Thread: Chopping a Disco 1 chassis

G'day Ozzie mates

So the Better Half chimed in the other day and said she'd like a Series 3 Shorty.

Now I've been down the Series Ownership Road previously and I can't say I enjoyed it.

I'm no softy, but the atrocious steering, stopping and handling eventually got me to sell the S2A 109 PUP as I just didn't enjoy driving it outside of the smallholding. I'd upgraded to front disks (Deefer pedal box and booster and MC with Deefer disks and Golf 1 slave cylinders and calipers) but I was starting to look at throwing out the steering relay, converting to a direct steering box, and and and........it was too much, the vehicle was being worked on more than I drove it and it was just sucking my wallet dry. I also found the gearbox and transfer case would need a serious rebuild at some stage. So it had to go.

Anyhoo.........

So since SWAMBO wants a cute 88 inch, and I want creature comforts like proper brakes and coils........and I've owned a couple of 110 V8s in the past..........

Has anybody chopped a D1 chassis down to 88 inches and dropped an S3 SWB body onto it?

(Please note, I'm not in AU, and we don't have to comply ADR, it just needs to start, stop, have the lights and horn working and not drip oil).

If so, I'd love some guidelines on where to cut, how to strengthen the join, and so on.

If nobody has done it.......

Maybe we can make this an R&D thread.

Why a D1 chassis and not a 90 chassis you say?
Strangely, the D90 chassis is virtually unobtainable over here. If they aren't being exported, they're being rebuilt and sold for silly prices.

But I can pick up a D1 V8 rolling chassis for a couple of hundred AU$ with reg papers.

And I can find S3 bodies without registration for another couple of hundred.

As long as we can provide receipts for the body and have it data-dotted the authorities are happy. One of the benefits of being in Africa where we have millions of rebuilds and built up wrecks.

Engine options: due to the space limitations, probably a 2.5L to 3.2L Jap TDi on an LT85 or R380 or even an LT95 if I have to.
Axles will stay D1, as will the LT230 transfer box.

The body will obviously need Series outriggers and crossmembers where required: that I can source these locally as UK import replacement parts. (Paddocks etc).
Everything else will be on mild steel sub-frames.

Please let me have your ideas, the pro's, the con's and even the "you're crazy" will be appreciated.

Originally Posted by jakeslouw

and not drip oil).

Aye, there's the rub!