Thread: Stirlsilver's Disco Ute Project

Originally Posted by Skiboy

Did you consider bracing the battery trays into the chassis vertical on the inner side of the trays?

Had to tell from pics just how well braced they are?
Getting close!

It would be easy add a horizontal stiffener like you suggest but the trays are very very stiff with the 3 vertical flat bars I added so I think I'll leave the design as is. Thanks for the suggestion though!

Another brief update, I wasn't able to do too much because I was only able to spend about 6 hours in the workshop this weekend.

I drilled and welded in a sleeve into the corners of the tray to allow me to add a frame over the tray for a canopy. The one at the back will need to be on top of the aluminium box. Actually as I type this I think I might add another sleeve half way along the tray, it could be useful down the line.





Started work on pulling off the axle from the wrecked discovery, I'm having to go to all this effort to cut off the sway bar brackets on the axles. I was hoping I could cut them off with the axle on the car, but that wasn't possible.



Anyone for a game of Jenga?

Sleeve for a canopy a great idea.

You have probably though about this - are you considering if you want this to have an extension out the back (soft top maybe) - we find we use the tray to make lunch on when out 4x4ing and then as a base for cooking on at night.

I made up a removable tarp canopy which sits on poles (gal water pipe) and extended out the back - this is great to stand under to make lunch on sunny days and also hand shade when cooking - also very handing when raining so can cook etc on a solid base.

I find the height of the tray much better than any camp table to work on and much sturdier.

Here is my gal pole tarp with spreader bar simple design - idea was quick set up for shade/rain.

Originally Posted by Skiboy

You have probably though about this - are you considering if you want this to have an extension out the back (soft top maybe)

Thanks for the suggestion. I hadn't thought about making an awning extension. I'll definitely keep it in mind when it comes to designing that part!

This weekend is probably one of where I have worked the hardest. Mainly because there was a lot of physical work involved.

I pulled out the front diff and cut off the sway bar brackets:



A lot of effort for these two measly pieces of steel:


I took the 9" grinder to the discovery. This is how far I got after 8 hours of work on Saturday:




Then another 6 hours of work on Sunday. I forgot to take a photo but I did manage to remove the ZF transmission and it is now in the workshop. I'll send it off for a rebuild in January:



The bits I came across that I figured were worth selling I posted on ebay:
s2shamro on eBay

I've also started work on a rough model for the engine. It's going to be necessary to work out the placement of the turbos and tubing.

I think I'm now done with the engine & turbo models. They aren't pretty but at least they show where all the important bits are

Did the garrett turbo models I sent through not work?

Originally Posted by Dougal

Did the garrett turbo models I sent through not work?

The message never came through. Do you think you can try again?

Originally Posted by stirlsilver

The message never came through. Do you think you can try again?

Sent again now to your hotmail address. About 8.6mb total (6.3mb zipped files).