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Jan 16, 2020 18:33:02 GMT
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Realised that I never did a thread on this. Even now it’s sold it may be of some interest to someone.
Bought for the massive sum of £400. 300tdi 3 door non sunroof rotbox discovery. All seemed well. Even drove it home on the motorway. In the rain. And got wet feet. Mmmmmm
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Jan 16, 2020 18:38:21 GMT
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Behold lardy the Landy. Throw some tyres on get it through a mot and have a play. Oh how wrong I could be. The whole sill, floor and a piller where let’s just say crusty. Out with the 6x2 box section to make some sills and mounts. Then some 3mm plate to piece in the floor. This was done inbetween some other “projects” that also need threads doing for. It took literally forever.
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Last Edit: Jan 16, 2020 19:57:01 GMT by 666coward
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Jan 16, 2020 18:52:12 GMT
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Decided I could make a relatively simple front bumper out of some 3mm steel I got folded by a local engineering firm. Also knocked up a roof bar to add spotlights and bush cables. Gave the engine a good service, finished the never ending welding and passed it’s mot. Hurray time to go off roading. Met up with some mates who have some pretty capable off roaders. All was good. 5 minutes in and was stuck. Got towed out. Thought more momentum would help. Got stuck again but also a lot deeper. Maybe off roading wasn’t for me. What I needed was more ground clearance so the diffs wouldn’t dig in. Cue a message from a mate about a cheap set of wheels and tyres. Now cheap I use loosely. If you ask the misses they where a lot less than what I actually paid but shhhhhh. Slight problem is the tyres where 37” and they can’t be fitted to a disco. 😂😂😂 sounds like a challenge. Off a went to meet the seller at hartshead services to pick up said 37” wheels and tyres. Holy moly they were even bigger than I expected. Once back I jacked lardy up and bolted the on. Success. Well until I lowered the jack. Mmmmmm Time to fire up the grinder.
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Jan 16, 2020 19:47:53 GMT
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Jan 16, 2020 19:50:32 GMT
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Oh the tape was a moment of madness. I contemplated cutting the back off.
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Jan 16, 2020 20:13:33 GMT
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thats a very neat idea
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Jan 16, 2020 20:18:34 GMT
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Drove round like this for a few days to work out what was catching and when. Pretty easy answer. Everything and all the time. The rear was straight forward. I needed to lift the suspension. There was plenty of clearance to the inner arch / tub. Now the front was a different story. With the offset of the wheels they turned on a larger ark. So caught the bulkhead, sill ends and inner wings. Major surgery was needed. I wanted to do all these clearance modifications before I lifted the suspension in the hope that where the suspension is at standard would be the max of the suspension travel when lifted if that makes sense. So the inner wing was flat on top then drops down to the headlight panel at 45 degrees. This fouled the tyre. So the front was chopped out and a straight panel was grafted in to make the front section follow on from the center section. I also chopped the corner off the headlight panel just incase.
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Jan 16, 2020 20:23:33 GMT
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And cheap. There is a running theme that will develop here. Also KISS. Keep it simple stupid.
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Jan 16, 2020 21:29:10 GMT
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Last Edit: Jan 16, 2020 21:35:42 GMT by 666coward
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Jan 16, 2020 21:58:17 GMT
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So I worked out I needed 6” of extra height from the wheels to the body. But after 2” longer springs the propshafts start to bind on the uj’s. Ok wide angle propshafts can be bought. But are a hell of a lot of money. So that ruled that out. Ok so I need to find 4” of extra “lift”. How about lifting the body up off the chassis then. Knocked up some 4” spacers using 2”x2” box section and capped the ends and drilled for bolts to pass through. Found some longer bolts at work that would replace the standard bolts too. Cheap as chips and works quite well. Now lifting the body 4” off the chassis through up many issues. 1 fuel filler neck 2 steering column 3 fuel filter 4Clutch pipe 5 brake pipes 6Gearstick and transfer lever The filler neck was cut and a section of slightly smaller bore tube was fitted and clamped in place. Cheap and works. The steering column has a section that is removable but is made of aluminium. But on a defender they are steel and just need a flat filing on one end to allow the pinch bolt past the splines. I had one sat in a spares box so it was cut and lengthened and then sleeved and pinned for good measure. Cheap but a little involved. The bulk head fuel filter just needed a drop down bracket making. Easy and cheap. The clutch pipe just needed rerouting slightly but had enough to use the original. The brake pipes I would end up buying when only for a 2” lift so I dropped the mounting brackets down 4”. The gear stick and transfer lever where a nightmare. I extended them both which looked fine. But the extra throw ment that I needed to put my fist through the dash to get first gear. Not ideal. I replaced all the linkages to remove some play which helped but wasn’t ideal for the transfer box lever. But after drilling some new holes for the linkage to attach to the operating shaft I got it to a acceptable range. Only pic I had of any of the faffing with extending parts. Ollie my little lad just checking the wheels where big enough.
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Last Edit: Jan 16, 2020 21:59:01 GMT by 666coward
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Jan 16, 2020 22:27:59 GMT
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Jan 16, 2020 22:41:09 GMT
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Another problem from lifting the body 4” was the top radiator brackets being 4” to high. Simple. Redrill the holes lower down the front panel. Easy. Not easy was routing the pipe work for the air box that now doesn’t fit as originally it sat behind the passenger headlight. So messed about with different pipes and a modified airbox off a 200tdi landrover. Also witted silicone boost pipes and removed the egr valve. Had to switch round the header tank and battery to so the bonnet would shut. Note the modified with a big hammer bonnet frame above the battery. Cheap yes. Did it work. Yes. Fitted a snorkel and led light bar to because that what you do apparently 🤔 So right let’s go and do off roading.
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Last Edit: Jan 16, 2020 22:43:18 GMT by 666coward
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Jan 16, 2020 22:51:07 GMT
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In hindsight I’m a bit of a tool. Didn’t occur that the massive difference in tyre circumference would affect gearing. It was like trying to set off in 3rd gear. So problem I’ll just slip clutch a little. Doh So one clutch, gearbox and transfer box later and a busted bank account, back, knuckles and sanity it was back together. Note the output shaft on the gearbox was torn to pieces. As a side not the transfer box on a disco is 1.2 1.4 on a 90 defender and 1.6 on a 110 defender. Went for the 1.6 transfer box that gave me pretty much what it was like originally but limited top speed to around 60mph. And yes I did try it. And yes I did have a code brown while doing so. The steering dampener couldn’t come and the resulting speed wobble must of made for a interesting site.
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Jan 16, 2020 23:01:01 GMT
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Jan 16, 2020 23:05:12 GMT
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Last Edit: Jan 16, 2020 23:37:25 GMT by 666coward
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Jan 16, 2020 23:09:42 GMT
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Jan 16, 2020 23:18:56 GMT
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Jan 16, 2020 23:25:37 GMT
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Great write up cheers, looks like you had great fun. Shame it had to go but life moves on to bigger and better things.
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Great write up cheers, looks like you had great fun. Shame it had to go but life moves on to bigger and better things. The reason I was away from home so much. Definitely bigger things but not necessarily better.
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Last Edit: Jan 18, 2020 7:37:06 GMT by 666coward
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