Building 10 Disco 2 vehicles for an expedition company..

[The Rover Shop]

So a problem with the disco2 vehicles is that they often get weak blower fan output... this is usually what causes this..

When the wiper cowl breaks it lets leaves and stuff get into the fresh air intake area and then sucked into the fan blower, which greatly reduces the blower output, makes terrible noises and vibrations..and the smaller pieces get past the blower cage and start blocking the evaporator fins.... this little mod before I put the wiper cowl on will stop this from happening as well as letting little bugs etc get inside..may also stop critters from nesting in there, you can also see the aluminum angle up on the Top area, this is tomstop heavy water downpours from washing over the lip into the blower housing area, a very common cause of water ingress and rusting floors in the passenger front compartment area. If the wiper cowl isn’t completely flush with the windscreen even just a little gap with heavy water running down the windscreen has direct path to inside the air intake, add in the wipers flicking the water down also and you definitely have wet carpets..
naturally all of these things shouldn’t be a concern if the wiper cowl iOS. It broken and completely tight on the windscreen but that only stays like that for a short while..

Sticks are just there until the adhesive caulk dries..

In this shot looking down the front windscreen you can see there is now a wall that stops it from flowing straight over..

 

[The Rover Shop]

Custom headliner about to be installed..

 

[Victory_Overland]

OMG.....my lady told me I should to the map headliner when I took Victory's headliner out! Dang it, you beat me to the punch! I have some waterproof fiber maps I was gonna try and do a few sections on to see if they would work.......

Now I gotta find another option! lol

 

[The Rover Shop]

Who says the ARB front bumpers are a 2 or 3 man install..


So I test fitted the front and rear bumpers and then sent them to my painter to be painted in an epoxy based tesxtured finish, when these bumpers are left in their original shiny finish they are extremely slippery when wet, and you know we love to stand on our bumpers to access the roof etc..this textured finish makes them less slippery when muddy or wet..





Truck is off having the fender flares done in the same textured finish, maybe a little less textured..

 

[The Rover Shop]

So while I wait for our basic rack from voyager so that I can add some custom brackets and mounting points and then ship back to them so that they can produce the racks I want.... I started on the next victim to get the makeover..this is a 2003 xd so no sunroofs and very basic trim... I like this one...on this one I’m removing the rear door glass, the last one caused some problems getting a decent paint job around the seal, lesson learned..;(

 

[The Rover Shop]

So we picked up another disco2 but I don’t think it’s going to make the grade to become a Moss Expedition truck, a bit too much underbody rust for my liking, such a shame as it’s the right colour, year and interior and looks pretty good in pics, but get underneath and oops... So it will make a good template rig for how I want the rack etc.. I picked up the rack from voyager so I could make some custom tweaks to it..

 

[The Rover Shop]

So I got to mount the ARB rooftop tent the way I wanted it as well as the ARB 6ft side awning.. as well as position the shovel and axe where I wanted it to make sure it didn’t interfere with the solar panel slide-in I am doing.. looks like it will all work well together..

 

[johnnyrover]

what ever happened to these build outs?

 

[The Rover Shop]

what ever happened to these build outs?

Still in process.....this bloody covid thing put a huge damper on evening.

 

[Arjan]

Would love to see / read more - very interesting.

 

[bri]

Would love to see / read more - very interesting.

There is a website for him now. That roof rack is fugly.