Chris Brown's Disco

Chris is doing a major upgrade project on his Disco.

Brief History:
 
I purchased the Disco V8i Auto, new in May 1999 (last of the series one's in Australia - there were 6 left when I signed up for this one) - In mid-2000, I decided to leave Oz so did a road trip from Kalgoorlie to Perth then around the entire southern coast (including any interesting little side roads) to Sydney with a swag, single burner cooker, and a beer fridge  - clocking up 14,000 km's on the way - Put the Disco in Storage, Flew home to NZ, several months later, flew back to Oz, drove from Sydney to Mackay, Inland to Emerald then followed all the in-land dirt roads back into Brisbane clocking up another 10,000 km's - about three days of cleaning followed, then drove the Disco onto a ship bound for Auckland - Great trip - would recommend it too anyone (Anyone not afraid of snakes and spiders that is)!!!! 
 
10 years and 68,000 km's on the clock, it's time for a bit of a tidy-up :)

 

The front end starts here:

BEFORE: 10 yrs and 68,000k on the clock

 

The spare room!

The spare room.... Chris' wife was not too impressed (but we are!)

 

I have been surprised by the combination of bolts/nuts/threads used - there is none of this '3 spanners for the lot'  (like on a Japanese (can I use that 'term' here) vehicles)
 
The idea behind this project is to make the Disco a bit more capable off-road (in an attempt to make up for my lack of experience or skill)!! while keeping some on road manners as it is my everyday commute ( at least it will be when it is back on the road)
 
Work undertaken will be as follows:
 
  • Old Man Emu +2" shocks & springs all round and OME Steering Stabilizer and complete replacement of all bushes with OME urethane
  • Scorpion racing evolution kit including new front shock turrets and lowered rear shock mounts, new brake hoses, new radius and trailing arms - all raked to suit 3" of lift, new adjustable panhard rod, front and rear dislocation cones, additional 30mm urethane spring spacers as the 2" lift wasn't quite enough
  • 75mm box section spacers for sway bars - glavanised
    Rock sliders - which I will have to trim as they are too long once I fit the wheel arch flares
  • Wheel arch flares - Flexi flares UK 
  • Scorpion racing steering guard and diff guards
  • Westy motor sport Engineering recovery points x 2 - glavanised
  • A set of Kumho Mud tyres for the sticky stuff
  • Safari snorkel and extension to all breathers
  • Relocated the coil to opposite side of engine bay, made up new mount for the PS reservoir and shifted (to make room for snorkel air inlet)
  • Fitted cross-connector for the dual battery system
  • Fitted UHF CB Radio
  • X-Engineering in-line temp sender housing for electric fans operation
  • Fit twin Kenlow 13" electric fans with 3 switching options (On 'manual' - Off (red light flashes on dash when fans off during wading) and Auto for normal operation)
  • Modify and fit rear dog guard
  • Re-fit expedition drawers
  • Refit spot lights
  • 30mm wheel spacers (depending on the LVV certifier)!!!

Lifted !

Finally! - managed to get it lifted high enough

(Note: Father's day present = decent trolley jack)

 

time for new bits to go on

Time for the new bits to go on

taking shape

New bits looking good!

 

Wife says "all the bits look them same as the old ones but brighter colours..."

Wife says "all the bits look them same as the old ones but with brighter colours..."

looking great!

Pretty sweet! but just discovered the new brake lines don't fit :(

 

wow! tall!

Had to check I hadn't left any axle stands in - seems to be sitting really high.

Note to self : Get milk crate to make climbing in easier..

Next: Snorkel fitting: looks like the compressor will need to be moved as well as the coil and the PS reservoir.

 

Time to fit recovery points from John Harvey, and the steering protector plate. Debating whether or not to fit the factory bull bar...

So far:
  • The panhard rod chassis end bushes were a bugger to get in - they are a bit worse for wear now...
  • I don't want to hex the project so far, but, I have had no trouble removing anything - not a seized nut or bolt in sight - YET!!
  •  Bit concerned with how much slop there is in the drive train - this will probably be the next job...
  • Decided to leave factory bull bar off - will wait until I can afford a winch bar and winch
 
If there are any particularly tough bits in the future, I will be sure to photograph them and add a brief note...