factory roof rail removal - any additional wisdom?

Tugela

Well-known member
May 21, 2007
4,754
562
Seattle
I am buying an XD style roof rack for my D1. A friend is getting rid of his and offered it to me at a price I couldn't refuse. I have said in the past that I wasn't a fan of the full-coverage roof rack but I've changed my tune and am willing to give it a go - mainly because this is the model that most appeals to me. I have read the write-up on this project from the tech section in the old DiscoWeb site (https://discoweb.org/oldsite/roofrails/index.htm) and have ordered the plugs for the holes. The directions seem straightforward, but experience tells me that in reality it's always a little harder. Among those of you who have done this, I'd appreciate you sharing any additional tips or tricks that aren't covered in the write-up.
 

pinkytoe69

Well-known member
Jan 14, 2012
1,689
182
minnesota
Have you ever removed the headliner?

It's pretty much that plus removing 4 nuts :)

Removing it isn't difficult but it is kind of tedious.

You end up with like 20 screws and a bunch of trim fasteners, but you don't really need to keep them sorted as it's pretty obvious where they go back.
 

Tugela

Well-known member
May 21, 2007
4,754
562
Seattle
I've refinished the headliner in my Range Rover but haven't messed with the one in my Disco. Just curious if there was anything that wasn't obvious.
 

pinkytoe69

Well-known member
Jan 14, 2012
1,689
182
minnesota
I've refinished the headliner in my Range Rover but haven't messed with the one in my Disco. Just curious if there was anything that wasn't obvious.

Highly recommend using a drill to remove all the Phillips screws...you'll get sick of doing it by hand before you've done half the front cubby thing 😁

That, a flat head for prying out panels & switches, and a good trim removal tool/set is all you need iirc

Oh, 8 & 10 mm sockets for the nuts in the lights.

I assume the diy covered it, but I think the only thing not obvious is the screw under the rear (maybe front too?) sunroof switch.
 
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terryjm1

Well-known member
Jan 23, 2011
1,486
375
Highly recommend using a drill to remove all the Phillips screws...you'll get sick of doing it by hand before you've done half the front cubby thing 😁

That, a flat head for prying out panels & switches, and a good trim removal tool/set is all you need iirc

Oh, 8 & 10 mm sockets for the nuts in the lights.

I assume the diy covered it, but I think the only thing not obvious is the screw under the rear (maybe front too?) sunroof switch.
Thanks, I have 2 headliners to do.
 

WaltNYC

Well-known member
Mar 3, 2010
707
135
NYC
re removal of the headliner....The trim pieces around the Alpine windows which run from the C to D pillars can be tricky to get back into place. Try to remove just one side and only loosen the other.

The fiber board can withstand some bending so don't worry too much about injuring it.
 

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
When I put in the plugs on mine, I gave each one a coating of black RTV to help them slide in better and seal it up.