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Thread: D1 First Build - Melbourne

  1. #41
    Join Date
    Jan 1970
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    St Helena,Melbourne
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    Most of that list arent rwc items so i would concentrate on those that are rwc items.

    Sent from my GT-I9300 using AULRO mobile app
    MY08 TDV6 SE D3- permagrin ooh yeah
    2004 Jayco Freedom tin tent
    1998 Triumph Daytona T595
    1974 VW Kombi bus
    1958 Holden FC special sedan

  2. #42
    Join Date
    Jul 2014
    Location
    Gold Coast, Qld
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    Cheap option which i think is better than replacing the head linner is to paint it

  3. #43
    Join Date
    Mar 2008
    Location
    Bayswater, Melbourne
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    Love the roof! looks good I think. Something different too.

  4. #44
    Join Date
    Aug 2015
    Location
    Ballarat, VIC
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    So I'm reviving this one after two years of inactivity...

    I have been making some very slow progress here and there but financial issues had stopped me from getting anywhere properly with it until the last few weeks.

    A quick run down of where I left off to where it stands now:

    After the rusty footwells and a-pillar were taken care of I put a ton of underbody paint down for peace of mind, then chucked on a load of sound deadener/heat shield in while the interior was sitting in my shed.

    IMG_1809.jpg IMG_1817.jpg IMG_2027.jpg

    Still haven't gotten around to the headliner though, might just go down the paint route, looks good!

    Interior and carpet went in after a proper steam clean.

    IMG_2032.jpg

    This was at the start of the year, but it sat longer until the long weekend last week where I had enough time and spare money (winning combo) to tackle the head gasket, it wasn't all good news though.

    IMG_2663.jpg

    It was a doddle to take apart but the bad news hit once the head was off.

    IMG_2692.jpg

    As you can see there's some corrosion in the cylinders from where there was some coolant sitting there, the gasket had blown between 2 + 3 so it was pretty bad, the worst of it was in cylinder #3 which had quite severe pitting at the top. Luckily the rest of it was just surface rust.

    IMG_2714.jpg

    After hours of razor blading and scouring with WD40 it came up looking great and moving freely with no unnerving noises or scratching.

    Got a new head that was well within tolerances and scrubbed up nicely with some 400 wet and dry + paraffin on a block.

    IMG_2716.jpg

    New hose kit went in along with the head.

    IMG_2757.jpg

    And after a bit of persuasion it started up.

    YouTube

    With a nice ticking sound to let me know it's running. In person the noise sounds quite short and 'hissy' so my money's on a bit of a gap with one of the injectors. I know it's bad behaviour but I reused the copper washers on all the injectors, I have a new set on order and will be replacing them all once they arrive. If the noise persists I'll have to delve deeper, just hope it's not blow-by in cylinder #3 because of the pitting, anyone know if that would make that noise?

    Btw, valve clearances are all bang-on, and was the first thing I checked after starting it up the first time.

    The other thing is a ton of soot was spat out once it fired and it smokes like hell when you give it some, at idle it's completely fine. This is with a cold engine that hasn't been put under any load, if there is blow-by would it be burning oil so quickly? Or would it have to get to a certain temp?

    Will also drop all the fuel and change fuel filter/sedimenter this weekend, hoping it's just old diesel that's burning a bit dirty.

    Feels like a big step forward regardless.

  5. #45
    DAMINK Guest
    This thread a while back is what inspired me to take out my roof lining and reline it. I will say cheers for that.

  6. #46
    Join Date
    Apr 2011
    Location
    Dungowan
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    Just done head gasket on mine, was quite Smokey for a bit, cleared itself tho
    '93 D1 V8 auto
    '93 D1 200Tdi 2-door, ARB's, MD transfer, sill tanks, winch, 2"lift.......
    '95 D1 V8 auto......gone
    '86 V8 RRC.....gone

  7. #47
    Join Date
    Aug 2015
    Location
    Ballarat, VIC
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    Talking

    So it's been another two years, time for another post

    I have been chipping away at the Disco, making a bit of progress here and there, but I made the call at the end of last year to whip out the original donk and replace the whole motor. When I did the head I found some pitting around the lip of cylinder 3 and even though it ran fine and would probably never come close to snatching a ring, I still wasn't confident with it.

    I picked up a donor car around October, a bone stock 300tdi auto from up in QLD which was brought to Melbourne a couple of years ago, never seen dirt by the looks of things. Obviously when you find a car that looks this good the smart move is to keep that and bring it up to scratch so I got it booked in to Ritter for a once over and the diagnosis was not good unfortunately. It needed a few grand thrown at it to bring it up to roadworthy and I just wasn't willing to fork that kind of money out. I put both cars through a roadworthy test to see what they needed done side by side, the blue Disco was still closer plus I'd done all the work fixing water ingress, replacing rotten sections as well as neatening up the interior and soundproofing it.

    So sticking with the original plan I pulled both motors out around December, I've never done anything like this before and it really was a lot of work on my own, certainly bent a bit of metal getting them out

    The original blue Disco had 270,XXX on the clock and the red one only had 165,XXX.

    IMG_1007.jpgIMG_2678.jpg

    This was as far as I got before the pandemic kicked in. I've been fortunate enough to be able to work from home and spend more time on this than ever before, now time is less of an issue it's really just money that's the bottleneck.

    As the red one was at 165,XXX it was just about due for a timing belt refresh and as I'd have the back plate off that I thought it best to do the rear main seal too. I got the flywheel skimmed at a machine shop down the road just while it was in my hands and then waited for all the new bits to turn up.

    I got the gearbox and transfer box out and on the bench too to take a good look at. Replaced a fews seals on the transfer and scrubbed up the gearbox. I was getting a LOT of rain water through the windscreen from when I first got the car and it had been pooling up in the centre console and actually found its way into the gearbox, the oil I dropped out was not a pretty sight. At least it wasn't silty, gritty river water or anything like that, but still I can see this box needing a rebuild in the not-too-distant future.

    IMG_2551.jpgIMG_2634.jpgIMG_2944.jpg

    Also replaced the brakes on all four corners, went with vented discs on the front and got a caliper spacer kit from Les Richmond. Replaced tie road ends, sway bar bushings, all four wheel bearings, new clutch, HD clutch fork and got a bias plate kit for the r380 too. Pretty useless at taking pics/documenting things (clearly).

    I did the timing belt, rear main seal, and new sump gasket with the engine hanging in a sling from the crane. It's not ideal and would have been far better with an engine stand when it came to getting the right torque values in but with a bit of work it went ok. Got the box attached and tried to slot it in as one unit but with this crane's upper limit not able to give me the angles I needed I had to pull out and separate them to install individually which was a pain. At times like this it's tempting just to roll the whole lot off a cliff into nearest body of water, but I thought it best to carry on seeing as I'd got this far.

    IMG_2974.jpg

    After getting the gearbox, transfer and engine in I finally had a complete car again. Spent a day figuring out the wiring which went far more smoothly than I was expecting, electrical understanding just eludes me so that's was always the most nerve-wracking part of the whole thing for me. When I pulled the motor out of the blue one I made the choice to disconnect the entire loom from the engine and leave it attached the the vehicle as best as I could, when I pulled it from the red one I did it the other way round and left the loom attached to the engine. When it came to the install I just traced the existing loom back with the new one and replaced connections where they needed to go. It worked really well and is one of those luxuries you get from having a complete donor car I guess.

    I took last week off work to try and rally through the remaining items on the to-do list, by Monday I had a running car!



    That was literally the first start, 5 year old diesel in the tank, didn't even prime the pump. This motor is an absolute peach and I can't explain the feeling of hearing it come to life after so much work, also the feeling of relief that I didn't launch the push rods into my neighbour's garden because I stuffed up the timing belt was a nice touch.
    There was one mistake though, and it's a bit of a doozy, I didn't fill the power steering system and it was completely dry when I went to fill it there must have been a ton of pressure build up and it spat a load of fluid out from the steering box all over my shiny engine bay. So now I've got to either rebuild that steering box which as far as I can tell is a pig of a job, or just do a direct swap from the other car. Either way it's a big task so that's the next thing in my sights.

    Other than that I've been doing a bunch of tedious jobs that will make life with the car more enjoyable, I replaced a load of interior parts from the donor, bits of dash, door cards, cup holders, speakers, headliner etc. but mainly I've been swapping over all the door hardware, all the locks and handles have been swapped over and dialled in, the only thing left is to take the ignition barrel from it too to make a one-key car.

    It's getting there, and it's such a great feeling to make some proper progress, certainly could not do it without having AULRO as a source of information, the hours spent under the car reading threads on my phone have been invaluable, thanks to everyone who shares their insights and knowledge on here.

    I'll try to get better at documenting what I do, otherwise I'll see you in two years

  8. #48
    Join Date
    Jan 2011
    Location
    Burpengary, QLD
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    If your new donor vehicle had a decent steering box I would just change them over, it's a bit fiddly but not a difficult job, and you don't have to worry about draining the system before you put it in if there's no oil in it anyway.

    You are an inspiration and I thank you for your posts, keep them coming
    P38 Range Rover , the best car in the world, when it's working

  9. #49
    Join Date
    Aug 2009
    Location
    Sunbury
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    Only just discovered your thread and love it. You obviously have enthusiasm and determination in bucket loads. Now there is light at the end of the tunnel I hope you are going to use the Disco to explore this great land. They are a great tourer, will go about as far off road as a stock Defender in much more comfort, and are pretty simple and reliable. Ours is nudging 400000 km and is full of red dust and it’s still going strong.
    Keep up the good work, you’ll have something to enjoy when you’re finished!
    Woolly.

  10. #50
    Join Date
    Aug 2015
    Location
    Ballarat, VIC
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    Had a crack at the steering box this weekend, dead windy but the rain held off which was lucky.

    I pulled the leaking box first and got it on my bench. I grabbed a rebuild kit just in case it looked repairable but unfortunately it looked to be leaking from the bottom seal as well as the input and after breaking my puller trying to get the pitman arm off I decided to just take the box from the donor car and do a straight swap.

    IMG_3464.jpgIMG_3468.jpgIMG_3475.jpg

    The donor box looks like it has been rebuilt at some point, lots of sealant everywhere and markings all over but still watertight nonetheless.

    IMG_3481.jpg

    Chucked the leaking box back in the donor so I can still move it around.

    IMG_3482.jpg

    Cleaned up all the hardware and got it ready to install.

    IMG_3484.jpgIMG_3486.jpg

    Got it seated and plumbed in looking tons better, filled it with fluid and started it up. Seems to be fine, no leaks so far, no grinding, bleeding was smooth but I did notice some 'weeping' from the pump and the flex hoses when I got underneath. This is the total amount of fluid that side of things has lost over the course of around a month so it's not streaming out by any measure, but I think it will mean new hoses in the not-too-distant future.

    IMG_3487.jpgIMG_3488.jpgIMG_3460.jpgIMG_3461.jpg

    The to-do list is shrinking and if all goes to plan I'll be looking at putting it through roadworthy once Melbourne's allowed out of house arrest, it's a good feeling!
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