LAND ROVER DISCOVERY 200TDI 1992 MODEL 4X4 RUSTY JEEP
4x4 Jeep offroading Discos in Bulgaria, Djebel, Kardjali Bulgaria
4x4 Jeep offroading Discos in Bulgaria, Djebel, Kardjali Bulgaria
LAND ROVER DISCOVERY 200TDI 1992 MODEL 4X4 RUSTY JEEP
4x4 Jeep offroading Discos in Bulgaria, Djebel, Kardjali Bulgaria
4x4 Jeep offroading Discos in Bulgaria, Djebel, Kardjali Bulgaria
LAND ROVER DISCOVERY 200TDI 1992 MODEL 4X4 RUSTY JEEP THE STORY OF THIS DISCOVERY plus some TIPS for you too
A Land Rover Discovery 200TDI was in seriously rusty condition.
The 1992 Discovery has been stripped and is currently receiving major work to the rust and holes
As you can see from these photos the TDI is coming along nicely!
Still more work to do and I will list the repair and replacement work I have carried out on my beloved Land Rover Discovery real soon!
The story of this discovery started when after driving a old series 3 land rover for many years I decided it was time to get something more able to drive around Europe towing a twin axle caravan, so I looked around England while visiting my daughters and found a 1992 200tdi in reasonable condition from anchor supplies in Ripley Derbyshire, a deal was done to the tune of 1,200 pounds including a nearly full tank of diesel. For that price it did need some attention, like the usual things, shocks springs and bushes.
It was decided to install heavy duty springs and shocks along with poly bushes, that returned the handling to what it should have been. When I returned to France I had to do some welding on the front inner wings to get it through the French MOT so that it could be registered. At that age all discovery's are starting to suffer the dreaded tin worm, it was noted that corrosion was present in the ends of the sills, rear floor and door pillars, that work would have to wait as I was leaving France to explore Europe with the caravan in tow. I settled in Bulgaria and made some new friends who run a garage, after a little time I was invited to put the caravan at the garage premises with electric hook up, in return I helped the garage with a little advice and work.
After spending nearly a year chasing around eastern Europe it was time to start sorting out the corrosion, the discovery was stripped down to see the extent of the tin worm, it never ceases to amaze me how much discovery's corrode, after a good session with the hammer it had holes everywhere (see photo's) so out came the Mig welder and work started. While the body was being welded the chassis was sent away to be shot blasted.2 weeks later the body was fully repaired ready to go to be shot blasted. So off we went with the body to the shot blasters and to collect the chassis so work could start to get a rolling chassis ready for the body's return.
A Land Rover Discovery 200TDI was in seriously rusty condition.
The 1992 Discovery has been stripped and is currently receiving major work to the rust and holes
As you can see from these photos the TDI is coming along nicely!
Still more work to do and I will list the repair and replacement work I have carried out on my beloved Land Rover Discovery real soon!
The story of this discovery started when after driving a old series 3 land rover for many years I decided it was time to get something more able to drive around Europe towing a twin axle caravan, so I looked around England while visiting my daughters and found a 1992 200tdi in reasonable condition from anchor supplies in Ripley Derbyshire, a deal was done to the tune of 1,200 pounds including a nearly full tank of diesel. For that price it did need some attention, like the usual things, shocks springs and bushes.
It was decided to install heavy duty springs and shocks along with poly bushes, that returned the handling to what it should have been. When I returned to France I had to do some welding on the front inner wings to get it through the French MOT so that it could be registered. At that age all discovery's are starting to suffer the dreaded tin worm, it was noted that corrosion was present in the ends of the sills, rear floor and door pillars, that work would have to wait as I was leaving France to explore Europe with the caravan in tow. I settled in Bulgaria and made some new friends who run a garage, after a little time I was invited to put the caravan at the garage premises with electric hook up, in return I helped the garage with a little advice and work.
After spending nearly a year chasing around eastern Europe it was time to start sorting out the corrosion, the discovery was stripped down to see the extent of the tin worm, it never ceases to amaze me how much discovery's corrode, after a good session with the hammer it had holes everywhere (see photo's) so out came the Mig welder and work started. While the body was being welded the chassis was sent away to be shot blasted.2 weeks later the body was fully repaired ready to go to be shot blasted. So off we went with the body to the shot blasters and to collect the chassis so work could start to get a rolling chassis ready for the body's return.
You can phone either
THE GARAGE WORKSHOPS
Lyubo on 0896 650 890 (Lyubo speaks Bulgarian only)
or
THE PARTS SHOP
Zehra on 0896 650 891 (Zehra speaks some English)
the 4x4 specialist speaks fluent English!
THE GARAGE WORKSHOPS
Lyubo on 0896 650 890 (Lyubo speaks Bulgarian only)
or
THE PARTS SHOP
Zehra on 0896 650 891 (Zehra speaks some English)
the 4x4 specialist speaks fluent English!
click photos to enlarge
LAND ROVER DISCOVERY 200TDI 1992
Photos, the renovation story plus some TIPS for you too...
Photos, the renovation story plus some TIPS for you too...
© Photos copyright Suzisunflowers
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4x4 Offroading in Bulgaria Jeep Safari Jeep Repairs Jeep Servicing and general 4x4 Jeep maintenance
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LAND ROVER DISCOVERY
200TDI 1992
LAND ROVER DISCOVERY
200TDI 1992
Very little welding had to be done to the chassis, discovery chassis are known to be built like the fourth bridge, the repaired chassis had 2 very thick coats of chassis paint to help keep the chassis in a good condition for many years to come. I decided at this time to order a lot of new parts from Paddock spares and MxM in England, 2 very well known suppliers of land rover parts, the new parts soon arrived, it was like being a child on Christmas morning opening all the parcels !!!!.
Here is a list of the parts ordered :
Steering guard
Heavy duty steering rods
Tank guard
Goodridge brake hoses, +2 inch
Rear brake disc's and pads
Center and rear exhaust
Safari snorkel
Turbo hose kit
Bonnet light pod
Front axle swivel kits
Arb locking diff
Arb compressor
Plastic headlight bowls
Exhaust temperature gauge
Oil pressure gauge
Volt meter
Checker plate for the body sides
The chassis was built up ready for the body's return, there is nothing like seeing a chassis being built up, see photo's.
A phone call from the shot blaster to tell me that the body had even more holes was not a surprise as the shot blasting equipment is very powerful, so away I went to do even more welding, that done the shot blasters worked some more and the body was collected late one Saturday night. What a difference shot blasting makes, the body looked like new. The body was sprayed with chassis paint and then Hyundai poppy red was sprayed around the door frames and roof. The underside of the body was given several coats of bitumen paint.
A lot of interest was shown by the garage customers as they had never seen this kind of work done before to a 4x4, many words of encouragement were given by the customers.
The rebuild of the body started, test fitting the outer panels, painting the outer panels , then fitting the panels with silicone sealant for all the joints as this stop's the electrolytic corrosion that normally occurs, silicon is much better than the original sealant as it is easier to remove any panels in the future if needed. The doors were adjusted to fit the gap, not an easy task as the doors are very heavy and a little adjustment can make a big difference to the door gap. The doors can be adjusted up or down, forward or back and in and out of the body, and land rover are not known for good panel gaps.
The installation of the electrics was a long slow process as I have installed a relay to connect both batteries only when the engine is running, this uses a 70 amp relay connected to the small brown and yellow wire connected to the alternator. Also installed was a second fuse box from a 300tdi discovery, the 1 from under the bonnet, this supplies all the current needed for the extra lights and Arb compressor, the supply to this second fuse box comes from the second battery. The second battery is a 90 amp leisure battery; so far it has stood up to the winch usage.
Leisure batteries are designed for a deep cycle usage. You can take a lot of power from them for a long time with no bad affects. Another modifications to the electrics include extra interior lights ( all LED bulbs so not to drain the battery if I leave the doors open for a long time ) connecting the alarm system to the central locking system and also the interior lights and little LED bulbs installed in to the door handles so that I can see the handles at night ( no more fumbling for the handle ) puddle lights are installed in to the bottom of the doors, land rover kindly left a hole in the door bottoms that is the same size as the little red light fitted into the edge of the back door.
I have also fitted these same light's to the door edges of the front doors. The bonnet pod light have been fitted through 2 relays to help reduce the load of the 100 watt bulbs fitted, the head light's have been changed for the round type fitted to early range rovers as these light's are a lot better than the original light's fitted, I installed HID light bulbs, the control unit for the HID's fits nicely behind the round headlights, other modifications to the lighting include small fiber optic cable fitted to the heater controls by drilling a very small hole it to the plastic knob and routing the fiber optic cable behind the heater fascia to a led bulb, this makes it possible to " see " the control lever at night. I installed small red Led bulbs to the instrument panel, red panel light's help maintain your night vision while driving at night.
Other modifications include painting the interior panels with black plastic paint; this has changed the interior from the horrible brown color it was to something more in keeping with a modern car. The seats will be recovered with new material as soon as I find a good hard wearing material.
Installing the Arb diff was quite easy with the instructions supplied, the diff is supplied with 2 bearing lock nuts of different sizes, make sure you only try to fit the correct one, the only problem was tapping the hole for the air pipe fitting as this is supposed to be a imperial thread, we only had metric taps here in eastern Europe, so a little bit of careful work with a metric tap and it fitted ok. I installed the compressor on the right hand inner wing just in front of the brake servo as hope fully it will be out of the mud and water. Fitting the diff lock has made the discovery even more capable than it already was, let's hope the half shafts stand up to the abuse it will be given !!!
Perhaps I might fit a Arb to the front axle later if I find I need it!!!!
Hopefully I will not have any problems in the heavy snow we have here in Eastern Europe.
Storage of all the bits and pieces we off roaders carry was done by fitting a checker plate panel to the inside of the rear door and fastening very strong cloth bags to the checker plate, these bags carry my shackles, chains, snatch blocks, wd 40, spare bulbs and all the other bits and pieces I like to keep in the disco.
If you are planning to do the same work as I have done, here are some tips, keep all the screws and bolts from the interior separate from the bolts and screws used elsewhere on the disco as a lot of them are not the same. Label all the all the electrical connections as rembering the different connections after a long time is difficult. The rear wings are very very difficult to remove as the sealant is very grippy and if you are not careful you can easily damage the panel. Take your time, don't rush the work, if in doubt about anything have a cup of coffee and look at the workshop manual, and most important have some good friends that can help lifting things in to place, they will also give encouragement when you start to suffer the rebuild blues.
Please keep coming back to the site as I'm sure I have not finished modifying the disco, do we ever stop playing with our toys!!!!
If you are thinking of doing a rebuild or just some modifications to your disco or any other 4x4 please contact me if you want any help or advice.
I must give a very big thank you to all the people who have helped me rebuild the disco, especially the garage staff and for the use of the equipment and work shop space. Thanks guys.
Here is a list of the parts ordered :
Steering guard
Heavy duty steering rods
Tank guard
Goodridge brake hoses, +2 inch
Rear brake disc's and pads
Center and rear exhaust
Safari snorkel
Turbo hose kit
Bonnet light pod
Front axle swivel kits
Arb locking diff
Arb compressor
Plastic headlight bowls
Exhaust temperature gauge
Oil pressure gauge
Volt meter
Checker plate for the body sides
The chassis was built up ready for the body's return, there is nothing like seeing a chassis being built up, see photo's.
A phone call from the shot blaster to tell me that the body had even more holes was not a surprise as the shot blasting equipment is very powerful, so away I went to do even more welding, that done the shot blasters worked some more and the body was collected late one Saturday night. What a difference shot blasting makes, the body looked like new. The body was sprayed with chassis paint and then Hyundai poppy red was sprayed around the door frames and roof. The underside of the body was given several coats of bitumen paint.
A lot of interest was shown by the garage customers as they had never seen this kind of work done before to a 4x4, many words of encouragement were given by the customers.
The rebuild of the body started, test fitting the outer panels, painting the outer panels , then fitting the panels with silicone sealant for all the joints as this stop's the electrolytic corrosion that normally occurs, silicon is much better than the original sealant as it is easier to remove any panels in the future if needed. The doors were adjusted to fit the gap, not an easy task as the doors are very heavy and a little adjustment can make a big difference to the door gap. The doors can be adjusted up or down, forward or back and in and out of the body, and land rover are not known for good panel gaps.
The installation of the electrics was a long slow process as I have installed a relay to connect both batteries only when the engine is running, this uses a 70 amp relay connected to the small brown and yellow wire connected to the alternator. Also installed was a second fuse box from a 300tdi discovery, the 1 from under the bonnet, this supplies all the current needed for the extra lights and Arb compressor, the supply to this second fuse box comes from the second battery. The second battery is a 90 amp leisure battery; so far it has stood up to the winch usage.
Leisure batteries are designed for a deep cycle usage. You can take a lot of power from them for a long time with no bad affects. Another modifications to the electrics include extra interior lights ( all LED bulbs so not to drain the battery if I leave the doors open for a long time ) connecting the alarm system to the central locking system and also the interior lights and little LED bulbs installed in to the door handles so that I can see the handles at night ( no more fumbling for the handle ) puddle lights are installed in to the bottom of the doors, land rover kindly left a hole in the door bottoms that is the same size as the little red light fitted into the edge of the back door.
I have also fitted these same light's to the door edges of the front doors. The bonnet pod light have been fitted through 2 relays to help reduce the load of the 100 watt bulbs fitted, the head light's have been changed for the round type fitted to early range rovers as these light's are a lot better than the original light's fitted, I installed HID light bulbs, the control unit for the HID's fits nicely behind the round headlights, other modifications to the lighting include small fiber optic cable fitted to the heater controls by drilling a very small hole it to the plastic knob and routing the fiber optic cable behind the heater fascia to a led bulb, this makes it possible to " see " the control lever at night. I installed small red Led bulbs to the instrument panel, red panel light's help maintain your night vision while driving at night.
Other modifications include painting the interior panels with black plastic paint; this has changed the interior from the horrible brown color it was to something more in keeping with a modern car. The seats will be recovered with new material as soon as I find a good hard wearing material.
Installing the Arb diff was quite easy with the instructions supplied, the diff is supplied with 2 bearing lock nuts of different sizes, make sure you only try to fit the correct one, the only problem was tapping the hole for the air pipe fitting as this is supposed to be a imperial thread, we only had metric taps here in eastern Europe, so a little bit of careful work with a metric tap and it fitted ok. I installed the compressor on the right hand inner wing just in front of the brake servo as hope fully it will be out of the mud and water. Fitting the diff lock has made the discovery even more capable than it already was, let's hope the half shafts stand up to the abuse it will be given !!!
Perhaps I might fit a Arb to the front axle later if I find I need it!!!!
Hopefully I will not have any problems in the heavy snow we have here in Eastern Europe.
Storage of all the bits and pieces we off roaders carry was done by fitting a checker plate panel to the inside of the rear door and fastening very strong cloth bags to the checker plate, these bags carry my shackles, chains, snatch blocks, wd 40, spare bulbs and all the other bits and pieces I like to keep in the disco.
If you are planning to do the same work as I have done, here are some tips, keep all the screws and bolts from the interior separate from the bolts and screws used elsewhere on the disco as a lot of them are not the same. Label all the all the electrical connections as rembering the different connections after a long time is difficult. The rear wings are very very difficult to remove as the sealant is very grippy and if you are not careful you can easily damage the panel. Take your time, don't rush the work, if in doubt about anything have a cup of coffee and look at the workshop manual, and most important have some good friends that can help lifting things in to place, they will also give encouragement when you start to suffer the rebuild blues.
Please keep coming back to the site as I'm sure I have not finished modifying the disco, do we ever stop playing with our toys!!!!
If you are thinking of doing a rebuild or just some modifications to your disco or any other 4x4 please contact me if you want any help or advice.
I must give a very big thank you to all the people who have helped me rebuild the disco, especially the garage staff and for the use of the equipment and work shop space. Thanks guys.
PLEASE GO HERE TO SEE THE WORK IN PROGRESS PHOTOS
thanks for your patience!
you will find three pages of photos of the extensive work on this Land Rover Discover 200TDI
there's three pages of the transformation of this Land Rover Discover 200TDI from green machine to little red devil including complete removal of the body from the chassis ... and more ...
thanks for your patience!
you will find three pages of photos of the extensive work on this Land Rover Discover 200TDI
there's three pages of the transformation of this Land Rover Discover 200TDI from green machine to little red devil including complete removal of the body from the chassis ... and more ...
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