04' DII build

[Drover]

Well some of you on here know my old disco

She served me well , traveling from Vermont to the overland expo 2013, and also participating in the Vermont overland trophy.




But sadly, two weeks after the VOT , I broke the frame. So that's what started this insanity. I found this 04' on craigslist and bought it to swap everything over to.
It was in in great condition, soccer mom owned, but had a blown engine. Not a problem since my engine was fine. A week later I blew the engine on the old disco!! So here's how it all begins!

I'm not much of a poster , but , I've had so much help from some really great guys. I wanted to do this build thread to really thank everyone who helped me, and possibly funnel some business their way.

The list consist of
Zach. Rovers north
Justin. Lucky 8
Bill. RTE
Steven. Cannibal V8
Dana. D.A.P.
Andy. Voyager racks

Oh , and my two mechanics who did all the work Dan and George , wouldn't have been possible without you.

 

[no-pistons]

How did you break the frame?

 

[Drover]

Here's what she looked like the day I bought her.
We started by stripping her completely down.

Interior and all, I'm not a big fan of the alpaca interior.
Swapped everything to black
This also includes replacing the headliner

Then it was on to the frame , suspension axles etc

Completely sandblasted the frame , primed , and repainted with industrial equipment paint.
Also removed the watts linkage and installed a panhard , sandblasted the axle housings and repainted.

 

[Drover]

While I was at it I installed 4.37s , and Ashcroft axles, thanks Justin!

Then it was on to the suspension, terrafirma springs , bilstien 7100 remote reservoir , front and rear. Front terrafirma radius arms, rear arms cut, lengthened and cranked, (RTE)
Slick rock quick disconnect sway bar links (front)
Rear quick disconnect sways extended bump stops
+4 extended brake lines
Extended abs
Terrafirma rotors
ARB lockers front , and rear




Soon after we also installed Tom woods double cardon shafts front and rear

 

[Drover]

At this point I have about 6" of lift and decided to go with 35"

I mounted them to steelies that Justin had made for me. I think they look much better than the terrafirma ones , and you can choose your own offset.

I've regretted to say that we completed this build in three weeks from start to finish. While all this work was being done, there was a motor being built , I wanted everything done so when the motor came in we could install and go!
So then it arrived


10:1 compression and 300hp

 

[Drover]

Soon after the motor was installed we installed the y pipe we removed the cats and installed o2 delete sensors , then installed NRP exhaust, ( thanks Zach) by the way Zach supplied all suspension parts ,exhaust, headliner

Installed voyager rack roof rack , rock sliders and Greg Davis bumper

 

[Drover]

I've reinstalled the tjm bumper while bill is making me a custom bumper, I'll post when the bumper comes in.
So anyway , like I said, 3 weeks. My big push was that I wanted to make it to the overland rally in Vermont. It's held in a town abou 30 min from me. The rally started on a Thursday and went till Sunday. I made it Friday night at about 9:30. Here are some pics

 

[Drover]

I'm sure there's a bunch of stuff I'm missing, cause I'm only listing the new items we installed, not any of the items that were salvageable from the donor truck. There's also dual batteries , optima yellow tops. Aux fuse box and on board air
Terrafirma gas tank skid and tranny t-case skid

Skid pic and arb compressor pic is from old vehicle, I'll post current pics tomorrow

 

[Drover]

How did you break the frame?

It was already cancerous, wheeled it pretty hard and ...... Snap!

 

[Howski]

Quite the transformation in just 3 weeks. Seems like you've done some proactive things for it to last you a very long time. Enjoy the 35's, they're something not a lot of Disco owners have the opportunity to experience

 

[ZG]

Haha... glad you finally got this up Drew.

For those who haven't seen this truck in person, the day he brought it to the VT overland rally you could eat a filet off any part of the vehicle, it was the cleanest disco I'd ever seen.

The next day he buried it twice up to the sliders in a swamp haha, Drew did not build this truck to show off how pretty it is.

 

[Drover]

Haha... glad you finally got this up Drew.

For those who haven't seen this truck in person, the day he brought it to the VT overland rally you could eat a filet off any part of the vehicle, it was the cleanest disco I'd ever seen.

The next day he buried it twice up to the sliders in a swamp haha, Drew did not build this truck to show off how pretty it is.

Haha , thanks Zach! In hindsight, that probably wasn't the smartest idea! I had just completed the initial 60 mile break-in , and drove it straight to the rally. She only had like 80 miles on her when I did that. There's something about running 35s that makes you do dumb ********!
Aside from that, I've actually done some proper wheeling

 

[rokrawlr]

Great lookin' rig! Love the flux capacitor switch! Also kudos to all involved on the quick turn-around from broken soccer mom-mobile to trail monster.

 

[Exploring Elements]

This thing is epic in person, and I can vouch for the 300 hp making this thing sound awesome and go like stink! Great build Drew. Looking forward to seeing it in action over the next few yrs as you dial it in. Rock on...

 

[ZG]

You're nuts Drew, no diff guard on that run???