Casper & Outono - 2x 1998 Discovery 1 Builds

[Outono]

So I bought a roof rack for my Disco that has two of those panels on the rear half. What it the purpose of the mats? I don't have any on the rack on my truck and haven't felt the need to have them. Maybe I just don't know what I'm missing?

They provide additional support for anything you put up there.

On the SD racks (like mine), there are rather large gaps between each metal bar. If you've got a smaller item you want to mount, there isn't a really good place to put it without adding some flooring. It also makes it easier to walk along the top of the rack should you need to.

 

[Outono]

Days like today really make me wonder if im cut out to to continue working on this truck. I don't know what it is, but the past few weeks have been nothing but setback after setback, usually caused by my own mistakes.

What should have been a simple fuel filter replacement ended up taking 5 hours and damaging a hard line.

It turns out that my truck had the original compression fittings on the inlet and outlet lines (whether they were the true originals, I dont know, but normally if someone replaces the filter they don't usually put those ridiculous fittings back on). Atlantic British recommends using a hacksaw to remove the fittings so for the first hour, I hacked at the inlet fitting and managed to get it off without much damage to the hard line itself. But the outlet line turned out to be a special level of hell.

Not only do small hacksaws barely fit in the space you need to operate in, but you're constantly inhaling fuel fumes (unless you're sweating it out in a mask like I had most of the time). We worked for hours trying to get this thing off, but made little progress.

Eventually, we threw caution into the wind and busted out the dremel. A dangerous solution due to the risk of fire, but we were sick of going nowhere with this project. We made relatively short work of the fitting and got the new bits back on the truck within the hour. I primed the fuel pump and....fuel sprays everywhere. It looks like the hacksaw managed to put a pinhole right where the hard line meets the soft line. This means there is no way to repair it quickly.



Fortunately, the truck does fire up and drives, but sprays fuel the whole time. I don't have the patience to put in a new hard line so I think this truck is going back to the shop to fix my mistake. I suppose i'll have them chase down my fuel venting issues while they're in there since I really don't want to dig into this part of the vehicle again.

Did I mention my brand new transfer case is already leaking too? Been a great week.

Building and learning on these trucks is a truly tedious and expensive hobby. This is my 5th build and by far the one with the highest highs and lowest lows. I don't know why I keep spending money on this thing, especially when the total investment has reached a point where I could buy a seriously nice brand new vehicle (it would be boring compared to a D1, of course). Most people would be happy with a brand new 4Runner or Tacoma for the same price, but I know I wouldnt...

How many of you get into a rut with your vehicle? I've cut and run a few times, like with my LR3 and Casper, but im in way too deep with this thing to sell it. This is going to be a family heirloom at this stage. I really hope my kids like old 4x4s because their entire inheritance is wrapped up in them.

UPDATE: ...and my truck got hit by a tree during the tropical storm

 

[Outono]

I've put together a collection of all the suppliers, fabricators, and reference material collected over my time working on these trucks. You can check that out here:

Land Rover Reference

I built this out of frustration with the dying Discovery online community. 10 - 20 years ago, the Discovery community was thriving much like the Defender and Land Cruiser communities today. Many of the insights and great material from those days are now either lost or completely buried in old archives. My goal with this collection is to keep some of that alive so we can preserve it for future classic Land Rover fanatics.

The reference has 3 tabs: Parts & Accessories, Fabricators & Assembly, and Reference Material. Everything in here is largely focused on classic Discovery, Defender, and Range Rover vehicles (pre-2004).

Hope this is helpful for some of you.

If you'd like something added, just let me know.

 

[YetiX]

I've put together a collection of all the suppliers, fabricators, and reference material collected over my time working on these trucks. You can check that out here:

Land Rover Reference

I built this out of frustration at the dying Discovery online community. 10 - 20 years ago, the Discovery community was thriving much like the Defender and Land Cruiser communities today. Many of the insights and great material from those days are now either lost or completely buried in old archives. My goal with this collection is to keep some of that alive so we can preserve it for future classic Land Rover fanatics.

The reference has 3 tabs: Parts & Accessories, Fabricators & Assembly, and Reference Material. Everything in here is largely focused on classic Discovery, Defender, and Range Rover vehicles (pre-2004).

Hope this is helpful for some of you.

If you'd like something added, just let me know.

Thank you for that! Since I'm just starting my Land Rover journey, I'm sure that's going to be a HUGE resource.

 

[Outono]

Another long week, but finally some cool things happening!

The fuel line repair turned out to be rather simple. It's not ideal, but it works and even after a good beating up Santiago Peak, it held together. All we did was pull the hose over the pin hole, clamped it, and called it a day. Eventually ill have a new line made...or maybe I wont.



On Friday, I pulled the headliner so that I could remove the factory roof rails. More on that in a moment...



Since I had already removed most of the trim in the back this was an absolute breeze. Unfortunately, it revealed that I had a rather bad mold problem brewing from an ongoing leak at the front sunroof. No surprise there I suppose...Plan is to tackle the sunroof first. I think the problem is the NPT connection to the drain. Then i'll get the liner cleaned and reupholstered. I probably won't do it myself because it seems like a pretty tedious process.



So why pull the liner? Well, I absolutely lucked out and tracked down an original Safety Devices low profile rack. Looks nearly identical to the original Highlander version I have, but far better lines since it hugs the roof of the truck. In order to fit this rack, you need to remove the factory rails, fill the holes with rubber grommets, then seal them with silicon.



Pure class. Just love the way this truck is coming along.

To wrap things up this weekend, I wired in an AC Fan switch so that I can enable them on demand when driving up prolonged inclines. This was wildly easy to do. Will post a tutorial in a bit.



Off to the Shaver Lake area this coming weekend for Outono's first long trip. Hoping it gets through it unscathed.

 

[mjm10]

Gorgeous rover!

 

[Outono]

900 mile trip and the truck didn't breakdown! Success!



But it wouldn't be a Land Rover unless something went wrong. About a quarter way through the trip, my transmission began sticking in certain gears, hard shifting, and overall acting like something was wrong. I managed to get through the trip without any major issues, but something isn't quite right. Im hoping its just a kick down cable adjustment, but it might end up being clutch packs or something else given that its got over 250,000 miles on the transmission.



I also noticed that the oil pressure light stays on for a good minute when the truck is started after sitting for a few days. I suppose this is common as these engines are known for losing prime, but its a bit disconcerting. If I need to replace the transmission, i'll probably do the main and rod bearings at the same time, along with the crucifix seals, which have been leaking since the beginning.

Otherwise, the truck is driving great!

 

[Outono]

Sheesh, almost a month since i've last updated. Traveled a lot in September for work so haven't had much time with the truck.

I don't have a photo, but the new Ashcroft Transfer Case w/ ATB is in. It's not something you'll notice much of a difference with, but it sure looks nice and should last the lifetime of the vehicle. It's already got a small leak so I need to chase that down, but overall I am quite happy. Price wasn't too bad all things considered.

The big annoyance lately is my brand new Classic British starter (Denso), which has been giving me a lot of trouble.



I know, I know...the oil is a problem. That's my rear main seal leak (more on that later). The real issue is that black wire hanging out. Now, for the past week my starter has been making nasty noises and, at times, wouldn't even work. After rummaging around in there earlier today my hand hit the ignition wire and sure enough it easily detached from the starter. I think i've found the problem....it's just such a shame how much of a pain in the ass it is to get in there to fix it.

You can hear the starter noise here.

So about that rear main seal. Well, since my transmission is beginning to let go I think it's about time I waste more money on another Ashcroft piece of art. This time, it's going to be a 4HP22 transmission w/ Stage 1 upgrade and high capacity sump.

That's right, im getting a rebuilt transmission in the next 2-3 weeks. Will it cost a fortune? You betcha, but since i've already spent mega $$$ on everything else, why would I skimp on getting a questionable used transmission from the junk yard? Once I drop the transmission, im going to get the rear main seal fixed, along with the cross seals and probably some new main + rod bearings. Might as well since it's all in there...

I've got some other fun toys for the Disco on the way, but i'll save that for the next post.

 

[Outono]

Quick update: easy repair on the starter. Despite the driveshaft and other bits, you can still easily reach the hot wire and ignition wire. Turns out, the ring connector was a gauge too large for the ignition wire. Swapped to a smaller connector and we're back in business.

Ashcroft transmission ordered and paid for today. Coming in 3 weeks!

 

[RoverFan]

I am curious what you think of that starter. I have never seen one, but it sure looks beefy. What advantage does it provide? I use new Bosch units on my rebuilds and they fit with stock manifolds or headers. They also start high compression 4.6s just fine. I have found that, at least on D1s and RRCs, an extra welding cable grade ground wire from the frame to the block does wonders for starting.

I saw your posts about lows and highs, and a dying LR community. I feel you, and I have had moments where I feel overwhelmed. I eventually take a breath, accept the amount of work that needs to be done, and just do it. Old 4x4s are just too cool to give up on, and they all want to be Land Rovers. I have owned 4Runners, they're OK but sloshy and more like an appliance. I even bought an 80 series to see what all the hype was about. They're comparable to a RRC but aren't as charming when everything is working. I'd take a P38 over one in a hot minute. Trucks are cool, and I am sucker for 90s Fords. They don't ride or climb nearly as well as LR. At the end of the day a classic LR exudes a metric ton of character. I much prefer the D2 to the D1, but the D1 is just as cool as any classic 4x4 these days. With EFI and air con they're usable classics though.

 

[Outono]

I am curious what you think of that starter. I have never seen one, but it sure looks beefy. What advantage does it provide? I use new Bosch units on my rebuilds and they fit with stock manifolds or headers. They also start high compression 4.6s just fine. I have found that, at least on D1s and RRCs, an extra welding cable grade ground wire from the frame to the block does wonders for starting.

I saw your posts about lows and highs, and a dying LR community. I feel you, and I have had moments where I feel overwhelmed. I eventually take a breath, accept the amount of work that needs to be done, and just do it. Old 4x4s are just too cool to give up on, and they all want to be Land Rovers. I have owned 4Runners, they're OK but sloshy and more like an appliance. I even bought an 80 series to see what all the hype was about. They're comparable to a RRC but aren't as charming when everything is working. I'd take a P38 over one in a hot minute. Trucks are cool, and I am sucker for 90s Fords. They don't ride or climb nearly as well as LR. At the end of the day a classic LR exudes a metric ton of character. I much prefer the D2 to the D1, but the D1 is just as cool as any classic 4x4 these days. With EFI and air con they're usable classics though.

The Classic British Starter is high torque so it really rips when it cranks. Does it make any real difference compared to the standard Bosch? Nah. It definitely sounds different (like the starter from a Japanese car) and it's made by Denso, which usually denotes quality. Worth the price? I suppose time will tell.

Thanks for the reply. I appreciate the engagement. I really need to try a P38 and RRC since i've heard so many good things.

I almost bought a D2 before going D1. It's more comfortable, more powerful, and has a bit better support from aftermarket vendors, but ultimately nothing steals my heart like the classic looks of a D1.

 

[Outono]

What a week! Oh man.

On Wednesday, a Discovery 1 popped up on my local junkyard that looked rather interesting. It has a ROXS.US sticker on it and some graphics that appeared to be associated with some sort of club. Apparently, ROXS held expeditions all over the world and the owner of this vehicle took his truck on some of them (though im unsure which). But this isn't what got me excited. It was the parts in the photos that piqued my interest.



Do you know what that is? It's an RPI 4.6l in a Discovery 1 with a manual transmission. This engine is mega $$$ and very rare in the US, especially in Discoverys.

RPI is a UK- based specialist in Rover engines so the previous owner must have sent his old engine overseas to get tricked out by the company. While I don't have the specifics on the engine build, I do know it it has a performance cam in it, performance heads, and it likely has sleeved liners, among other goodies. In fact, the intake has 250hp+ written on it.

Unfortunately, this engine looks like it has been sitting for quite some time (last registration for the truck is 2005). My guess is the previous owner blew it up, but there aren't any clear signs of that. The engine oil looked clean and there were very few leaks. Many of the ancillaries were gone before this truck arrived at the yard (based on the early photos posted by yard), but some of the best things were yet to be taken...



So what do we have here?

• Hedman Hedders
• Safari Gard sliders
• OEM wiper tank (good condition)
• OEM D2 airbox (great condition)
• OEM steering gear (excellent condition, no leaks. Recently rebuilt?)
• Stainless ultra heavy duty front track bar
• Braided stainless oil cooler lines (looks like Trailhead 4x4)
• Some high quality interior bits (not shown), including a center console top and ceiling trim

Me and a literal wheelbarrow of parts.



Martin and me pulling this thing apart.

So what next? Most of this will find it's way onto my truck. I think the headers will fit, but will need a custom Y piece to accommodate my cats. I know, I know...why put headers on and keep the cats? I don't have a choice being in California. But hey, they were like $30 (lol, can't believe it) so they're going on!



You know, this truck reminds me of how far the Disco community has fallen. Something so cool, so special, just tossed away and most people not even noticing what's in it. It's going to be crushed in no time and its history forgotten. This would never happen to a Land Cruiser or a Defender with similar high quality bits. Just heartbreaking.

Anyway, the block is still there for the taking, as is the manual transmission. I can't pull it by myself and I really don't have space for it. Moreover, i've been to this truck 2 times in 2 days so im a bit fried. I think its going to need quite a bit of work so whoever does snag it should plan for an overhaul.

I've picked this thing over so there really isn't much else left unless you want some interior bits in modest condition, relays, or glass. There are no other HD parts on the truck, though there is an old Tom Woods double cardan drive shaft on the front, but it has seen better days. I didn't feel it was worth pulling, but it might be worth it to someone else whos still running stock and is willing to overhaul it.

The diffs are stock (no need to change when you're pumping big horsepower with that RPI), the control arms are stock and in sad condition, the suspension is ancient OME and probably toast, but the swivel joints are really clean and not leaking so if you need those they're available...

 

[Outono]

Decided to go back to the yard for the 3rd time to snag the nice headliner. Turns out someone already got to it and ruined the whole thing by bending it in half.

I did manage to snag a few nice ceiling vents, along with this nifty multi-switch the previous owner made from a D2 panel. I think the pigtails are toast, but this will be perfect once I get some lights on the rack.



I also slapped my 3D printed Carling switch mount in today so the AC Fan switch finally has a good home.

 

[Outono]

Spent part of the weekend getting the flooring put in on the low profile Safety Devices rack and throwing on a rear light. It's not wired up yet since im waiting to get a set of front facing ones. Im thinking rectangular, but if not then it'll be 9" circular Hellas.

Martin and I also siliconed the front sunroof since it couldn't open all the way due to the low profile rack. It was already leaking and I really didn't want to deal with another moldy headliner. The silicone is removable so any future owner can get it working again, but for now this truck will finally be leak free this winter!




I've also got my original Safety Devices "Highlander" rack for sale. This one is slightly higher than my low profile so it can accommodate the OEM rack rails.

Asking $1300, pick up in Orange County, CA.

 

[_ExpeditionMan]

Another long week, but finally some cool things happening!

The fuel line repair turned out to be rather simple. It's not ideal, but it works and even after a good beating up Santiago Peak, it held together. All we did was pull the hose over the pin hole, clamped it, and called it a day. Eventually ill have a new line made...or maybe I wont.

View attachment 793786

On Friday, I pulled the headliner so that I could remove the factory roof rails. More on that in a moment...

View attachment 793787

Since I had already removed most of the trim in the back this was an absolute breeze. Unfortunately, it revealed that I had a rather bad mold problem brewing from an ongoing leak at the front sunroof. No surprise there I suppose...Plan is to tackle the sunroof first. I think the problem is the NPT connection to the drain. Then i'll get the liner cleaned and reupholstered. I probably won't do it myself because it seems like a pretty tedious process.

View attachment 793788

So why pull the liner? Well, I absolutely lucked out and tracked down an original Safety Devices low profile rack. Looks nearly identical to the original Highlander version I have, but far better lines since it hugs the roof of the truck. In order to fit this rack, you need to remove the factory rails, fill the holes with rubber grommets, then seal them with silicon.

View attachment 793789

Pure class. Just love the way this truck is coming along.

To wrap things up this weekend, I wired in an AC Fan switch so that I can enable them on demand when driving up prolonged inclines. This was wildly easy to do. Will post a tutorial in a bit.

View attachment 793792

Off to the Shaver Lake area this coming weekend for Outono's first long trip. Hoping it gets through it unscathed.

Looking forward to the tutorial for this one!