Stirlsilver's Disco Ute Project

Just a quick update on progress:
Rear winch is now mounted [bigsmile1] not yet wired up though.
https://www.aulro.com/afvb/images/im...017/11/937.jpg

https://www.aulro.com/afvb/images/im...017/11/938.jpg

Also I improvised a way to address the Engineer's concern about the possibility of the long brake lines getting crushed in the front coils. I would have preferred to do it in a single spring but this is the best I could do!
https://www.aulro.com/afvb/images/im...017/11/939.jpg

Finally a short clip from when I headed out in the rain to get some final measurements taken from the car and then pick up the finished tray.

https://youtu.be/s6XT3TcInNg

Very nice work.

Quote:

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Originally Posted by stirlsilver

Hi Davo,
So far the car is keeping cool, i've driven out a few times in stop-start traffic and also at 90-100km/hr. Earlier today when I was driving it at high speed, the coolant temperature was sitting at 78degC. So it doesn't seem like I am having trouble keeping the engine cool. However having said that today, for the drive it was abour 22degC outside. As for the bonnet scoops, some older muscle cars used rear facing bonnet scoops so that they would pick up pressure from the high pressure zone at the base of the windshield. That's the reason why all cabin air vents take their air from that location as well.

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22C! Oh come on, I'd need a parka for that sort of weather. Let's see what happens when it gets into the mid-30s! My humble V8 stays at around 80C-ish when it's in the high 30s here, which is actually why I'm so picky about the airflow since I don't have much room for error. My scoops are far enough forward not to be influenced by that high pressure zone you mention, so it would appear I've somehow managed to get that engine bay low pressure I was hoping for. One way I tested them when I realised what was going on was to sprinkle line-marking dust, (that stuff you put on string - just because that's what I had handy), and watched it being sucked into the scoops as I accelerated. Later on I could see how it had been spread forward across the batteries and then down towards the back of the radiator. I hate to think what's been happening with the airflow down there! You're right on the money with that Magnahelic gauge, something I've been meaning to get for ages now. I have to get more scientific about finding out what's really happening.

Another update on activities over the last week or so:
The tray panels were glued on, starting to make it look like a proper car!
https://www.aulro.com/afvb/images/im...017/12/182.jpg

https://www.aulro.com/afvb/images/im...017/12/183.jpg

https://www.aulro.com/afvb/images/im...017/12/184.jpg

When the ratchet rivet nut tool arrived, I got straight to inserting some closed M6 threaded inserts into the tray frame to hold the panels in position.
https://www.aulro.com/afvb/images/im...017/12/185.jpg

Finally I took the car up to the engineer's. Mostly so that it can be weighed for the selection of the right spring sets for the car.
https://www.aulro.com/afvb/images/im...017/12/186.jpg

https://www.aulro.com/afvb/images/im...017/12/187.jpg

So issues from the engineering inspection:

• The indicators I fitted on the sides to address the bullbar blocking issue weren't ADR approved.
• The noise levels are too high - mostly because the exhaust finishes in front of the diff meaning the noise meter gets placed under the car where all the noise is reflected. I'll need to run the pipe out to the back of the car
• The front axle is overloaded. The V8 discovery has a front axle load limit of 1,100Kg. Strangely the 300tdi discoveries have a limit of 1,200Kg. I need to somehow prove that the axles between the two cars (or even to a defender) are identical which is proving tricky.

Do the tray edges curve up at the sides? If they do, how will you get water out?

For the axles, aren't part numbers enough?

Quote:

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Originally Posted by disco2hse

Do the tray edges curve up at the sides? If they do, how will you get water out?

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There are plenty of places for water to leak out, but I'll drill some drainage holes out the back as well.

Quote:

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Originally Posted by disco2hse

For the axles, aren't part numbers enough?

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I wish they could! I was scratching around the internet earlier and as far as I could tell, there is a different axle part number between the V8, the 4Cyl Petrol (Which I didn't even know existed until yesterday!!) and the 300tdi. With the 300tdi sharing the same axle with the Defender 90:
FRC4307 - Defender 90, Defender 110 (axle code 20L, 21L, 22L, 23L)
FTC2223 - D1 4Cyl Petrol, D1 300tdi, Defender 90 (axle code 61S)
FTC4413 - D1 4Cyl Petrol, D1 300tdi, Defender 90 (axle code 61S, 63L, 64L)
FTC825 - D1 300tdi
FTC2509 - D1 V8
FTC4417 - D1 V8
FTC823 - D1 V8

Then I decided to look up what axle code I currently have fitted to the car (because I bought the axles from TRS) which is 73L. A 300tdi would be 71L or 72L:
FRONT AXLES
10 L A R/ROVER RHS RANGE ROVER
11 L A R/ROVER LHS RANGE ROVER
12 L A F.AXLE V8 RHS TO 1987 RANGE ROVER
13 L A F.AXLE V8 LHS TO 1987 RANGE ROVER
14 L A F.AXLE DIESEL RHS TO 1987 RANGE ROVER
15 L A F.AXLE DIESEL LHS TO 1987 RANGE ROVER
16 L A R/ROVER RHS ABS KESTREL PET. RANGE ROVER
17 L A R/ROVER LHS ABS KESTREL PET. RANGE ROVER
18 L A F.AXLE RHS V8 NON-VENTED RANGE ROVER
18 L B/C F.AXLE V8 RHS NON-VENTED DISCOVERY
19 L A F.AXLE V8 LHS NON-VENTED RANGE ROVER
19 L B/C F.AXLE V8 LHS NON-VENTED DISCOVERY
20 L A > F.AXLE RHS 110" LAND ROVER
21 L A > F.AXLE LHS 110" LAND ROVER
22 L A F.AXLE RHS 90" LAND ROVER
23 L A F.AXLE LHS 90" LAND ROVER
24 L F.AXLE RHS HEAVY DUTY 110" 3.54 RATIO LAND ROVER
25 L F.AXLE LHS HEAVY DUTY 110" 3.54 RATIO LAND ROVER
26 L F.AXLE RHS HEAVY DUTY 110" 4.7 RATIO LAND ROVER
27 L F.AXLE LHS HEAVY DUTY 110" 4.7 RATIO LAND ROVER
28 L NOT DEFINED
29 L F.AXLE LHS SWISS 110" 4.7 RATIO OERLIKON LAND ROVER
30 L L/ROVER LLAMA RHS LAND ROVER F/CONT.
31 L L/ROVER LLAMA LHS LAND ROVER F/CONT.
32 L NOT DEFINED
33 L NOT DEFINED
34 L F.AXLE RHS DIESEL NON ABS NON-VENT RANGE ROVER
34 L B/C F.AXLE DIESEL RHS NON ABS NON VENTED DISCOVERY
35 L A F.AXLE LHS DIESEL NON ABS NON-VENT RANGE ROVER
35 L B/C F.AXLE DIESEL LHS NON ABS NON VENTED DISCOVERY
36 L R/ROVER ABS KESTREL DIESEL RHS RANGE ROVER
37 L R/ROVER ABS KESTREL DIESEL LHS RANGE ROVER
38 L F.AXLE RHS V8 ASBESTOS FREE VENTED NON ABS RANGE ROVER
39 L F.AXLE LHS V8 ASBESTOS FREE VENTED NON ABS RANGE ROVER
40 L F.AXLE RHS ABS V8 PETROL RANGE ROVER
41 L F.AXLE LHS ABS V8 PETROL RANGE ROVER
42 L F.AXLE RHS DIESEL ASBESTOS FREE VENTED NON ABS DISCOVERY
42 L F.AXLE RHS DIESEL ASBESTOS FREE VENTED NON ABS RANGE ROVER
43 L F.AXLE LHS DIESEL ASBESTOS FREE VENTED NON ABS DISCOVERY
43 L F.AXLE LHS DIESEL ASBESTOS FREE VENTED NON ABS RANGE ROVER
44 L F.AXLE RHS ABS DIESEL RANGE ROVER
45 L F.AXLE LHS ABS DIESEL RANGE ROVER
46 L A F.AXLE V8 RHS NON-ABS 1991 MY RANGE ROVER
47 L A F.AXLE V8 LHS NON-ABS 1991 MY RANGE ROVER
48 L A F.AXLE V8 RHS ABS 1991 MY RANGE ROVER
49 L A F.AXLE V8 LHS ABS 1991 MY RANGE ROVER
50 L A F.AXLE DIESEL RHS NON-ABS 1991MY RANGE ROVER
51 L A F.AXLE DIESEL LHS NON-ABS 1991MY RANGE ROVER
52 L A F.AXLE DIESEL RHS ABS 1991MY RANGE ROVER
53 L A F.AXLE DIESEL LHS ABS 1991MY RANGE ROVER
54 L A F.AXLE V8 RHS NON ABS - A/S AIR SUSPENSION 1993MY RANGE ROVER
55 L A F.AXLE V8 LHS NON ABS - A/S AIR SUSPENSION 1993MY RANGE ROVER
56 L A F.AXLE V8 RHS ABS - A/S AIR SUSPENSION 1993MY RANGE ROVER
57 L A F.AXLE V8 LHS ABS - A/S AIR SUSPENSION 1993MY RANGE ROVER
58 L A NOT DEFINED
59 L A NOT DEFINED
60 L A NOT DEFINED
61 L A F.AXLE 90" SOLID DISK RH 1994MY> 4 CYL DEFENDER
62 L A F.AXLE 90" SOLID DISK LH 1994MY> 4 CYL DEFENDER
63 L A F.AXLE H/D VENTED DISK RH 1994MY> DEFENDER
64 L A F.AXLE H/D VENTED DISK LH 1994MY> DEFENDER
65 L A F.AXLE HEAVY DUTY RH 1994MY> DEFENDER
66 L A F.AXLE HEAVY DUTY LH 1994MY> DEFENDER
71 L A F.AXLE TDi/T16 RHS 1995MY> DISCOVERY
72 L A F.AXLE TDi/T16 LHS 1995MY> DISCOVERY
73 L A F.AXLE V8 PI RHS 1995MY> DISCOVERY
74 L A F.AXLE V8 PI LHS 1995MY> DISCOVERY
75 L A F.AXLE TDi/T16 ABS RHS 1995MY> DISCOVERY
76 L A F.AXLE TDi/T16 ABS LHS 1995MY> DISCOVERY
77 L A F.AXLE V8 PI ABS RHS 1995MY> DISCOVERY
78 L A F.AXLE V8 PI ABS LHS 1995MY> DISCOVERY
79 L A F.AXLE RHS AIR SUSP. G3 RANGE ROVER
80 L A F.AXLE LHS AIR SUSP. G3 RANGE ROVER
81 L A F.AXLE RHD AIR SUSP. ABS G3 RANGE ROVER
82 L A F.AXLE LHD AIR SUSP. ABS G3 RANGE ROVER
83 L A NOT DEFINED
84 L A NOT DEFINED
85 L A AX280 (MODULE)
86 L A NOT DEFINED
87 L A NOT DEFINED
88 L A NOT DEFINED
89 L A NOT DEFINED
90 L A F.AXLE V8 PI RHS 1995> NEW RANGE ROVER
91 L A F.AXLE NAS/JAPAN 90" LHD 1997 MY> DEFENDER
92 L A F.AXLE RHS DISCOVERY 2 DISCOVERY 2
93 L A F. AXLE LHS DISCOVERY 2 DISCOVERY 2
94 L A F.AXLE 1998 MY RANGE ROVER
95 L A F.AXLE 2 PIN 1999 MY RANGE ROVER
96 L A F.AXLE 4 PIN 1999 MY RANGE ROVER
97 L A V8 4.0 DEFENDER AUTO DEFENDER
98 L A RHD 4.0 V8 DEFENDER AUTO DEFENDER
10 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
11 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
12 M A FRONT AXLE DEFENDER 1999 MY ABS 1999 MY DEFENDER
13 M A FRONT AXLE DEFENDER 1999 MY ABS 1999 MY DEFENDER
14 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
15 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
16 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
17 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
18 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
19 M A FRONT AXLE DEFENDER 1999 MY 1999 MY DEFENDER
241 F.AXLE RHS SERIES 2A 88" LAND ROVER
244 F.AXLE LHS SERIES 2A 88" LAND ROVER
251 F.AXLE RHS SERIES 2A 109" LAND ROVER
254 F.AXLE LHS SERIES 2A 109" LAND ROVER
355 A F.AXLE V8 RHS RANGE ROVER
358 A F.AXLE V8 LHS RANGE ROVER
881 F.AXLE V8 RHS 109" SERIES 3 LAND ROVER
884 F.AXLE V8 LHS 109" SERIES 3 LAND ROVER

So I'm hoping there isn't a physical difference between the 300tdi axles (I read it was just the springs that were different). But so far the part numbers are saying they are actually different parts. I really don't want to have to pull the axles out and source a 300tdi axle. That would be a pain in the arse...

Is it worth and email to Land Rover?

Or one of the recognized official clubs?

Anything you can remove from the front/make lighter?

Only Ian seems to have a problem with front axle weights... I recommend Young engineering in South windsor.

A mate had the same issue when engineering a RRC ute chop and Ls1 conversion .
The engineer was happy if he removed the B/Bar and winch and put a standard bumper on[wink11]
I know it is not what you wanted to hear as by sounds of it you want it all legit from the word go so as it does not come back to Bite you[bighmmm]
Im sure there are plenty of 4wd`s getting around that would tip the scales but maybe not as modified as your`s that would be waiving a red flag[bigwhistle]

Hello everyone! Happy new year! And I'm still alive.

A few loose ends - on the Axle front, I think Ian will accept the fact that the V8 and Tdi axles are the same, given the fact that they have the same offroad load ratings. So it should just pass when I load the winch with the Dynema rope. Thanks for the advice everyone.

On other fronts, things are a bit chaotic because I'm getting married in a couple of weeks! So there has been a bunch of planning going into that. I had hoped to have the car finished in time, but it wasn't possible. I am chipping away at a few things at the moment though. The car is currently at Allsprings, to have some custom coils made up, Aldo wasn't 100% sure he would be able to help, because he thinks it is going to need long variable rate coils for the front and back. Let's see what he says.

In other areas, I'm in the process of chopping out the small side indicators I fitted on the front to address the bullbar obstructing the main indicator. I had fitted non compliant lights before, so I've had to swap them out:
https://www.aulro.com/afvb/images/im...018/01/844.jpg

I'm also in the process of addressing the crack that developed on the back of the body between where the Fibreglass joined the steel wall. A little bit of corrosion got in causing a crack to form. I'm also dealing with the deformation on the scoop as well. None of this is finished, i'll have to get back on to it when the car is back and I'm married!
https://www.aulro.com/afvb/images/im...018/01/845.jpg

https://www.aulro.com/afvb/images/im...018/01/846.jpg

Till next time.