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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Wed Oct 10, 2012 11:31 pm Post subject: disco 2 trayback challenge truck
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well lads, hi from donegal ireland, in the process of building my challenge truck based on a 99 td5 disco 2 i picked up for breaking minus engine, taking shape slowly, only get at it in evnings after work, (which is handy as its just outside the door of my work at burnside 4x4 landrover specialist) and weekends
aneway ill let the pics do the talking.
a good 5 ft off the chassis, bonnet 10 inch shorter,used a 300tdi bonnet disco 2s are pricey to be cutting up.
experimented with a sort of 3 link setup on rear and got the frame welded in for the rear of cab,
decent articulation
weld on diff guard and the unnecessary bits tidyed off,
the 2nd bush cut off, the difference this made to articulation was brill
panhard rod will be fitted to control sway
Last edited by andyrob on Fri Oct 12, 2012 8:16 pm; edited 4 times in total |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Wed Oct 10, 2012 11:45 pm Post subject:
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how it sits now with35 10.50 simex fitted
also have 16.5 superwinch for rear.
sliders now and trays and its ready for caging.
all comments welcome
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teamidris Mud Obsessed
Joined: 24 Feb 2008 Odometer: 3372 Location: Staffordshire UK
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Thu Oct 11, 2012 8:14 pm Post subject:
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yup rad in the rear, false floor in passenger footwell for pipes to run through, keeping the winch as close to engine as possible, hoping 90+ degrees approach angle.
just in from working at it there, got the outriggers on for the sliders and cage this evning
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teamidris Mud Obsessed
Joined: 24 Feb 2008 Odometer: 3372 Location: Staffordshire UK
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Posted: Fri Oct 12, 2012 8:30 am Post subject:
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He'll be needing a charge cooler then?
They fit in there real nice with the turbo on one side and intake on the other.
Out of my good/bad mods rear rad has been good one, even back in the trialing days. My rope misses the water pump by about 2"
More picture required
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Fri Oct 12, 2012 7:28 pm Post subject:
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not shure if ill charge cool or i was thinkin of fitting a slim aftermarket intercooler like this
should fit in nicely above aney winch, ive saw 300 tdi's run without ic's as there not needed for top end power just need quick spool ant low torque, wonder could the same be done on td5?
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Fri Oct 12, 2012 7:55 pm Post subject:
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few more random pics
my old 300 tdi that i sold in january to buy a drift car, couldnt cure the offroad bug
2'' box for the rear frame, welded to rear doors an to the roof support
the mount for the top link and the link fitted, i used a bush that was
left from radius arm, a section of prop and a ball joint fron a
defender to make it,
the rear roof panel i cut out and used for the rear window and one corner, bent round to meet the small window, thats the glass from the back of rear doors moved up, bottom section was done with 2mm plate for strength.
wil have pics tomorrow of work on the rear tray and sliders!
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teamidris Mud Obsessed
Joined: 24 Feb 2008 Odometer: 3372 Location: Staffordshire UK
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Posted: Sat Oct 13, 2012 8:30 am Post subject:
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The no-intercooling story is odd? Some customers insist it is absolutely vital to have it, or the engine will overheat. Others arn't worried like the 3406 CAT which is 425hp without and 450-500 with and of course the 200-300tdi on challenge. It's probably conditions and engine specific?
At least if you have one, you know there isn't much risk?
__________________________________ https://m.youtube.com/channel/UC3l3zoaCabKrgBSULSV1YgA |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Sat Oct 13, 2012 7:20 pm Post subject:
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well the only thing an intercooler does is cool air so the turbo works more efficiently,doesnt affect engine cooling, and from my experience of performance cars a smaller or lack of only affects the engine at topend. pros would be quicker spool up and torque deliverd earlier in the rev range, only the top end would be affected, as it would be purely winch challenge id be doing its more low down torque id need. ill have to experiment i suppose, see which suits best as both can be done easily.
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Sat Oct 13, 2012 7:27 pm Post subject:
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few pics
rear outrigger for slider and cage, sum bracing to do yet
and the front
slider, tree bars to go on aswell
rear tray
gona brace inside and out the chassis leg for strength
well over 90degrees approach
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boss Just got MTs
Joined: 17 Dec 2007 Odometer: 262 Location: norfolk
1995 Land Rover Discovery
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Posted: Sun Oct 14, 2012 7:54 am Post subject:
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can you post up some more pics of your rear liks? doesnt look like there is any a-frame, panhard or watts linkage.......if that is the case you axle will move side to side.....alot!
as for the no cooler thing.....my dad is running circa 230bhp out of his TD5 disco and to say it gets hot is an understatement......******* hot is still an understatement. . the main problem he has with it is heat soak, if he sits in traffic for a while the under bonnet temp gets silly high and there is no go in it becasue of the the charge temp becomes innadequate.
the cooler will cool the engine a little due to the cooler charge going through the turbo, it wont be much but the oldman had to recently replace an exhaust manifold due to warping it.
just my 2p
__________________________________ BOSSFAB
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2lb club hammer?......HA! my club hammer is a cut down sledge! |
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bigbuggy Just got MTs
Joined: 12 Dec 2010 Odometer: 260
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Posted: Sun Oct 14, 2012 11:07 am Post subject:
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must.......not.......post............
on a side note to the OP,
please tell me you put spreader plates under the outriggers where you are intending to mount the cage?
if you havent im assuming you arent intending to do any events run under the msa?
__________________________________ Big Tyres, Big Turbo, Big noise
Go big or go home |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Sun Oct 14, 2012 1:27 pm Post subject:
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boss wrote: | can you post up some more pics of your rear liks? doesnt look like there is any a-frame, panhard or watts linkage.......if that is the case you axle will move side to side.....alot!
as for the no cooler thing.....my dad is running circa 230bhp out of his TD5 disco and to say it gets hot is an understatement......******* hot is still an understatement. . the main problem he has with it is heat soak, if he sits in traffic for a while the under bonnet temp gets silly high and there is no go in it becasue of the the charge temp becomes innadequate.
the cooler will cool the engine a little due to the cooler charge going through the turbo, it wont be much but the oldman had to recently replace an exhaust manifold due to warping it.
just my 2p |
will be fitting a panhard yes, waiting on adjustable ones.
thanks for that, i have a ic so ill be fitting it then
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Sun Oct 14, 2012 1:30 pm Post subject:
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bigbuggy wrote: | must.......not.......post............
on a side note to the OP,
please tell me you put spreader plates under the outriggers where you are intending to mount the cage?
if you havent im assuming you arent intending to do any events run under the msa? |
was waiting for sumone to spot that,haha
was late and welded without thinking, only the one welded yet so i ave to change it.
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bigbuggy Just got MTs
Joined: 12 Dec 2010 Odometer: 260
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Posted: Sun Oct 14, 2012 4:47 pm Post subject:
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what you really need is a charge cooler, like this one
plus with the assorted goodies that are bolted to the engine in the picture you will end up with a genuine 200+ td5 that is about as point & squirt as it comes, nearly zero turbo lag, full boost at approx 1800 rpm,
still got more tuning to come but it currently goes very very well,
__________________________________ Big Tyres, Big Turbo, Big noise
Go big or go home |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Mon Oct 15, 2012 1:17 am Post subject:
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bigbuggy wrote: | what you really need is a charge cooler, like this one
plus with the assorted goodies that are bolted to the engine in the picture you will end up with a genuine 200+ td5 that is about as point & squirt as it comes, nearly zero turbo lag, full boost at approx 1800 rpm,
still got more tuning to come but it currently goes very very well, |
ooo, me likey,lol didnt kno allisport did them, theyre not too dear either for that type, some are just an ic with a water jacket
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bigbuggy Just got MTs
Joined: 12 Dec 2010 Odometer: 260
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Posted: Wed Oct 17, 2012 4:54 pm Post subject:
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Allisport have done all the alloy fabrication on my truck, (rear rad & pipework, charge cooler pipework & rad plus storage box's & other stuff)
all the products are built to work, it just so happens they are shiny,
any questions give me a shout,
on your truck i would say you need to strengthen the aframe balljoint mount on the axle as at the moment with it going through the flat plate WILL rip that off,
i also have to say that the top link does look very short, you might find as the suspension articulates it will bind the prop up
__________________________________ Big Tyres, Big Turbo, Big noise
Go big or go home |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Thu Oct 18, 2012 11:01 pm Post subject:
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i was on their site and didnt see the charge coolers just,
as for the suspension ive decided to bite the bullit and 4 link it front and back when im at it.
got the other outriggers done this time with spreaders,
and finally getn back to my own shed, no room at work and no good lying on stones trying to work. sourced an engine and box for it too but cant get my drift car sold to free up funds, always the case.
gona do the cage myself to, wel try atleast,haha with some guidance now that i have the space.
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bigbuggy Just got MTs
Joined: 12 Dec 2010 Odometer: 260
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Posted: Fri Oct 19, 2012 4:44 pm Post subject:
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4 link on the back is pretty straightforward,
4 link on the front is a pain in the hoop, infact cant think of anyone who has 4 linked the front of a d2 in the uk,
once you try & do it you will realise theres not enough space/clearance to get everything in there, especially as the engine will ocupy the space needed for the links,
i have spent a bit of time looking at mine to do it, & its far easier to stick with what i have as it works very well
__________________________________ Big Tyres, Big Turbo, Big noise
Go big or go home |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Fri Oct 19, 2012 6:36 pm Post subject:
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wel supose i mean 5 link front really, running the links paralell with a panhard. think itl work, if not as u say ill stick with what ive got.
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parrotveasey81 Mud Obsessed
Joined: 13 Feb 2009 Odometer: 7480 Location: bradford on avon (wiltshire)
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Posted: Fri Oct 19, 2012 6:48 pm Post subject:
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andyrob wrote: | wel supose i mean 5 link front really, running the links paralell with a panhard. think itl work, if not as u say ill stick with what ive got. |
the links will binde up easy in that setup and limit flex
3 link with panard rod with give you more free flex
but imo i perfer more flex on the rear than equal flex front and rear
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Angry parrot fabrications,check me out on Facebook |
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boss Just got MTs
Joined: 17 Dec 2007 Odometer: 262 Location: norfolk
1995 Land Rover Discovery
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Posted: Sat Oct 20, 2012 8:59 pm Post subject:
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ive just finished my 4link set up for my 300tdi.....3-link with the panhard would be alot easeyer and it would prevent bumpsteer.
__________________________________ BOSSFAB
pm me for tube manipulation
2lb club hammer?......HA! my club hammer is a cut down sledge! |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Tue Nov 20, 2012 2:03 am Post subject:
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im guessing a updates in order,
loads done, well feels like loads, when ya put it all together i guess its not alot altogether.
moved back to my own shed, more room etc
axles have all been rebuilt and lots of nice shiny bits fitted, trays are all finished,some suspension in, stil unshure what shocks to use. interior fitted again. and lots of other wee fiddily bits and pieces. waiting on engine box etc and a fuel tank atm. should be frunning shortly.
aneway some pics
the new home for a while,
invsted in some tools to make life easier
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Tue Nov 20, 2012 2:15 am Post subject:
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all stripped for rebuilding
some shiny stuff
tuning chip
tray
rear axle brake line protctor
for recovery shackles
front rebuilt
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Tue Nov 20, 2012 2:19 am Post subject:
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springs in
interior, starlet semi buckets fitted to the lr rails, kept pretensioners etc,
switch box, winch controls at top fall easily to hand without taking up too much room
thats it atm, engine should be in shortly. then onto finish suspension and cage.
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Mistyborn Spaniels TD5 Gate Opener
Joined: 17 Jul 2012 Odometer: 6 Location: suffolk
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Posted: Tue Dec 11, 2012 9:17 pm Post subject: disco
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nice build btw, out of interest how much did you buy your breaking disco 2 for?
__________________________________ "A Dog Is For Life, Not Just Friday Nights!!"" |
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wezbee Just got MTs
Joined: 18 Oct 2006 Odometer: 321
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Posted: Tue Jan 15, 2013 1:21 pm Post subject:
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updates?
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www.nobbyssigns.co.uk
"Life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways"
"broken bones are a mechanical problem. you can fix them" |
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Sat Feb 02, 2013 9:58 pm Post subject:
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been a while since i updated,have had some progress tho still no engine not easy to come by at the right money over here.
had to move shop again but in the final stage now.
really all thats done since is a bit of fab for shocks steer guards etc and the biggest bit is the cage. made a start on it about a week ago and almost finished now. its no easy
job by yourself i must say but getting there eventually. now its not msa compliant as its not in force here but its plenty strong and if it does ever come into force ill change it
but for first time bending my own cage it made sence. all tubes 48.3 x 3. and the roll hoop is 48.3 x 5. all was done with a centre push bender but the main tubes were packed with sand
to stop deforming. theres a few braces and gussets to fit yet before the comments are made about the straight from chassis to hoop braces
aneway heres a few pics
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Mon Feb 04, 2013 3:04 pm Post subject:
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andyrob Gate Opener
Joined: 19 Jul 2011 Odometer: 33
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Posted: Tue Feb 05, 2013 1:28 am Post subject:
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