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Thread: Stirlsilver's Disco Ute Project

  1. #761
    Join Date
    Jun 2007
    Location
    Ashfield, NSW
    Posts
    960
    Car has been dropped off for the final modifications to the exhaust to comply with noise (I hope!!)





    Stirling
    My other project - Hobby Society

  2. #762
    Join Date
    Jan 1970
    Location
    In my D2a Ripping It Up
    Posts
    9,681
    Looking good mate
    cheers chris


    My Toy 04 D2a Td5 Manual With Lots of Goodie Goodness
    S111 Swb a work in progress

    Two Wheel Fun Factor
    Triumph Sprint St 955i
    Bultaco Tss 250
    Moto Guzzi 650

  3. #763
    Join Date
    Feb 2005
    Location
    Bracken Ridge - Brisbane - QLD
    Posts
    12,907
    I doubt you will want to do he read screen a third time but I always thought the locking strip go on the inside of the car......only going off how itís done on defenders.

    Oh....the car is looking sweet.

    2000 110 Hardtop

  4. #764
    Join Date
    Jan 1970
    Location
    In my D2a Ripping It Up
    Posts
    9,681
    Quote Originally Posted by weeds View Post
    I doubt you will want to do he read screen a third time but I always thought the locking strip go on the inside of the car......only going off how itís done on defenders.

    Oh....the car is looking sweet.
    A lot of cars run the strips on the out side
    Maybe just a Landy thing .
    cheers chris


    My Toy 04 D2a Td5 Manual With Lots of Goodie Goodness
    S111 Swb a work in progress

    Two Wheel Fun Factor
    Triumph Sprint St 955i
    Bultaco Tss 250
    Moto Guzzi 650

  5. #765
    Join Date
    Feb 2005
    Location
    Bracken Ridge - Brisbane - QLD
    Posts
    12,907

    Stirlsilver's Disco Ute Project

    Quote Originally Posted by rangieman View Post
    A lot of cars run the strips on the out side
    Maybe just a Landy thing .
    Probably is a Land thing.......Iíve never had a close look at other cars.

    2000 110 Hardtop

  6. #766
    Join Date
    Jun 2007
    Location
    Ashfield, NSW
    Posts
    960
    Hello everyone,
    It's only been 3 months since the last update. A few things happening, one of which being the garage which I was using the store the car in was no longer available so the car got relocated to the inlaws. We are soon going to be moving to a new place in Oatley, and the property has a double bay garage so I'll be sorted on that front.

    Anyway, after dropping the car off to have the exhaust extended to the back with a resonator, I took the car to the engineer for the final inspection. And... it failed:
    • Too much body roll
    • Too much offset on rims
    • Concerns on the rear license plate holder
    • Exhaust too loud!!!


    I couldn't believe that there was still a problem with the exhaust noise level. What may not have helped is that the exhaust system was 2 x 2.5" to just before the rear diff. The modification collected these into a single 3" which being larger diameter probably didn't help the noise situation. A 2" insert should do the trick though.

    For the wheel offset, I got a set of standard discovery rims, but being 16" I was strugging to find some tyres that were equivalent to 33". I ended up getting two 285/75/R16 tyres, but I now need two more!!

    For the body roll, I have a couple of extra heavy duty sway bars on the way, they are being made and won't be ready until the end of the month.

    Finally, the engineer did turn to me and say that certifying the tow bar was not in scope, I kicked up a fuss about this but then after he showed me the standard, I agreed I would test it and send the photos. Roughly speaking, for the older cars you load the tow bar in tension and compression with 1.5x the rated towing capacity, then left to right is done at 0.5x towing capacity and finally up and down at 0.5x towing capacity.

    I decided to rate the tow bar to 2,000kg, given the car itself weighed about that much. So I hired a load cell and tried to do this using a 10t chain block. For the tension test (where I needed to put 3,000kg). I chocked up the car with some wooden blocks and anchored it to a 200 series Land Cruiser. I started pulling on the chain block and got to about 1,800kg before it was nearly impossible to pull any more, and then I also realised that I was starting to drag the car over the wooden blocks on the concrete...

    So getting 3,000kg of load on the tow bar was becoming tricky. I even tried low ratio with the centre difflock engaged and on bitumen, there I only got to 2,000kg before tyres started to slip on the bitumen!

    So in the end I called in a friend with an escavator and we got the job done. Some photos below:

    The car between a power pole and an escavator. What could go wrong right?


    Setup for the 3,000kg tension test


    Setup for the 3,000kg compression test




    Setup for the 1,000kg vertical up load test. Had to put about 500kg on the back.


    Axles weren't on the bump stops with 500kg on the back, springs are possibly too stiff.


    Setup for the 1,000kg vertical down load test.



    The photo below is some other work i've done. I've fitted some anchor rails onto the tray to give me some achoring points. The tyre is standing vertically because I was about to put the car cover on, my first attempt and water pooling on the cover in lots of places and starting to seep through the fabric!



    That's it! next update will hopefully be from Oatley when I fit the new swaybars on. If anyone has a couple of spare 285/75R16 tyres, please get in touch!
    Stirling
    My other project - Hobby Society

  7. #767
    Join Date
    Jun 2007
    Location
    Ashfield, NSW
    Posts
    960
    Alright, the move to Oatley is 99.9% done. Not something I would like to do again any time soon. I think in the end we had enough stuff to fill 2 Trailers, 1 Large truck and about 7 car loads...

    The Discovery is now in it's new home, however all the tools and camping gear is just sitting on the floor...




    Also, the swaybars have finally arrived, and they are absolutely enormous. Especially when you compare it against the skinny stock rear sway bar. I'll have a better photo when I am in the process of fitting it.


    That's it for now, progress is real slow because the move has been such a mammoth task!! Hopefully some more updates soon.
    Stirling
    My other project - Hobby Society

  8. #768
    Join Date
    Jun 2007
    Location
    Ashfield, NSW
    Posts
    960
    At last some progress!

    Sway bars are in. I did a bit of a comparison side by side before they went in.

    The rear sway bars were significantly thicker than original!




    The front bars were about 3mm or so thicker.




    One of the other requirements from the engineer was that the exhaust was too loud, despite taking the car to an exhaust shop a second time to have the exhaust extended all the way to the back and a resonator fitted. So to deal with it, I made a 2" reducing insert, which seemed to cut down the noise by a reasonable amount.


    Progress on clearing up the garage, it's pretty much a usable space now
    Stirling
    My other project - Hobby Society

  9. #769
    Join Date
    Jan 1970
    Location
    Melbourne - Eastern sector
    Posts
    960
    As always great job!!

    How are you going to deal with the rear sway bar inverting with long travel shocks?? Hugh issue on the D1's / RRCs
    1996 Td5 Disco UTE
    2003 Td5 D2a

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