1994 D1 Project

Contractor

Member
Mar 27, 2015
24
1
The South
This is my first Discovery, I own a couple of Series Trucks and have had a couple of Classics.

I got this truck last week and intend to correct what's wrong and hang on to it for a while. After poking around it for a while I quickly realized that you could literally Fred Flintstone the drivers floor board. The foam was soaking wet and had obviously been that way for a while.

I pulled all the wet foam out and and started cutting away rotten metal. The seat bases need a little work too as the welds have broken and are not very stable. These seats came out of some other truck and are not original to this truck. I am going to order YRM Sills, brackets and pillar bottoms and will end up fabricating the floor pans out of sheet metal myself. The passenger side floor pan looks pretty good and just needs some cleaning. The sill and pillar bottoms are rotten and will need to be fixed. It also has the same issue with the seat bases and one of them is actually totally broken off.

Other than those issues I don't think I really have any other rust related problems.

I plan on doing the following items in addition to correcting the rust problems:

- Head Liner
- Re-Upholster the two front seats
- 2" Lift
- ARB Winch Bumper and Warn Winch
- Floor Mats
- Maybe some alternate to carpet or maybe new carpet; not sure yet?
- I got some 235/85 MT's with the truck so I will either use them on this or buy another set of tires.
- Window Seals on the rear windows
- Service it
- I might either fabricate some sliders myself or buy some already made.


Anyway, it's probably a little more rust than I was expecting but otherwise I'll plug away at it. I am looking forward to this truck since my family can ride in it and we can all go to Rover events. The Series trucks make it a little tough to ride in with Children.

So far the only bone headed move I made is cutting through the damn brake lines. I knew they were there and did it anyway........I'lll get them fixed.





ETA - Once I figure out how to reduce the size of the pictures I'll update.






























 
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Contractor

Member
Mar 27, 2015
24
1
The South
I got a Delivery from YRM this week and had some time today to mess with it.

I got the A Pillar bottom, Inner Sill, Outter Sill and a couple brackets welded in today. I hope to get the pans installed tomorrow if I have time and wrap the drivers side up.

Also posted are a couple of pictures of what happens when you grind with no guard. It caught something and jerked out of my hands and cut my welding jacket pretty good. If I did not have the jacket on I would of probably been getting stitches. I hate guards, but they are there for a reason.



















 

Contractor

Member
Mar 27, 2015
24
1
The South
Holy hell that seems like zero fun. Props to you for diving in and taking care of it.
It's not horrible, but I'd rather be doing something else for sure.

Thats a true labor of love. Good luck. Hope everything stays square.

I have been pretty careful so far. The only thing that's gotten a little out of whack was the A-Pillar. I knew it would happen, but when you weld that joint it wants to draw the entire piece out some (away from the truck). I pulled it back as best I can and am pretty sure it will be fine.......I'm spitting hairs on how far out it is.
 

Contractor

Member
Mar 27, 2015
24
1
The South
Repaired my brake lines today and finished the drivers side. I need to weld the seat bases, paint it and put it back together. Hopefully I'll tackle the passenger door pillars next weekend.








 

Contractor

Member
Mar 27, 2015
24
1
The South
what did it cost for the parts from YRM if you don't mind me asking ?
I have about $530 in the parts delivered to my door (in less than 1 week). The quality is great they saved me an insane amount of time.

I?ll have maybe $200 in consumables, additional sheet metal and of course my time which is so far about 15 hours. I?m not sure I?d of gone this route had I not been able to do it myself.
 

rover rob

Well-known member
Mar 29, 2016
121
5
upstate NY
I have about $530 in the parts delivered to my door (in less than 1 week). The quality is great they saved me an insane amount of time.

I?ll have maybe $200 in consumables, additional sheet metal and of course my time which is so far about 15 hours. I?m not sure I?d of gone this route had I not been able to do it myself.
thank you. I have inner wings to take care of and some sill work but the floors are great. I plan on doing it over the spring. I can do the welding no problem but the fab would be a pita with only a 2 foot box brake.
 

Contractor

Member
Mar 27, 2015
24
1
The South
I had some time this afternoon to mess around.

I got the passenger B-Pillar Bottom replaced and repaired a couple of bad spots on the sill. I also got the seat frames welded back in place. I was not really happy with the install job that someone did before me, so I used some 3/4" angle to make a little better support. Lastly, I installed the little door seal lip on the driver side and got some paint and a little filler on it.





















 

Contractor

Member
Mar 27, 2015
24
1
The South
Not much in terms of pictures, but here are a few. I sprayed bed liner on the sill and ran it up about 6 inches onto the door pillars and also sprayed the floor pans. I did it on the pillars mostly because matching 20+ year old paint will be impossible and the contrasting black looks good.

Other than that, I put the doors back on, took the bumper off, etc.....

Plenty of things to work on, but here is what I will do over the next week or so as time allows:

- Sandblast and Paint the 2" longer Coils
- Sandblast and Paint the Bumper
- There are two pieces on the front of the truck that I need to paint. One had damage, so I have a spare but it's the wrong color.
- New Leather on the Seats
- Re-Install the covers over the sills.


I have a few questions, but maybe I'll ask outside of this thread.








 

Contractor

Member
Mar 27, 2015
24
1
The South
Thanks for the comments.

My nightmare continues........haha.


I had not really messed around with the rear load space yet mostly because I knew what I would find.

Anyway, got most of it cut out and have to cut some more out and order a new piece. I also got a couple of parts painted.

What a pain in my ass.










 

Contractor

Member
Mar 27, 2015
24
1
The South
Well, I have slowed down a little.........I sold my house and am scrambling to get some things in order and move.

I did pick up my bumper and springs from the powder coat shop and hope to get my seats back this week too. I'll at least get my front end back together in the next several days and then hopefully finish welding in new sheet metal.








 
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