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-   -   The Re-Build - Discovery 1 TDI (http://www.expeditionexchange.com/forums/showthread.php?t=1274)

Stevepurvis April 12th, 2009 04:47 AM

The Re-Build - Discovery 1 TDI
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Here is the story of my discovery rebuild......hope it will be of interest and possibly of use.....pictures below....The vehicle has sat for over a year doing nothing.....so you can see the tin worm has been busy even on the bits I started before....also you see in one of the pictures a small family has moved into the space behind the grill....will keep you posted on their progress...hope fully putting the grill back hasn't disturbed them to much....

The plan of parts for the finished vehicle is as follows....im open to sugestions of ideas or alternatives to what I have planned:.....The ones in red are set in stone

ARB Bull Bar – Is There Any Other
Safety Devices Roof Rack
Warn Lights x 6

Snorkel – Mantec Steel
Springs – 2” Lift Old Man Emu
Shocks - 2" longer Old Man Emu

Fuel Tank Guard – Southdown
Receiver System….
Bonnet Anti Glare….Camel Style
Paint – Silver
Shocks – Old Man Emu
Steering Damper - Genuine Land Rover
Braided Brake Lines- Extended
Rock Sliders – Home Built
HD Rear Bumper – Home Built
Tyres x 6 – Cooper ST
Air Compressor – Air Con Compressor Adapted to Run Air
Split Battery Charge – National Luna
Window Panels (Ally) – Home Built
Window Tints - Local
Head Lamp Guards – LR Perspex
Second Battery - Optma
Silicon Hoses – Not sure where yet
Heavy Duty Body Mounts – Home Built
Heavy Duty Radiator Mounts – Home Built

Map Light – Rally Style
D2 Cup Holders – Genuine Parts
Compass - Silva
CB Radio - Cobra
Nav Equip – Home Built Around Tough Book
Shelving Rear – Home Built
Fridge – National Luna Weekender
Seat Covers - genuine Land Rover
Water System - Jerry Cans and Charcoal Filter

to be continued.............

Stevepurvis April 12th, 2009 06:32 AM

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***UPDATE*** just to let you know the robins are still being fed...so it looks like im going to be at the other end of the vehicle for a few weeks ...

Removed today:

Front left wing - photo shows what i found!
Raised air intake
Roof rack

Stevepurvis April 14th, 2009 11:14 AM

**Update** :( sorry to report that the robins were abandonned...really gutted....hoepfully my next update will have more good news....

Stevepurvis April 19th, 2009 01:35 PM

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Did some grinding today mostly on left inner wing .....or should that be most of the front left inner wing.....

Whilst I was in that area I drilled the hole for the raised air intake.....

Then I decided to remove the rear bumper to see how bad the rear body mounts are......as you can see bad

I have decided to use a white primmer so that I can see which bits are done as I go along ....but also so that when I spray the chassis black on it is easy to see that its covered everwhere....

I also have put mastic sealer on all the areas that dirt and grime may hide in......

jaime April 20th, 2009 07:08 AM


I can see which bits are done as I go along

as a suggestion and along the same line, mark with a paint stick any bolts you have torqued so you can reference that the work has been completed.


Stevepurvis April 20th, 2009 11:14 AM

Great idea......Thankyou very much.....new piccies coming soon

Stevepurvis April 20th, 2009 11:24 AM

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Well took the right hand wing off today.....much the same with tin worm....although some bits better other bits worse......all started to strip front end.....

Stevepurvis April 22nd, 2009 04:32 AM

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Took out the front seats today as need t remove carpet....centre consol to come out later.....also nice view of what is under the floor that is no more.....

Front end all wire brushed back and some undercoat on to stop surface rust.....

Stevepurvis April 22nd, 2009 10:03 AM

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Well busy day today managed to get the centre consul out and start to get rid of alot of surface rust, exceptone small bit that went though, patch for tha area needed..... when taking the consul out I took some piccies to remind me of where the switches and plugs went.....once again white spray means its done.....

Picture of why the rear floor had to come out....

Also took some pictures of the CB radio external speaker mount and the Split Charge Battery Monitor (national luna) ...the later is going to be changed by cutting a slit in the moulding or the consul so the plate is not on display....more of that later......

Stevepurvis April 25th, 2009 12:04 PM

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Drivers side floor now all sparkly...well apart from the big hole that will need welding near the B pillar

The Whole in the foot well that will need plateing.....

The front inner wing all prepared an awating a bit of plateing...

Stevepurvis April 26th, 2009 10:18 AM

no progress today........had to do a days work....hahaha...wasnt all that bad got to play with a D3 in some serious mud...........yipeeeeeeee

Stevepurvis April 28th, 2009 03:29 PM

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Better weather today so got a bit done.....

Sorted the seat bases out bit of surface stuff quickly ground off and then painted.....

Rear cross member was not as bad as I thought it would be....just the body mounts rotten as allready shown.....the rest just a bit of flakey surface that ground of quickly....

Found anouther bit I wasnt expecting around the seatbelt mount n the drivers side rear....

Stevepurvis April 29th, 2009 03:59 PM

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Anouther productive day ....

The seat bases are back to the colour they started....

More grinding this time round the RH rear seat belt fixing area

The rear left passenger foot well

Included a couple of pictres of my fine workshop.....as you can see well venilated good lighting and plenty of spill soil should it be needed!!!!!

I aslo have shown some pictures of home my CB is mounted and the switches that replace the sterion controls (Now Long Gone) to control the lighting etc....

A picture of my next project ...sankey trailer...

And the springs and shocks are gone bring on the Emu's!!!

Oh yes and a bit more rust the bumpstop plate on the axle needs replacing.....

Stevepurvis May 20th, 2009 12:39 PM

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Well the rain stayed away today so managed a little bit of work on the Discovery..Took off the front shocks and springs....sounds so easy when you type it....believe me it wasn't and the angle grinder had a good work out here and there.....

Stevepurvis May 25th, 2009 11:22 AM

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More work on the suspension areas today.....lots of wire brushing to get rid of the surface rust and then a good coat of Hammerite to try to keep it back for a while in the future.....Pictures show before and after of the front and then just after at the back....

Stevepurvis June 2nd, 2009 01:32 PM

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More sunshine today so a bit more grinding and wire brush work....slowly slowly its starting to turn the corner towards getting there hahahah....and yes that is a hole in the bottom rear spring mount....well two actualy, one is meant to be there....so new one ordered today...ebay has had such a workout this last few weeks hahaha

Stevepurvis August 19th, 2009 05:16 AM

Change of Plan its now going to be a 100" Defender Tray Back
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I have had a change of plan now going down the Defender Tray Back route......

jrose609 August 19th, 2009 10:44 AM


Originally Posted by Stevepurvis
I have had a change of plan now going down the Defender Tray Back route......


I have been following your thread. What was the deciding factor in making this a pickup?


Stevepurvis September 12th, 2009 03:44 AM

sorry cant log into this at home so havnt been able to update....just the amount of rust and availability of the defender parts....

Stevepurvis September 12th, 2009 04:17 AM

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sorry for the delay but some new piccies as i cant log on at home....

Stevepurvis September 12th, 2009 04:19 AM

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and some more

Stevepurvis April 16th, 2010 02:35 AM

Up dates
I am still working on this vehicle and have many more pictures.....which if people are interested I will post....

discotdi April 16th, 2010 03:08 PM

go for it. like to see them

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