Member Since: 13 Jun 2014
Location: south wales
Posts: 3169
Epic what a project bet the wife and neighbour's love the site when they open the curtains in the morning Discovery 3 se gone
Range rover sport supercharged here:)
10th Jul 2020 4:22 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
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.
AdrianSeries 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
10th Jul 2020 8:42 pm
Moo D3 Decade
Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13805
Funny how rust often looks worse than it is. Good job though 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
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
10th Jul 2020 8:45 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
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!
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
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.
AdrianSeries 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
10th Jul 2020 8:51 pm
Dazz360
Member Since: 03 Sep 2016
Location: West Mids Walsall
Posts: 871
PROFSR G wrote:
What the f@xk You're a brave man, are you addicted to Iron Brew?
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 ideasMetal 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)
10th Jul 2020 9:04 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
geoffsnook wrote:
Epic what a project bet the wife and neighbour's love the site when they open the curtains in the morning
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!
AdrianSeries 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
10th Jul 2020 9:15 pm
motorworks
Member Since: 14 Nov 2019
Location: Usk
Posts: 401
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
10th Jul 2020 9:45 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
I thought the LR body removal procedure might be of use to others.
AdrianSeries 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
22nd Jul 2020 9:16 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
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.
AdrianSeries 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
29th Jul 2020 10:35 pm
darrind
Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2863
Impressive Must stop buying shiny toys....
29th Jul 2020 10:51 pm
Breg90
Member Since: 04 Feb 2017
Location: Falkirk
Posts: 347
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 - .....
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.
AdrianSeries 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
30th Jul 2020 11:03 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 4580
Well, no going back now
At least you have the easy bit done 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.
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
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