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My Discovery Trayback build
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 8:50 am    Post subject: My Discovery Trayback build Reply with quote

Well I guess its time to start to catalogue the build process of my Trayback build before the photos overwhelm me. Its taken about 6 weeks to bring me to the point I am at now but only really able to put in about 2 evenings a week.
Starting point was my 1991 Disco 200tdi 5 door with 145K on the clock. Has proven very reliable and generally good condition compared to some I have seen. BUT removal of rear panels and trim reveals the rot was much worse than suspected and rear dickie seat archorages for ewxample were non existant.

A few pics


The beginning
P1040041.jpg

first panels removed
P1060100.jpg

floor out
P1070101.jpg

the evidence
P1070101.jpg

shorter by about 2 feet
camel cut 003.jpg

mocking up the sides
camel cut 001.jpg

starting work on rear bulkhead
camel cut 005.jpg

beginnings of the rear winch tray
camel cut 006.jpg


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It's the job you never start that always takes the longest to finish.
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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2248
Location: Rossendale


1998 Nissan patrol

PostPosted: Thu Apr 12, 2007 9:22 am    Post subject: Reply with quote

Looks like you have you work cut out, there will be times you wanna give up i have been there but just think of the grin you are holding for when its done. Is worth it for that.

Good luck
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ciderman
Off-Road Guru


Joined: 22 Oct 2002
Odometer: 1194
Location: Zummerzet


2000 Land Rover Hybrid

PostPosted: Thu Apr 12, 2007 8:44 pm    Post subject: Reply with quote

Wahay , Fair play Mark Youve started it .
I guess that space behind the seats will come in handy for carrying your trophys home Laughing

We have another project we have just started its a cross between a 1990 V8 Disco and an 1984 110 Hi cap , Its being called the Disccap project .
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stodd
Just got MTs


Joined: 27 Mar 2007
Odometer: 267
Location: Kent



PostPosted: Thu Apr 12, 2007 9:52 pm    Post subject: Reply with quote

Good luck with that.

Discos arent as easy to cut up as defenders, but its well worth it. Im still amazed at some of the places mine will go.

Keep the pics coming.

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Stodd

I couldnt fix your brakes, so i made your horn louder !
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hughie
Just got MTs


Joined: 07 Oct 2005
Odometer: 158
Location: Out the back O Laurencekirk



PostPosted: Thu Apr 12, 2007 10:03 pm    Post subject: Reply with quote

Don't envy you starting pikey, I'm right glad I'm gtting to the other end of my build.
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 10:51 pm    Post subject: Reply with quote

Thanks for the encouragement lads.

Next instalment of pics


Getting first rear door cut down and attached
camel cut 007.jpg

corner detail
camel cut 008.jpg

From inside
camel cut 010.jpg

Roof braced to help prevent distortion during welding
camel cut 014.jpg

Roff welded
camel cut 022.jpg

Start work on infilling the rear bulkhead (used galvenised tin as its what I had left over from making some shed doors!)
camel cut 020.jpg

Lower bulkhead complete and winch tray mounted
camel cut 028.jpg

From inside
camel cut 032.jpg


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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2248
Location: Rossendale


1998 Nissan patrol

PostPosted: Thu Apr 12, 2007 10:53 pm    Post subject: Reply with quote

Looking good there that winch tray looks super strong the only way Cool
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 10:54 pm    Post subject: Reply with quote

Right last lot of pics to bring the build up to date

Fuel tank (Triumph Spitfire) and second battery mounted
camel cut 036.jpg


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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 10:58 pm    Post subject: Reply with quote

Opps pressed submit by mistake.....

more


Infill on corners to make weatherproof
camel cut 035.jpg

tin folded and formed to cover corner
camel cut 037.jpg

The other side finished
camel cut 040.jpg

Finally all weathertight, now the work on the cage can begin
camel cut 049.jpg


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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2248
Location: Rossendale


1998 Nissan patrol

PostPosted: Thu Apr 12, 2007 11:01 pm    Post subject: Reply with quote

Weather tight I think you will be getting a job at solihull if you can do that Laughing
Only messing keep the pics coming
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 11:03 pm    Post subject: Reply with quote

Just a couple of shots of it unddergoing sea-worthyness trials Very Happy Very Happy

Does look a bit wierd doesn't it!!
camel cut 044.jpg

Grips like a real grippy thing
camel cut 056.jpg

arty farty shot
camel cut 076.jpg


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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2248
Location: Rossendale


1998 Nissan patrol

PostPosted: Thu Apr 12, 2007 11:05 pm    Post subject: Reply with quote

Well what more could you want than a real grippy thing.

Looks like its going to be interesting.
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Thu Apr 12, 2007 11:09 pm    Post subject: Reply with quote

big_patrol wrote:
Well what more could you want than a real grippy thing.

.......


hows about a nice set of Nissan Axles complete with lockers Twisted Evil

thats what I really want now Very Happy Very Happy

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goodie
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PostPosted: Thu Apr 12, 2007 11:30 pm    Post subject: Reply with quote

be nice.

why not go mog and be done with it.
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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2248
Location: Rossendale


1998 Nissan patrol

PostPosted: Thu Apr 12, 2007 11:50 pm    Post subject: Reply with quote

Might be able to help you there matey i will keep ya posted
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Fri Apr 13, 2007 12:17 am    Post subject: Reply with quote

suzota wrote:
be nice.

why not go mog and be done with it.


want to stay wide and low rather than narrow and high. Suits me better (scared of heights ! Laughing )

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Tiny One
Mud Obsessed


Joined: 22 Jun 2006
Odometer: 2909
Location: Aberhonddu


1997 Subaru Justy

PostPosted: Fri Apr 13, 2007 7:39 am    Post subject: Reply with quote

i like that a lot a wide set of axles would do nicely

tiny "likes disco cut downs looks really really cool" one Very Happy Very Happy Very Happy Very Happy Very Happy

nice work pikey Wink

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"Blind as a welders dog!"
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Winnet
Difflock Royalty


Joined: 03 Dec 2003
Odometer: 11580
Location: Aberdeen


1985 Land Rover

PostPosted: Fri Apr 13, 2007 7:51 am    Post subject: Reply with quote

Looking good Pikey.

G.

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Chaos! Panic! Disaster! (My work here is done)
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SmilingHound
Just got MTs


Joined: 18 Jun 2005
Odometer: 347
Location: Perthshire, Scotland


1993 Toyota Landcruiser

PostPosted: Fri Apr 13, 2007 8:13 am    Post subject: Reply with quote

Looking fantastic Pikey, I think mine will go that way next year to get some more weight off. G
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Nigel Head
Mud Obsessed


Joined: 05 Jul 2004
Odometer: 3867
Location: Mid Devon


1990 Suzuki Samurai

PostPosted: Fri Apr 13, 2007 11:01 am    Post subject: Reply with quote

****, that was quick work Mark! (uh, have we got a swear filter again?)

Lets try it and see, ******, ****, - hmm, some get through but doo-doos and fornication are filtered Laughing

See you down this way next month maybe?

Nigel.

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Chris™
Mud Obsessed


Joined: 28 Sep 2005
Odometer: 2953
Location: Herefordshire / Cardiff-lock


1986 Suzuki SJ413

PostPosted: Fri Apr 13, 2007 11:44 am    Post subject: Reply with quote

Wow! Looking good Mark! Very Happy
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_This is clearly filler material_
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marsie
Articulating


Joined: 13 Jul 2005
Odometer: 562
Location: sheffieldish


1997 Land Rover Defender

PostPosted: Fri Apr 13, 2007 9:06 pm    Post subject: Reply with quote

Looks GOOD Mark ,does this mean you are swapping Steves co driver seat for your own driving seat?and doin challenges
Paul Twisted Evil
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watermains
Articulating


Joined: 04 Nov 2004
Odometer: 596
Location: Y-FENNI CYMRU DIG FOR VICTORY


1994 Land Rover Defender

PostPosted: Sun Apr 15, 2007 7:58 pm    Post subject: Reply with quote

r those my old wheels and Tyre's off my old disco???
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Sun Apr 15, 2007 8:01 pm    Post subject: Reply with quote

Could be Dai! Very Happy
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Jon Caveman
Off-Road Guru


Joined: 18 Mar 2006
Odometer: 1041
Location: south wales



PostPosted: Mon Apr 16, 2007 8:21 pm    Post subject: Reply with quote

Lookin good, nice work Mark...........Applause

She looks like she'll whip them gay lookin 90's the other 2 drive..... Very Happy Very Happy Very Happy

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A.R.5.E. Member #2
T.U.S.C. Member #

I will not follow where the path may lead, but I will go where there is no path & leave a trail !
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zacspeed
Mud Obsessed


Joined: 19 Feb 2006
Odometer: 2190
Location: Norwich



PostPosted: Tue Apr 17, 2007 11:37 pm    Post subject: Reply with quote

Nice work there Mark, She's looking good. Keep us posted mate Applause
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Dave
____

Women priests. Great. Now there's priests of both sexes I don't listen to - Bill Hicks.
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imatthew
Guest








PostPosted: Tue Apr 17, 2007 11:55 pm    Post subject: Reply with quote

Did you have to cut the back off or did it fall off with the amount of rust in it.
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Tim.
Mud Obsessed


Joined: 15 Nov 2005
Odometer: 3359



1997 Land Rover Defender

PostPosted: Wed Apr 18, 2007 10:25 am    Post subject: Reply with quote

Pikey,
have just found this on my musings of the internet....



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97 Defender 90 Hardtop - 300tdi

Member #3846
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The Pikester
Mud Obsessed


Joined: 14 Jan 2004
Odometer: 3535
Location: The Mountains of Waleshire



PostPosted: Wed Apr 18, 2007 11:46 am    Post subject: Reply with quote

Laughing Laughing lol at Ian. Thats about par for course over here mate. You won't see it in Oz since it all gets shaken off by the corrogations!

Tim... that trayback is being built concurrently by a lad called Russel. We have met at various Challenge events and kind of dared each other to go for the full trayback. We started our builds within a few weeks of each other but he seems to be getting on quicker! But then mine will be a work of art (literally) when I finish........

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Nigel Head
Mud Obsessed


Joined: 05 Jul 2004
Odometer: 3867
Location: Mid Devon


1990 Suzuki Samurai

PostPosted: Wed Apr 18, 2007 12:24 pm    Post subject: Reply with quote

Mark,

Russell, as in Exeter Russ?

Nigel.

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