Got up to the CSK again this weekend and had some lovely weather too! Managed to make further headway;
N/S rear wing removed
rear bumper removed
headlining removed - this seems to be a GRP replacement but will need recovering as it's starting to come free in a few places
All ECUs removed
Rear windows removed
C-pillar trim removed
bottom of dash and TX tunnel sound proofing removed
gear stick and gaitors removed
Sunday was spent removing all the body mounts, radiator and various bits from the inner wings, disconnecting various wiring and cutting through flexible hoses till we got to the stage where we could do this;
Found a few holes in the top of the chassis but noting major, certainly easy to patch. Fuel tank is aluminium, I would guess the capacity is lower than the steel or plastic equivalent but since I'm fitting LPG this is no biggie to me, might help keep the weight down!
Probably not going to be much of an update for a few weeks so that's it's resting place for the time being.
Well, I can purchase all the panels to rebuild the body shell so not too much of an issue there. Next step is to get a good chassis to work from before re-fitting the body and welding in all the repair panels!
Moved forwards a little bit more since the last update;
Body was placed back onto the chassis so concentration could turn back to metal work rather than mechanics (the mechanics are the easy bit)!
Started building up the panels for the front end on Monday evening by the end of the week the front headlamp sections and a front inner wing were finished;
Front wings removed, holes uncovered and cleaned up and patched. Body mounts were fabricated and welded on (hopefully in the right place).
Headlamp sections were bolted down, bonnet slam panel is bolted in position for the moment (I could leave this bolted or I can weld it back, currently undecided). One of the completed inner wings was offered into place and trimmed to fit before being welded in place;
I've been a bit shy of the updated for the past few weeks, my attention had been focused elsewhere, sorry!
I took advantage of the bank holiday weekends to press on with the work, amongst other things.
Firstly the front wings were finished off and roughly painted in whatever I had laying about to keep the rain off them;
These are going to need sanding back before getting a proper coat of paint but the idea was to get a coat of something on them rather than to make them pretty
Attention then turned to what was left of the O/S sill section. The remaining metal work was removed at the sacrifice of several cutting discs and the new sections trial fitted;
These were then welded together in what I hope is the right shape and offered back up to the car, the floor was cut back till all the rot was gone. This was fairly easy to fit as both the A post and B post were pretty far gone so were removed with the sill allowing me to slide it into place and bolt it back down onto new mountings before being welded into place.
Attention then turned to the A-post and B-post. I had a 2-door repair panel for the A post so that eased the rebuild slightly but the B-post was a little more difficult, I had purchased some B-post repair panels but they were very wrong. Armed with some cardboard and a pencil I constructed something that I hope is correct;
purchased B-post repair;
what I hope it's supposed to look like;
the whole lot was dressed back with a sanding disk and grinder before being covered in red-oxide;
Attention was then turned to the sill on the other side, while the B-post on this side was mostly still there the A post had vanished further up the bulkhead so reconstruction was going to be a PITA. The supplied A-post panels only provided the outer-skin and not the internal hinge mounts, tubes etc.
Sill was ripped out and damage surveyed;
Replacement sill was welded up and wrestled into place, B post welded on and A-post repairs were started. The parts of the footwell that could be repaired were done so, once all the rot has been removed from the top the body is coming back off and being turned onto it's side so welding repairs can be completed underneath and it can all be cleaned up.
once again the whole lot was covered in red-oxide;
So, this is how she's sat at the moment;
I searched high and low for rear body repair sections, apparently you just can't get them any more
So, I've purchased 2x large sheets of 1.2mm steel (apparently it doesn't interface well with my discovery headlining!), 2x discovery floor skirts from YRM and a boot floor for a discovery from Paddock should be getting collected this week ready to start next weekend!
Moving back from the B posts it was time to look at the side panels, wheel arches, rear X-member and rear floor.
Before I started they looked like this;
As previously mentioned I was unable to find the repair sections for the back end so set about cutting out the rot and letting new metal in. The replacement steel is a lot thicker so should add some more strength. It's not the prettiest looking job but at the end of the day it's hidden. The panels I got from YRM were cut and shaped. I had to fashion a flange for the end closest to the tailgate in the style of the old floor.
The new rear X member means that every body mounting is now new
The Discovery rear floor is shorter than the Range Rover one, I could have bought an ally one but am fairly sure I can make this fit with the addition of some strapping across the rear of the floor. I got 4x crossmembers with the new floor but am convinced I only need 3, the two angled ones that sit on the chassis stand-offs and one more towards the back, the Disco ones seem to have bolts welded to them though?
Anyway, here's the floor rested in place so you get an idea of how it all looks
There's a lot of dressing to do, I am aware it looks a little patchwork but it's very strong now and at the end of the day is hidden by trim and the wings.
I've been a little shy of updates on here, so if anyone is still watching, here goes;
The engine was rebuilt with new shells/cam/followers/timing chain/seals/water pump/head gaskets (inc bolts) and pieced back together. Flywheel and spigot bush added. (I had ordered a spigot bush earlier in the week but, despite ordering a LOT of rover v8 parts the supplier decided to send a bush for a 200/300/TD5?!). A trip to paddocks sorted that out.
The gearbox (LT77S) was given a wash down and the new clutch components fitted. I drove the car about 150 miles before strip down and the gearbox itself was spot on so didn't feel the need to do anything with this, it's an easy thing to drop out if needs be at a later date. This was dropped in to the chassis and the engine followed suit.
Props/steering box/exhaust/fuel lines and then a heavy coat of waxoyl followed. Axle/t-box/g-box fluids were all refreshed and then the body was dropped back for what I hope to be the last time.
That's how she was left Saturday night, Sunday the rear ARB was fitted, all the body mounts were pulled down tight and cleaning of the brake calipers began. I seam-sealed the insides further and managed to empty a can of acid-etch primer over the zinced parts (and some non-zinced ones too). The engine bay was further tidied and seam-sealed in places.
No photos of this though, I forgot :/
I had a trip out to a RRC breakers, where I purchased enough bits to fill the back of my Discovery up! Amongst those parts was a sequential LPG system (AG/SGI) so that's a further problem solved.
Also picked up some carpets in better condition, a filler neck, air-con rad and a few other bits and bobs.
I attacked the back of the S/S exhaust with the make-shiney attachment in the drill, went from this;
Finished the welding on the windscreen surround and A-posts and put the tubes in for the door hinges;
replaced the hinges on the doors and hung them, they fit! I was a little worried after replacing the sills and the
A/B posts there would be issues, they fit like a glove though
the inner wings front and rear were painted with underseal to try and stave off madam rust, the whole lot is going to
be smothered in waxoyl once the painting has been completed too.
I've spent a week or so stock-piling parts and cleaning bits up. Brake calipers have been painted and I have all the unions and pipe to fit them
the rear wings are with a mate who's welding up the birmabright, I should get them back this week.
Sunroof has been stripped apart and is ready for painting.
I've cleaned up the SGI manifold and have the parts ready to build the top end of the engine.
Brakes plumbed and wired, apart from the ABS Stop Light Switch. The dog knocked the pedal box over in the garage and snapped it off already ordered a new one from Land Rover. Tried a pattern part one years ago and it was useless.
Fitted the rest of the exhaust pipe, now all shiny
The clutch was plumbed with a new flexi and AP/Lockheed master cylinder.
A-posts were painted and the windscreen fitted.
Roof painted and fitted along with replacement rear wiper motor.
New heater resistor pack fitted.
Doors painted and fitted.
Bottom tailgate painted and fitted.
Top tailgate fitted loosely to keep weather out. I have a alluminium one and a genuine one, both could be made to very good condition with a little work but I'm undecided on which to fit. I'm probably going to fit the genuine one once I have made it work with central locking unless anyone can think of a good reason why not?
The rear of the car inside has been painted and the rear windows were fitted.
I also fitted the inlet manifold that came with the AG SGi LPG kit I bought, it wasn't till I'd torqued down the last bolt when the realisation that the inlet was for a multi-belt engine and not a serpentine as I fitted. That was a little annoying. I now need to find a tap and tapping drill for the LPG injectors, once I work out what the thread actually is.
Appologies for the photos being a bit sparse, been a fairly intense and tiring week but it's starting to look more like a Range Rover. Hope you like.
Here we go with an update again. The focus of the past few weeks has pretty much been bodywork.
I've avoided buying new panels for the time being and tried to repair what I had. There aren't many "before" photos, I forgot :/
The rear wings were welded by a friend with a fancy TIG
The rear quarter panels had patches welded in and bashed back into shape.
Front wings were cleaned up and had glass-fibre matting put behind any hole to strengthen it
All sections had acid-etch sprayed on, copious amounts of filler thrown at them before a few layers of high-build. They were all then sprayed with the Beluga Black celly top coat.
Fired the engine up, starts and runs fine. Bled the clutch this morning and drove it up and onto the ramps! Felt good to have her move under her own steam.
Fitted centre console, handbrake, rebuilt most of the dashboard and put in the drivers seat..
Bled the brakes, they're a PITA on these. Had to swap out the pressure pump as it seems the one I fitted was faulty :/
Side skirts are on and I've been creating the ties to keep the wings in place. Hope to finish off underneath tomorrow and get the new wheels fitted (looking forward to that bit).
bought some wood to remake the bottom doorcards and need to adjust the top ones so they sit flush on the doors properly. Whilst they're apart I'm going to fit speakers and do the rest of the audio kit.
Have also been bust cutting/polishing/waxing the panels. Started with the rear tailgate, I think it's come out ok...
Also fitted the CSK and Range Rover decals, makes a big difference. Might have to get a set of mudflaps though.
MOT passed, road tax applied for. Finished the cutting and polishing and applied coach lines;
The inside is very nearly finished, just the audio gear left to fit really
She's now been in use for over a month, have the LPG kit fitted also along with some rear mudflaps.
I started mid October doing same job on my own 93 200tdi 2 doors "normal" Range. So i see this pictures live every day. I used this car daily last 4 years and drove it from 260000km to 360000km and now it was really necessary to give fresh metal to the car. I found your restauration history some days ago via a link of a member from blacklandyforum in germany. Really every cm rust is in detail at same places as in my car, even the big hole on the right side of fuel tank inspection gate. I will replace this with an aluminium one from a 87 Range, not original 93 but i like the possibility to have really good reach to the top of the chassis in the back with Boge, fuel tank mounts etc. Without seeing your photos before i nearly found on many places the same solutions as you, especially with the sills, A- and B- Posts and i cutted and welded the rear sidewalls nearly in the same way as you. The inner front wings i replaced 4 years ago directly after buying the car. I used that time second hand wings from a 89 disco. The front sections i only fixed with screws and sikaflex, al parts are rust prevented from "inside" between the parts and nothing is burned away as it happens, if i am welding. These frontwings are still in very good condition as i can see now. Thanks to Branthokorux rust prevention.
I really can feel with you what a job you have done, how much dust you have "eaten".
And i hope some more people will do the same, some more of this beautiful cars will survive and seen on the roads, not only dry stored in big halls!
Best Regards from germany and i wish you a lot of fun without repairs with your beautyful CSK Range!
If you wanted to know more I have 100's of photos stored in various places
David, the wheels are very much a love/hate thing. My options for 18" wheels are limited to these or using hub-adaptors which I wasn't so keen on. I still have the lovely original wheels you supplied the CSK with waiting for some of my time to rub them back and spray them the correct colours. Glad to see you've seen this thread too, if we're ever down your way I'd be happy to drop by for a coffee and you can re-acquaint yourself with the old girl
In other news;
I've replaced the distributor with a new one, a new set of 10mm HT leads and an uprated coil. This has made a big difference to how she performs.
I had a friend take a few photos out-and-about so thought I would post them here too, the suspension seems to have settled a bit. These photos were pre-LPG kit, the whole thing has now also been coated in waxoyl inside and out to try and slow down the rusting process.
> Axel, any links to a thread on your rebuild?
> If you wanted to know more I have 100's of photos
> stored in various places
> David, the wheels are very much a love/hate thing.
> My options for 18" wheels are limited to these or
> using hub-adaptors which I wasn't so keen on. I
> still have the lovely original wheels you supplied
> the CSK with waiting for some of my time to rub
> them back and spray them the correct colours. Glad
> to see you've seen this thread too, if we're ever
> down your way I'd be happy to drop by for a coffee
> and you can re-acquaint yourself with the old girl
> In other news;
> I've replaced the distributor with a new one, a
> new set of 10mm HT leads and an uprated coil. This
> has made a big difference to how she performs.
> I had a friend take a few photos out-and-about so
> thought I would post them here too, the suspension
> seems to have settled a bit. These photos were
> pre-LPG kit, the whole thing has now also been
> coated in waxoyl inside and out to try and slow
> down the rusting process.
i will post some pictures via my facebok account over some days. last days i was busy with bringing the car to an other place to finish it there.
I give you a sign if the pictures are online.