Advertise on DISCO3.CO.UK
Forum · Gallery · Wiki · Shop · Sponsors
DISCO3.CO.UK > Maintenance & Mods (D3)

Rusty boot floor / Body removal
Post Reply  Down to end
Page 2 of 15 <123 ... 131415>
geoffsnook
 


Member Since: 13 Jun 2014
Location: south wales
Posts: 3169

Wales 

Epic what a project bet the wife and neighbour's love the site when they open the curtains in the morning Rolling with laughter Rolling with laughter
 Discovery 3 se gone
Range rover sport supercharged here:) 
 
Post #216028710th Jul 2020 4:22 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

So the reason to lift the body was due to a rusty boot floor, like this:

Click image to enlarge




There is actually LR applied underseal in the middle part of the body. Its held up well. What the hell were they thinking missing the entire boot floor and the inner sills??

After a power wash I ended up with this:



This felt a bit disheartening. No rust holes (well not quite, but I'll get to that), but it looked sh*it.

But after a lot of surface rust removal I ended up with this:



Much better! And it looked better after a quick coat of paint:




Feels like progress, so opened up some wine tonight. And this post is now up to date.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 


Last edited by Breg90 on 10th Jul 2020 8:55 pm. Edited 1 time in total 
Post #216032310th Jul 2020 8:42 pm
View user's profile Send private message View poster's gallery Reply with quote
Moo
D3 Decade 


Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13805

Ukraine 2005 Discovery 3 TDV6 S Manual Zambezi SilverDiscovery 3

Funny how rust often looks worse than it is. Good job though Thumbs Up
 New Defender L663 110 SE (known as Noddy!)

Sold Volvo XC90 R-Design (known as Basil)

Sold - D4 HSE (Known as Gerty)

No longer the Old Buses original owner Sad
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control 
 
Post #216032610th Jul 2020 8:45 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

nigethecat wrote:
Most impressive! The only part I don’t believe is that you are in Falkirk as it's not raining in three of the photos! Rolling with laughter

An excellent job although I share the Profs safety concerns... look at the brake pipes as well if this hasn’t been mentioned... and also deal with any rust on the rear chassis

More photos as you progress please Thumbs Up


Nigethecat,

Re safety concern, I estimated the body at 1.6 tons. Assumed 1 ton was at the rear (0.5 ton load at each sill onto the white beam) and did a beam stress calc for the beam section (120x65x5) and length. Max stress is 57 N/mm2. Its BSEN 10219 Grade S235 steel, so has a minimum yield strength of 235 N/mm2. So I have a factor of safety of 4.12.

It didn't do a buckling calculation on the uprights, but there more than man enough. Hence I sit under the body on my stool quite happily.

Regarding brake pipes - they have already been 'done' with the custom tie-in point half way. However the entire front to back brake pipe runs are now in the bin as even the copper replacements were looking ropey.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216032810th Jul 2020 8:51 pm
View user's profile Send private message View poster's gallery Reply with quote
Dazz360
 


Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

PROFSR G wrote:
What the f@xk Shocked You're a brave man, are you addicted to Iron Brew? Laughing

Edit: Have you actually used this set up yet? If you don't mind I would advise against it especially on grass. If it buckles while you are working on it you're dead!


First time I’ve seen the prof swear

Good effort on that, it’s Gave me ideas
 Metal auto sump & fluid change (3 hrs)
LR door puddle projectors (10 mins)
Tinted Bonnet wind deflector (10 mins)
All Intercooler pipes and Tbolts (2hrs)
3 injectors replaced so far (30mins)
Sunroof drain pipes both sides 2.5 hrs)
Rear discs, shoes,pads,callipers,flexi hoses, rigid brake line, n/s upper hub carrier bush and rear n/s upper arm (13hrs over 2 days) 
 
Post #216033110th Jul 2020 9:04 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

geoffsnook wrote:
Epic what a project bet the wife and neighbour's love the site when they open the curtains in the morning Rolling with laughter Rolling with laughter


Geffsnook,

Nieghbours are used to me and my projects and are very tolerant. They also know they can turn up any time to borrow a tool, ask for a repair, etc. Response is more curiosity and 'what the f*ck are you doing now'. A good nieghbour told me that his niegbour asked what was I doing - 'car restoration'. Apparently the response was 'whats wrong with buying a new one?' - Depreciation man, DEPRECIATION!

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216033410th Jul 2020 9:15 pm
View user's profile Send private message View poster's gallery Reply with quote
motorworks
 


Member Since: 14 Nov 2019
Location: Usk
Posts: 401

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Tonga GreenDiscovery 3

I find this impressive and a little scary. I posted some details about D3 COG on a two post lift. Your frame is supporting about 1300kg. The balance point is a few cm behind the gap between the doors, so it is certainly heavier at the rear.

I would say the critical parts are the straps ground front to top rear. If either of those were cut, melted or released gravity would prevail.
 Chris  
Post #216033910th Jul 2020 9:45 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

I thought the LR body removal procedure might be of use to others.

https://www.disco3.co.uk/gallery/albums/us...l_proc.pdf

Its for a left hand drive auto. But you can swop left for right and if you have a manual just release the gear stick.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 


Last edited by Breg90 on 22nd Jul 2020 9:03 pm. Edited 3 times in total 
Post #216281922nd Jul 2020 8:58 pm
View user's profile Send private message View poster's gallery Reply with quote
kajtzu
 


Member Since: 10 Aug 2017
Location: Helsinki
Posts: 6538

Finland 2005 Discovery 3 4.4 V8 HSE Auto Cairns BlueDiscovery 3

Might want to change the img tags to url tags Thumbs Up
  
Post #216282022nd Jul 2020 9:01 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

Kajtzu,

Sorted !!!

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216282122nd Jul 2020 9:02 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

And my write up/pictures of the order I did it in:

https://www.disco3.co.uk/gallery/albums/us...record.pdf

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216282322nd Jul 2020 9:16 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

Managed to find the pictures of the initial jacking:

At the rear with a transit van scissor jack:



At the front with a disco 1 bottle jack:



Obviously the white beams were passed under the body once it was high enough.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216446129th Jul 2020 10:35 pm
View user's profile Send private message View poster's gallery Reply with quote
darrind
 


Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2863

England 2013 Discovery 4 3.0 SDV6 HSE Auto Santorini BlackDiscovery 4

Impressive Bow down Bow down Bow down
 Must stop buying shiny toys....  
Post #216446329th Jul 2020 10:51 pm
View user's profile Send private message View poster's gallery Reply with quote
Breg90
 


Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347

United Kingdom 2008 Discovery 3 TDV6 XS Manual Java BlackDiscovery 3

So after all the effort to get the body in the air it seemed a shame not to look at the chassis. I always knew I'd do this, just hadn't told the wife what level I was taking this too.

So on inspection a simple tidy up wasn't going to do. So I started stripping the chassis. It will either be shot blasted and painted, or galvanized.

Started removing the gearbox first, then back tracked the took out the engine. So 1st was the rad pack removal, then the exhaust and fuel connections. After that lift out the engine:





Pro tips (Translation: don't do what I did):
1/. Remove the upper arm heat shields or your likely to crush one with the engine mount like I did
2/. Disconnect and remove sump oil sensor or your likely to knacker the connector and wiring like I did - Censored .....



Followed by the gearbox:



Ending up with this:



I seem to be generating interest. Caught a guy from a few streets away cycling past for a rubber neck session. Also James (Next delivery dude) stopped and had his lunch while I lifted out the engine the other day (hadn't realized how many clothes my wife orders!). The week previously he had the cheek to complain I wasn't getting on with it.

Adrian
 Series one 1949 - in bits, chassis is strapped to the ceiling in my garage (beside the canoe)
LR 90 - In bits
Disco 3 - currently in bits 
 
Post #216475130th Jul 2020 11:03 pm
View user's profile Send private message View poster's gallery Reply with quote
PROFSR G
 


Member Since: 06 Mar 2017
Location: Lost
Posts: 4580

Ukraine 2009 Discovery 3 TDV6 Commercial XS Auto Stornoway GreyDiscovery 3

Well, no going back now Smile

At least you have the easy bit done Laughing Putting it all back will be a tad slower, but plenty to keep the neighbours jaws exercised for a while yet. It's a great project and I'm sure it will be a credit to you when its done.

Many others with a fully equipped workshop might struggle to find the maracas to take that job on.

Well done. Thumbs Up

Edit: If you're going to galvanise the chassis don't forget to plug any threaded holes!!
 yµ (idµ - eAµ) ψ=mψ

 


Last edited by PROFSR G on 31st Jul 2020 12:18 am. Edited 1 time in total 
Post #216476131st Jul 2020 12:15 am
View user's profile Send private message View poster's gallery Reply with quote
Display posts from the last:  
Post Reply Back to top
Page 2 of 15 <123 ... 131415>
Jump to:  
Previous Topic | Next Topic >


Posting Rules
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum



DISCO3.CO.UK Copyright © 2004-2024 Futuranet Ltd & Martin Lewis
DISCO3.CO.UK RSS Feed - All Forums

DISCO3.CO.UK is independent and not affiliated to Land Rover.
Switch to Mobile Site