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disco 2 trayback challenge truck
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andyrob
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Joined: 19 Jul 2011
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PostPosted: Wed Oct 10, 2012 11:31 pm    Post subject: disco 2 trayback challenge truck Reply with quote

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) Very Happy 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
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PostPosted: Wed Oct 10, 2012 11:45 pm    Post subject: Reply with quote






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
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Joined: 24 Feb 2008
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Location: Staffordshire UK



PostPosted: Thu Oct 11, 2012 1:40 pm    Post subject: Reply with quote

Like it Very Happy




Rear rad-ing it while you're in there Question

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andyrob
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PostPosted: Thu Oct 11, 2012 8:14 pm    Post subject: Reply with quote

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
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PostPosted: Fri Oct 12, 2012 8:30 am    Post subject: Reply with quote

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" Very Happy

More picture required Wink

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andyrob
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PostPosted: Fri Oct 12, 2012 7:28 pm    Post subject: Reply with quote

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
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PostPosted: Fri Oct 12, 2012 7:55 pm    Post subject: Reply with quote

few more random pics

my old 300 tdi that i sold in january to buy a drift car, couldnt cure the offroad bug Wink


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, Idea



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!Very Happy

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teamidris
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PostPosted: Sat Oct 13, 2012 8:30 am    Post subject: Reply with quote

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?

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andyrob
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PostPosted: Sat Oct 13, 2012 7:20 pm    Post subject: Reply with quote

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
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PostPosted: Sat Oct 13, 2012 7:27 pm    Post subject: Reply with quote

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
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1995 Land Rover Discovery

PostPosted: Sun Oct 14, 2012 7:54 am    Post subject: Reply with quote

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

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bigbuggy
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PostPosted: Sun Oct 14, 2012 11:07 am    Post subject: Reply with quote

must.......not.......post............ Rolling Eyes

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?

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andyrob
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PostPosted: Sun Oct 14, 2012 1:27 pm    Post subject: Reply with quote

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
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PostPosted: Sun Oct 14, 2012 1:30 pm    Post subject: Reply with quote

bigbuggy wrote:
must.......not.......post............ Rolling Eyes

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. Embarassed
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bigbuggy
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PostPosted: Sun Oct 14, 2012 4:47 pm    Post subject: Reply with quote

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 Cool 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,

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andyrob
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PostPosted: Mon Oct 15, 2012 1:17 am    Post subject: Reply with quote

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 Cool 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
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PostPosted: Wed Oct 17, 2012 4:54 pm    Post subject: Reply with quote

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

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andyrob
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PostPosted: Thu Oct 18, 2012 11:01 pm    Post subject: Reply with quote

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,Razz



and finally getn back to my own shed,Very Happy 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. Mad
gona do the cage myself to, wel try atleast,haha with some guidance now that i have the space.
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bigbuggy
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PostPosted: Fri Oct 19, 2012 4:44 pm    Post subject: Reply with quote

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

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andyrob
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PostPosted: Fri Oct 19, 2012 6:36 pm    Post subject: Reply with quote

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
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PostPosted: Fri Oct 19, 2012 6:48 pm    Post subject: Reply with quote

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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boss
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1995 Land Rover Discovery

PostPosted: Sat Oct 20, 2012 8:59 pm    Post subject: Reply with quote

ive just finished my 4link set up for my 300tdi.....3-link with the panhard would be alot easeyer and it would prevent bumpsteer.
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andyrob
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PostPosted: Tue Nov 20, 2012 2:03 am    Post subject: Reply with quote

im guessing a updates in order, Smile
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. Very Happy

aneway some pics


the new home for a while,


invsted in some tools to make life easier




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andyrob
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PostPosted: Tue Nov 20, 2012 2:15 am    Post subject: Reply with quote

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
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PostPosted: Tue Nov 20, 2012 2:19 am    Post subject: Reply with quote


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
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PostPosted: Tue Dec 11, 2012 9:17 pm    Post subject: disco Reply with quote

nice build btw, out of interest how much did you buy your breaking disco 2 for?
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wezbee
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PostPosted: Tue Jan 15, 2013 1:21 pm    Post subject: Reply with quote

updates?
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andyrob
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PostPosted: Sat Feb 02, 2013 9:58 pm    Post subject: Reply with quote

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 Wink

aneway heres a few pics















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andyrob
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