has a 130, and i have noticed they have a front (curved above diff), middle (staight), rear (curved above rear diff). Each section is joined by a verticle weld and the top and bottom flange is reinforced by what looks like 50x3 flat that is fully welded all the way along. I guess the 90, 110 and 130's all share the same chassi ends and the mid section is made depending on the wheel base.

my engineer was probably a little over cautious but hey i am driving it and i want to to survive a crash

Keep up the good work!

[Disco_ute84]

I didn't call that many so that i could find one that was dodgy, and who would pass an unsafe vehcile.
As i said lot of them wont touch a vehcile if it has SRS airbags, one wanted an internal roll cage, and some wanted payment before they would speak to me.

cheers,

Tim

[Psimpson7]

I have noticed that Land rover make the Defender rails in 3 sections. Dad has a 130, and i have noticed they have a front (curved above diff), middle (staight), rear (curved above rear diff). Each section is joined by a verticle weld and the top and bottom flange is reinforced by what looks like 50x3 flat that is fully welded all the way along. I guess the 90, 110 and 130's all share the same chassi ends and the mid section is made depending on the wheel base.

Nothing like that at all on my 90. chassis rails are one piece for each side of each rail. Dont remember seeing that on any 110's either....?

[discowhite]

me to X2^^^^?

dont remember seing anything like that on the little bro's 130 either?

cheers phil

[Vern]

130's i'd seen were joined in the middle with a vertical weld and a plate about 2foot long top and bottom, it looks pretty ordinary

[sclarke]

Every 130 has a join in the Chassis, they all come out or LR Special vehicles.
130 are custom so to speak...

Someone correct me if i'm wrong, but i have a LR expert telling me this and ive looked under many a 130.

[4x4x2]

This might be a silly question but has anybody made a dual cab out of a disco?

[matbor]

This might be a silly question but has anybody made a dual cab out of a disco?

mmm, i want one of these !

130 dual cab disco, still haven't seen any pics of someone doing one, would have to be one good looking tray!!

[Disco_ute84]

Over the last couple of weeks I've been thinking about what to do with the suspension on the disco.

So far I've worked out that I want a 2" lift, as the ute will mainly be used for touring.

At this stage I am thinking about putting air springs in the rear. My thoughts for this are that some times the ute will only have an empty tray on the back ( no weight), and other times it will be fully loaded for long distance touring (lots of weight).

If I use Coils then the ride will be very hard or very soft depending on how much weight it is carrying.

However if I use air springs then the spring rate will remain consistent (somewhat) no matter what load conditions they are under, as will the lift.

I spoke to a couple of land rover wreckers in melb this week and they suggested that if it hasn't got air springs already don't do it, its to much work..... Yeah right, cant be any were near as hard as some of the things I've already done to it.

My understanding (correct me if I'm wrong) is that there is 3 main components to air susp. 1 air spring 2 compressor 3 valving (incl height control), were the hight control opens the valve after a set time (about 10s in trucks)

From what I can tell most of the wiring is already in place, plugs and wiring for height control switches, plugs and wiring for push button in dash etc etc. Being electronic height control i presume that there is an ecu that plugs in some where for the delays and over rides etc. So the conversion should be somewhat straight forward.

I'm still waying up the pro's and con's but if anyone give me some valid reasons why I shouldn't go down this path it would be greatly appreciated.

Cheers,

Tim

[locorr]

A much easier way would be to put air bags inside your springs. You can have it set up for light weight with the springs then just add air when loaded for a trip. Not as easy to adjust but how often do you carry heavy loads. Low tech and cheap. Well that's what I'm doing but my brain functions at low tech.

[disco_ute]

Try these guys Light Vehicle (http://www.airbagman.com.au/lightvehicle.html#)

what i did was similar to the LR OE but not automated

i had coil bags with 2 LPG lock off switches one to let air in and one to let air out with an in cab switch and gauge. Wasn't automated but it was all in cab and a press of a switch. I had the air comp all hooked in also. So when i had weight in the rear i would flick the switch and let air in to the bags until i was happy with ride height and everything was level.

Parts
2x lock off switches
6mm or plastic tube 10 mtrs to be safe
push lock connectors
set of coil bags
psi guage
few relays and some wire
few hours in the shed

I am going to set this back up with the alloy tray due to the huge difference in load carrying coil v's nothing in the back coils

Also if you are going to buy coil bags you can get the Firestone ones direct from the US much cheap so shop around and then you might want the 2" lift bags or you can buy the rubber spaces from polyair

HTH
Mick

[disco_ute]

Timbren, Hellwig Helper Springs, Bilstein Shocks, Firestone, Air Spring Kits, Mile Marker Winch (http://www.truckspring.com/)

was the place i got my coil bags from

Mick

[Disco_ute84]

Try these guys Light Vehicle (http://www.airbagman.com.au/lightvehicle.html#)

what i did was similar to the LR OE but not automated

i had coil bags with 2 LPG lock off switches one to let air in and one to let air out with an in cab switch and gauge. Wasn't automated but it was all in cab and a press of a switch. I had the air comp all hooked in also. So when i had weight in the rear i would flick the switch and let air in to the bags until i was happy with ride height and everything was level.

Parts
2x lock off switches
6mm or plastic tube 10 mtrs to be safe
push lock connectors
set of coil bags
psi guage
few relays and some wire
few hours in the shed

I am going to set this back up with the alloy tray due to the huge difference in load carrying coil v's nothing in the back coils

Also if you are going to buy coil bags you can get the Firestone ones direct from the US much cheap so shop around and then you might want the 2" lift bags or you can buy the rubber spaces from polyair

HTH
Mick


Mick,
When you say that you used coil bags, are you talking about proper air spring (OE sls) only system, or a coil spring and polly-bag type set up?

Depending on the cost of a sls ecu, I may well end up designing my own system. I was thinking today maybe a couple of timers, or even a small plc.......

I was told today that the sls ecu may talk to the main ecu ( ie sls is off when doors are open etc etc) having said that, the main ecu may have to be configured to tell it that the vehicle has sls. Does any one know/ have access to the logic of the system? P/M me if needed.

Cheers,

Tim

[disco_ute]

I have the Firestone Coil bags not sls bags as such.

FYI when i have factory airbags in my 93 rangie it did talk to the the main ecu as it new what speed i was doing to lower itself when the doors were open and even when it was in park with the hand brake on. I would think that a custom system would be cheaper and easier to install

Mick

[Disco_ute84]

Ok so it has been a while since I have done an update.... so here it is.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs088.snc1/5072_91720344116_612654116_1997784_3601282_n.jpg

I've bought some new shoes. 6 of them. 267-75-16. Very nice.:) As you can see the front is a little sagged from the ARB winch bar.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs088.snc1/5072_91720364116_612654116_1997788_1239297_n.jpg

Tested the flex, all stock suspention, Just to make sure that the rear wheels didn't rub, all good.:) Theres about 18" under that back wheel.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs108.snc1/5072_91720369116_612654116_1997789_1795370_n.jpg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs108.snc1/5072_91720354116_612654116_1997786_7948220_n.jpg

I made up these mounts for the tray.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs108.snc1/5072_91720359116_612654116_1997787_2190214_n.jpg

I've got my tray basicaly tacked up except for the hurdle. I'll make it out of 3" stainless, that way i can use mandrel bends.

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs108.snc1/5072_91720374116_612654116_1997790_5363063_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs088.snc1/5072_91720379116_612654116_1997791_5059294_n.jpg

Rough measurements are 7' by 6'. The rear wheels sit in the middle. The main thing is that the OZTent fits.

Here are some pics for Stirlsilver, this is what I done for the corners on the roof. The sections came from the rear of the disco, and seem to blend very well.
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs088.snc1/5072_91720339116_612654116_1997783_5139416_n.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs108.snc1/5072_91720334116_612654116_1997782_5916279_n.jpg

Hope you all enjoy.

Cheers,

Tim

[Hendrik]

Mate looking fantastic so far, loving it.
Love the look of those MTZ's too, its gonna be one sweet rig once its done.

Cheers
Hendrik

[RVR-BOi]

i can tell that when your finished its going to be one very neat truck.:thumbsup:

[MR LR]

Nice job mate mate my mum has a 01 D2 from dads old Landie dealership i like the idea of meeting the 9" angle grinder with the side of it but not for a while mums getting a TD4.e freelander manual so i'll get the D2 TD5 manual to truckerise maybe a few more years its still the major tow car (we have 2800 kg veteran cars and only this'll pull em)

Ill have a page up soon

I like what ya done

Cheers MR LR jnr

[Disco_ute84]

We have body filler on the roof, and things are starting to go into etch primer. Its all systems go out in the shed. I'll post pics when I can.

Gee I'm very VERY excited.

Cheers,
Tim

[dullbird]

So am I hurry up with those pics already :D

[Disco_ute84]

So here is a very quick up date.

The rear quarter is welded in.
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs268.snc1/9524_126175724116_612654116_2511922_5462065_n.jpg


Another shot.
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs268.snc1/9524_126175734116_612654116_2511923_4222470_n.jpg

The roof is almost ready to prime.
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_126175739116_612654116_2511924_6198217_n.jpg

Another couple of hours work and it will be finished. I dont think I will ever get the bog dust out of the shed.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_126175744116_612654116_2511925_1297823_n.jpg


http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_126175754116_612654116_2511927_4585550_n.jpg

I am very happy with how this came up.
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs268.snc1/9524_126175764116_612654116_2511929_5606196_n.jpg

Ahhh it looks so good!!!!
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_126175769116_612654116_2511930_8165607_n.jpg

Thats all for now. Not much will happen in the next couple of weeks. Working in Geelong from tomorrow onwards for a week, (no weekend for me). Then I'm off to S.A for a service trip for 4 days.

Cheers Tim

[sclarke]

Very impressive....
Love it....

Want one... Cant afford one, But want one.....

[roversmith]

Hey Tim if you are heading S.A from Geelong, call in on your way through. Swap notes and all that.

Cheers Greg

P.S You know your booked in at Wandin so the dead line cometh.

[Disco_ute84]

Thanks for the offer Greg, Next time I'm in the area I might take you up on that. When is Wandin?

I've been trying to sort out the wiring this weekend. Basically all done now. RAVE is very handy. There's only a few of plugs I cant find listed in it, maybe the version I have doesn't cover D2a's?

So I have one plug (same as rear bar reverse/tail light plug) with 3 wires, Brown/green, Green/Light green and Brown/yellow. The Brown/yellow then goes to another plug, which has it and an earth (black).

Then there are these plugs.
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_139293179116_612654116_2648823_1114600_n.jpg

There are only 3 wires that go back to the main loom from these, a Red/Grey, a Grey, and a Light green/Orange. I cant find it any were in Rave. I'm pretty sure it wasn't connected to anything when I pulled the disco apart..... but that was a long time ago.

The last plug I am unsure of is C0666, Sounder - Alarm - Battery backed up. RAVE has it listed for all models but I don't remember seeing it, and its not in the cupboard.

I done the trial fit up of the hood lining last weekend.

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs248.snc1/9524_138433804116_612654116_2639250_5599920_n.jpg

Thats all for now.

[roversmith]

Tim Wandin is set for feb 21, if you run out of time with the disco come for a look anyway. Usually a good weekend had by all. Sorry can't help with electrics, would be the only job in thirty odd years as a mechanic that I tagged every plug that was in use. A lot of unused wiring in the back is ICE and dvd stuff.

Cheers Greg

[Lucus]

This is a fantastic build up! do you have any updated pics?

[Disco_ute84]

Well a lot has been happening in the shed since the last update.

The left rear is basically done, I just have one small panel to make on the inside.
https://www.aulro.com/afvb/

Its all tapped up and is ready for bog, that might happen this weekend.
https://www.aulro.com/afvb/

I've turned it around..... what a job that was..... Can anyone say 47 point turn?
https://www.aulro.com/afvb/

https://www.aulro.com/afvb/

I've even got carried away and started putting some etch primer on. Deep down all land rovers are green right?

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/

I'm hoping to have it painted in a couple of months, but because I want to change it to metallic silver, (it was white), it may take a bit longer. I may have to hold a rubbing back party for the engine bay, under the wipers, around the wipers etc etc.

Can anyone with a silver disco tell me what color the inner guards are in the engine bay? Mine are a light grey, even though the rest of it is white, it must be a primer color?

Thats all for now.

Cheers,

Tim

[Franz]

Well a lot has been happening in the shed since the last update.

The left rear is basically done, I just have one small panel to make on the inside.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186899899116_612654116_3022571_3020009_n.jpg

Its all tapped up and is ready for bog, that might happen this weekend.
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186899914116_612654116_3022574_6127613_n.jpg

I've turned it around..... what a job that was..... Can anyone say 47 point turn?
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186899894116_612654116_3022570_3234290_n.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186899889116_612654116_3022569_676987_n.jpg

I've even got carried away and started putting some etch primer on. Deep down all land rovers are green right?

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186896379116_612654116_3022562_1628673_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs042.snc3/12953_186896389116_612654116_3022564_5782572_n.jpg

I'm hoping to have it painted in a couple of months, but because I want to change it to metallic silver, (it was white), it may take a bit longer. I may have to hold a rubbing back party for the engine bay, under the wipers, around the wipers etc etc.

Can anyone with a silver disco tell me what color the inner guards are in the engine bay? Mine are a light grey, even though the rest of it is white, it must be a primer color?

Thats all for now.

Cheers,

Tim
Tim,

It's a silver colour, just not glossy like the outside. Land Rover speak "Zambezi Silver"

Cheers,

Franz

[Disco_ute84]

I had a feeling that it would be a flat version of the exterior. Thanks.

[Jordos D2]

hi mate that looks bloody awsom great job i cant wait to see the finished job

[jessie_xa]

hi disco ute84

any progress with the vehicle love to see more pics of it

[Disco_ute84]

Time for another update.

Things have been a little slow out in the shed lately. On Xmas day I proposed to my partner Alison, so now I am very busy getting things organized for the wedding in November, and trying to get the back yard tidy for the engagement party in a couple of weeks time.

Here is a couple of pics of what I have got done.

New door and guard for the drivers side the ones I had were very ordinary, thanks Bundalene.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs216.snc3/22347_288010314116_612654116_3447826_2106944_n.jpg

Done some more work on the tray.

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs216.snc3/22347_288010329116_612654116_3447827_4483996_n.jpg

The passenger side is now fully welded and now only needs painting.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs236.snc3/22347_288010344116_612654116_3447828_1398074_n.jpg

Made a set of 4 of these stands. As you can see they fold up for easy storage. They can also adjust in height.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs236.snc3/22347_288010354116_612654116_3447829_814417_n.jpg

The rear is now on factory SLS, once again thanks Bundalene. I'll do a tutorial once it is finished.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs216.snc3/22347_288010379116_612654116_3447830_5760221_n.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs216.snc3/22347_288010404116_612654116_3447831_6996165_n.jpg

The roof is finished to.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs236.snc3/22347_288010504116_612654116_3447836_3568945_n.jpg

[dullbird]

looking very nice mate great project!!

[Franz]

Congratulations on making an honest woman out of your partner.

I drove past you on Friday on my way to the Murray - which apparently had an algal bloom warning issued - guess who new nothing about that and went swimming in the river!

Oh, and, nice job with the ute.

Cheers,

Franz

[LR2A38A]

What a ripper of a ute, give me more, it looks great. Well done!!!
I have a 38 & want to do the same. Keep the picks coming.

Regards Garth

[Disco_ute84]

Few more pics.

I have been working on the rope rails lately, oh and fuel fillers. (Sub tank to come.)

I deciced to make them out of stainlees. When the tray gets painted I will leave the rails unpainted, that way with use there will pe no paint to chip off, and stainless looks sexy.:D

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs432.snc3/24871_369936319116_612654116_3675722_2179555_n.jpg

The "U" around the fillers is made up of 5 pieces.

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs432.snc3/24871_369936324116_612654116_3675723_6029573_n.jpg \

Notching out the pipe.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs412.snc3/24871_371978814116_612654116_3688637_2758962_n.jpg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs432.snc3/24871_369936314116_612654116_3675721_431274_n.jpg

More to come....

Cheers,

Tim

[Piddler]

Bloody great job Tim,
a mate of mine has done a Nissan your quality is sooooo much better.

Cheers

[Landy Smurf]

thats because he started with better quality

[tastrax]

Any recent progress? I cant wait to see the finished product!

[oyamum]

thats some top quality work mate.. cant wait to see this thing finished will look awsome and factory at the same time which is a massive task... well done

[Disco_ute84]

Time for another update.

I have been making up an aluminium sub tank. It should almost double my range.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs331.ash1/28703_388566294116_612654116_4076136_7928099_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs331.ash1/28703_388566299116_612654116_4076137_5915035_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs331.ash1/28703_388566309116_612654116_4076138_3515205_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-sjc1/hs302.snc3/28703_388566319116_612654116_4076139_7014274_n.jpg

I also got the passenger side in etch primer, it has been such a long time coming. It's actually feeling like I'm getting somewere now.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs322.snc3/28703_388566344116_612654116_4076142_7021132_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs331.ash1/28703_388566349116_612654116_4076143_5960972_n.jpg

More to follow as it progresses.


Cheers,

[Disco_ute84]

Lots has been going on lately, flat out working in the shed when I'm not doing stuff for the wedding or playing with our new pup Mack. I wasn't allowed Rover, Disco or Landy, so we settled on Mack seeing Dad and I have a few old Mack trucks.

Here is the Chief rag stealer hard at work!
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs134.ash2/40061_412303504116_612654116_4695263_8074844_n.jpg

Anyway back to the Disco. The body work is almost done!!! If I said I was excited it would be the understatement of the century! By the end of the weekend I am hoping to have only the filler and painting to do.

All tapped up, just needs a thin smear of filler and its ready to prime.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs254.snc4/40061_412303459116_612654116_4695254_4326374_n.jpg

Another view.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs134.ash2/40061_412303464116_612654116_4695255_3476940_n.jpg

This panel was a nightmare to make, it has a complex shape to it. Lots of curves and folds, and because of the shape I couldn't do it in a pan break, so most of it was done by hand.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs134.ash2/40061_412303469116_612654116_4695256_1560258_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs254.snc4/40061_412303479116_612654116_4695258_4374125_n.jpg

This is the last panel just before i welded it in. All done now, I just have to put a small piece in down the bottom of it.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs134.ash2/40061_412303489116_612654116_4695260_1488113_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs134.ash2/40061_412303494116_612654116_4695261_7410810_n.jpg

Chief rag stealer is all worn out, at least he found a good seat.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs266.snc4/39636_412869914116_612654116_4705796_338823_n.jpg

If I can get the rest of the body work done this weekend I might see if i can get the engine started, it hasn't been running since about June 2007. With a bit of luck it will fire into life.

Cheers,

[dullbird]

looking awesome mate!!! :cool:

[rovercare]

Fantastic work, Cute lab:)

[Travis]

top work mate im looking at doing similar after too many low ball offers. How long is your tray? i was looking a 2.7m

[Disco_ute84]

top work mate im looking at doing similar after too many low ball offers. How long is your tray? i was looking a 2.7m

I think its about 2.3 or 2.4 I'll have to run the tape over it tonight to be sure.

I made some progress over the weekend. I started the engine for the first time in about 3 years last night. After primming the fuel system it fired first crank.
:D:D:D
I couldn't help myself so I idled out of the shed then back in.

[Dreamer]

absolutely enthralling to read from go to woe. still dreaming but great execution dude ,inspiring!

[Disco_ute84]

Quick update, more will follow on the weekend.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs219.snc4/39290_431782779116_612654116_5137252_5498076_n.jpg

Better photos and more info to come.

Cheers,

[disco2hse]

Can't wait to see the results.

[Papa Smurf]

i know they already have the defender utes but i wish they brought a discovery ute out, i know that the chassis is small but a single cap with custom tray and there is one great 4x4.i love watching these conversions you have got alot of talent. the final result will be great, love your work
papa smurf

[Disco_ute84]

I know I said I was going to do this a couple of weeks ago, but things have been a little busy with our wedding only 2 weeks away from today. I haven't touched the disco in about 3 weeks and I wont' be starting back on it until we get back from the honeymoon.

As promised here are some more pics of the side steps, not finished but you can see what they are supposed to look like.
This is the rear mounts, still to put some supports under the sill.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs808.snc4/68854_440419114116_612654116_5287690_1470678_n.jpg

Front mounts.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs905.snc4/71880_440419184116_612654116_5287692_6023847_n.jpg

Rear mounts.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs894.snc4/72705_440419209116_612654116_5287693_5697214_n.jpg

Bolt on scrub bars.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs452.ash2/72565_440419244116_612654116_5287694_5934431_n.jpg

Starting to look as it should.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs464.ash2/73765_440421359116_612654116_5287717_3435059_n.jpg

I promise I won't make a habit of it getting towed by a Nissan. (work ute)
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs445.ash2/71859_440421309116_612654116_5287716_5718065_n.jpg

Other side.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs776.snc4/67611_440421419116_612654116_5287718_3280935_n.jpg

I have the pattern written down for the scrub bars, the one on this side only took about 10 Min's to bend up. (Future father in law has some good toys) One friend has already asked for a set for his D2.
Thats all for now, off the Melbourne today to pick up the wedding rings.

Cheers,

[Homestar]

Lookin' great! You are one talented individual. Can't wait to see the finished product. Have a great wedding & honeymoon!

Cheers - Gav.

[philco]

Looks great, it will be a real head turner when its finished

[dirtdawg]

It's been a while since an update hows it ball going

[Disco_ute84]

Progress has been very slow. Bought a house this earlier this year, and have been busy builing a shed. 10.8m x 7.6m (36'x25'). The shed isn't far off finished so the rush will be on to get the disco finished.
I'll put some photos up of the shed latter.

[jaacina]

What is the status of the UTE?

[disco2hse]

What is the status of the UTE?

He got married...

[Disco_ute84]

He got married...

And my wife is 37 weeks pregnant........

This project has been put on the back burner for a while, more important jobs need doing first.

Cheers,

Tim

[Homestar]

And my wife is 37 weeks pregnant........

This project has been put on the back burner for a while, more important jobs need doing first.

Cheers,

Tim

You have been busy...:)

[peatbog]

This build sounds great, but i cant see any of the pictures, am i doing something wrong?

[disco2hse]

This build sounds great, but i cant see any of the pictures, am i doing something wrong?

Try opening your eyes :P

[peatbog]

That doesn't really help!

It's like the links have failed, could someone please re-post a few of the pics so I can see what's going on?

Thanks

Pete

[isuzutoo-eh]

That doesn't really help!

It's like the links have failed, could someone please re-post a few of the pics so I can see what's going on?

Thanks

Pete

They appear to have been hosted on facebook, so who knows if they have been moved, deleted or permissions changed.

[Disco_ute84]

Well its been a long time since I have worked on the ute, 3 years actually. I have bought a new house, built a brand new shed, built a trailer (with discovery 2 hubs), started a new job, bought a 2004 discovery (this one wont be getting cut in half), ohh and have a daughter who is now 7 months old. Its been a busy time.
Today I put the ABS mod back together,(parts were borrowed to fix the 3 amigos in the new d2) and started the ute for the first time in a year and a half. I was a little worried it wouldnt go as I have had rats in my shed and there are little foot prints all over the ute. Rats love electrical wire, but thankfully it looks like they havent eaten anything major.
Hopefully this will be a sign of things to come, motivation has come back for this project so watch this space.
I'm going to try to fix some of the missing photos in this thread as time permits.

[Disco Muppet]

Any updates? I too cannot see the pics :(
Really like to see your workmanship!