300Tdi Disco DailyDriver-Expedition Build - Defender Source
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  #1  
Old January 22nd, 2014, 01:14 PM
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300Tdi Disco DailyDriver-Expedition Build

I just bought Oliver, a 1997 Disco 300Tdi/R380 and I am going to turn him into a Daily/Expedition truck. Below are my plans/parts list; any advice and/or suggestions would be great! Will post pictures as the build continues.

Old Man Emu HD Kit
Dislocation Cone - Rear
Dislocation Cone - Front
Spring Retainer HD - Rear
Spring Retainer HD - Front
Old Man Emu Steering Damper
Alloy Protection Skid Plate
ARB Winch Bar for Disco 1 w/ SRS
Hella 500 Driving Lamp Kit
WARN XD9000 Winch
MUDUK POD
ARB Safari Snorkel 300Tdi
Landy Lubber 5 Way Breather Manifold
Brownchurch Full Length Roof Rack
Access Ladder Rear
VDO EGT Gauge 300Tdi

Heavy Duty Rear Bumper
HELLA 4000 Driving Lamp Kit
HELLA 4000 Fog Lamp Kit
HELLA 4000 Wiring Harness
Contura II Blue Light Rocker
ARB Air Locker - 24 Spline (x2)
ARB Air Compressor
BF Goodrich All Terrians 235/70/16 (x5) Looking into new sizes and tires
Disco 1 Steel Wheels (x5)
Limestone or White Paint Job
Discovery 1 Bonnet Blackout Decal
Wrap around Diff covers (x2)

------ Follow up post added January 22nd, 2014 01:15 PM ------

Mantec or Safari Snorkel? Is it just an aesthetic difference?
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  #2  
Old January 22nd, 2014, 01:22 PM
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Old Man Emu HD Kit : Note this will change the ride a fair amount. It is stiff unloaded.

No point in any of this unless you are doing something else to increase shock travel.
Dislocation Cone - Rear
Dislocation Cone - Front
Spring Retainer HD - Rear
Spring Retainer HD - Front

Old Man Emu Steering Damper: Not really needed. Just makes the steering heavier.

VDO EGT Gauge 300Tdi: I would suggest digital with memory and alarm is more useful. Auberins does a great low cost unit

BF Goodrich All Terrians 235/70/16 (x5): Why not go a bit bigger? Stock will looks weird with the lift. Don't use these tires if there is any mud in your life.

ARB Differental Cover (x2): Not for a Rover diff???
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  #3  
Old January 22nd, 2014, 01:28 PM
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Quote:
Originally Posted by Red90 View Post
Old Man Emu HD Kit : Note this will change the ride a fair amount. It is stiff unloaded.

No point in any of this unless you are doing something else to increase shock travel.
Dislocation Cone - Rear
Dislocation Cone - Front
Spring Retainer HD - Rear
Spring Retainer HD - Front

Old Man Emu Steering Damper: Not really needed. Just makes the steering heavier.

VDO EGT Gauge 300Tdi: I would suggest digital with memory and alarm is more useful. Auberins does a great low cost unit

BF Goodrich All Terrians 235/70/16 (x5): Why not go a bit bigger? Stock will looks weird with the lift. Don't use these tires if there is any mud in your life.

ARB Differental Cover (x2): Not for a Rover diff???
I like a stiffer ride and need to load bearing ability

What would need to be done to increase travel?

I will check out Auberians

What size do you recommend? Mud is not constant but may be encountered, ideas on other tires? XZL's?

Does a standard wrap around cover work?
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  #4  
Old January 22nd, 2014, 01:31 PM
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Quote:
Originally Posted by IvanKV View Post
Hella 500 Driving Lamp Kit
Not sure I meet many people who actually use these things. Save your money.

Quote:
Originally Posted by IvanKV View Post
VDO Boost Gauge
Aside from diagnosis, unnecessary.

Quote:
Originally Posted by IvanKV View Post
HELLA 4000 Driving Lamp Kit
HELLA 4000 Fog Lamp Kit
HELLA 4000 Wiring Harness
Again, very few people actually use this stuff. LED lightbars are preferential if you're dead set on this kind of lighting.

Quote:
Originally Posted by IvanKV View Post
Limestone/White/Sandglow Paint Job
This is a little out there. I don't understand how/why you are going to do this without disassembling the entire truck. Otherwise, it's a waste of money and time, especially on an off-road disco.
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  #5  
Old January 22nd, 2014, 01:35 PM
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Quote:
Originally Posted by sonoronos View Post
Not sure I meet many people who actually use these things. Save your money.


Aside from diagnosis, unnecessary.


Again, very few people actually use this stuff. LED lightbars are preferential if you're dead set on this kind of lighting.


This is a little out there. I don't understand how/why you are going to do this without disassembling the entire truck. Otherwise, it's a waste of money and time, especially on an off-road disco.
Will strike off the gauge.

I hate the look of LED lightbars and I rather have the lights and not need them rather than need them and not have them.

I dislike black SUV's. I really like the Limestone or White look. It was planned for late summer when I can afford the downtime. Not in a rush to repaint.
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  #6  
Old January 22nd, 2014, 01:40 PM
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Quote:
Originally Posted by IvanKV View Post
I like a stiffer ride and need to load bearing ability

What would need to be done to increase travel?

I will check out Auberians

What size do you recommend? Mud is not constant but may be encountered, ideas on other tires? XZL's?

Does a standard wrap around cover work?
Increasing travel requires a bunch of changes. For a DD/Expedition vehicle, there is no reason. stock travel is fine.

245/75/16 or 235/85/16. I like the Goodyear Duratracs for an all around tire. It depends a lot on your intended terrain.

Personally, I would suggest taking things a bit at a time. It is better to get out with experienced people, learn and determine what is best and what YOU need.
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  #7  
Old January 22nd, 2014, 01:45 PM
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Quote:
Originally Posted by Red90 View Post
Increasing travel requires a bunch of changes. For a DD/Expedition vehicle, there is no reason. stock travel is fine.

245/75/16 or 235/85/16. I like the Goodyear Duratracs for an all around tire. It depends a lot on your intended terrain.

Personally, I would suggest taking things a bit at a time. It is better to get out with experienced people, learn and determine what is best and what YOU need.
Oh this is not a quick build by any means. I fully intend to take my time. Just more of a wishlist and a list to draw suggestions from; which it is doing quite well.

Intended terrain will vary. We(my housemate and I) are planning to do the Trans-America Trial from Tennessee to Oklahoma for Spring Break. I would expect dirt, gravel, lite mud, water, sand to all be present.
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  #8  
Old January 22nd, 2014, 01:46 PM
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If you need to change the color, plasti dip is a reasonable idea for around $800 and some places can do sandglow(I'm doing it this summer). BFG a/ts are great if all you care about is longevity and highway miles.

Like John said, tire choice is based off your location and what you'll spend time driving on.

ARB makes a great locker but so does Ashcroft. Think about upgraded axle shafts as well.
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  #9  
Old January 22nd, 2014, 01:47 PM
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Suggest not throwing good money after bad.

Winch - good
Slimline off-road bumpers - good
5 inch lift kit - good
new tires - good
front / rear weld-on diff guards - good
HD tie rod - good
rocksliders - good

That will make your truck look killer, make you poor quickly, and will take your mind off of wild ideas like repainting a 1997 disco.

The advantage of a disco as an "expedition vehicle" is that it seats 4 and is comfortable. Solo, you can sleep inside it knowing you are surrounded by a weatherproof steel box as opposed to in a tent on a roof, which is archaic and moist.
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  #10  
Old January 22nd, 2014, 01:50 PM
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Yes, I would also suggest the Ashcroft locker if you want a manual locker. It is a better design.

Of more importance for an expedition truck would be spare parts, tools and enough knowledge to fix things. We do trips up here where it is multiple days of off road driving to reach any road. Being able to fix anything in the field is the primary concern.
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  #11  
Old January 22nd, 2014, 01:52 PM
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Quote:
Originally Posted by Z.G View Post
If you need to change the color, plasti dip is a reasonable idea for around $800 and some places can do sandglow(I'm doing it this summer). BFG a/ts are great if all you care about is longevity and highway miles.

Like John said, tire choice is based off your location and what you'll spend time driving on.

ARB makes a great locker but so does Ashcroft. Think about upgraded axle shafts as well.
What advantages do upgrading the shafts bring?

Quote:
Originally Posted by sonoronos View Post
Suggest not throwing good money after bad.

Winch - good
Slimline off-road bumpers - good
5 inch lift kit - good
new tires - good
front / rear weld-on diff guards - good
HD tie rod - good
rocksliders - good

That will make your truck look killer, make you poor quickly, and will take your mind off of wild ideas like repainting a 1997 disco.

The advantage of a disco as an "expedition vehicle" is that it seats 4 and is comfortable. Solo, you can sleep inside it knowing you are surrounded by a weatherproof steel box as opposed to in a tent on a roof, which is archaic and moist.
I will take my mind off the repainting....for now
I forgot about rock sliders!
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  #12  
Old January 22nd, 2014, 01:54 PM
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As for the snorkel; ARB Safari or Mantec?
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  #13  
Old January 22nd, 2014, 01:56 PM
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ARB no question.
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  #14  
Old January 22nd, 2014, 01:57 PM
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Originally Posted by JSBriggs View Post
What about metallic silver?
If he was doing a full frame-off resto, then I would say go for it!
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  #15  
Old January 22nd, 2014, 01:59 PM
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Don't waste your money on Hella 500's, they are crap. Save up for some 4000's if you don't want to go LED. If you don't intend to go larger than stock on the tires, there's not much reason to install a lift. ARB isn't a great bumper for a D1, there are plenty of options out there. I'd suggest visiting Discoweb and searching and reading for a wealth of information about D1's. Diff guards and sliders should be much higher on your list than something like a snorkel. They look cool but your sliders and diff guards will be much more beneficial on the trail
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  #16  
Old January 22nd, 2014, 02:04 PM
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Originally Posted by IvanKV View Post
What advantages do upgrading the shafts bring?
Not having to replace a broken one after you break it

Also for a snorkel, do that last.

Edit- snorkel- forgot it was a Tdi for a moment. Go all out on sealing the snorkel path.
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  #17  
Old January 22nd, 2014, 02:06 PM
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What advantages do upgrading the shafts bring?
The stock shafts are not very strong. With lockers, they will break. You also would want to do the CV joints. http://www.lucky8llc.com/Products.aspx?ProductID=7881 is the best bang for the buck for the front. Ashcroft in the rear.
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  #18  
Old January 22nd, 2014, 02:07 PM
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Originally Posted by FSU_Disco View Post
Don't waste your money on Hella 500's, they are crap. Save up for some 4000's if you don't want to go LED. If you don't intend to go larger than stock on the tires, there's not much reason to install a lift. ARB isn't a great bumper for a D1, there are plenty of options out there. I'd suggest visiting Discoweb and searching and reading for a wealth of information about D1's. Diff guards and sliders should be much higher on your list than something like a snorkel. They look cool but your sliders and diff guards will be much more beneficial on the trail
Other than the lift, the list is not in any real order. Diff guards will definitely be on by the trip.

4000's all round? I will look into that.

I intend to go larger than stock....now

Quote:
Originally Posted by JSBriggs View Post
Are you thinking for water or for dust? Are you talking aesthetics? Ease of installation?

-Jeff
Water mainly. Dust will be encountered but nearly as often as water. I am going to have a place install it, this is not something I want to screw up.
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  #19  
Old January 22nd, 2014, 02:11 PM
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Originally Posted by JSBriggs View Post
I didnt see extended breathers on the list.

-Jeff
Its's there. I did not forget
- Landy Lubber 5 Way Breather Manifold -

http://shop.urbanlandcruisers.com/sh...-vent-300-tdi/
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  #20  
Old January 22nd, 2014, 02:12 PM
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So my thoughts from the D1 owner perspective:

Old Man Emu HD Kit: Good, get 2" and be done
Dislocation Cone - Rear: Retain vice cones, but thats personal pref
Dislocation Cone - Front: See above. EE has a great kit.
Spring Retainer HD - Rear
Spring Retainer HD - Front
Old Man Emu Steering Damper: sure
Alloy Protection Skid Plate: Sure, also do HD steering components
ARB Winch Bar for Disco 1 w/ SRS: many better bumpers than this, for sale, on Dweb right now.
Hella 500 Driving Lamp Kit: 4k's or 4k compacts (depending on bumper)
WARN XD9000 Winch: ok, I'm a superwinch guy but this doesn't matter too much.
MUDUK POD
ARB Safari Snorkel 300Tdi: Mantec looks much better...IMHO
Landy Lubber 5 Way Breather Manifold
Brownchurch Full Length Roof Rack: SD looks much better...IMHO
Access Ladder Rear
VDO EGT Gauge 300Tdi

Heavy Duty Rear Bumper: tough to find these cheap.
HELLA 4000 Driving Lamp Kit
HELLA 4000 Fog Lamp Kit
HELLA 4000 Wiring Harness
Contura II Blue Light Rocker
ARB Air Locker - 24 Spline (x2)
ARB Air Compressor
BF Goodrich All Terrians 235/70/16 (x5) Looking into new sizes and tires: go 245/75/16 KM2
Disco 1 Steel Wheels (x5)
Limestone or White Paint Job
Discovery 1 Bonnet Blackout Decal
Wrap around Diff covers (x2): Do sewercaps if you can

Another thing I'd advocate for is consider dual battery and battery mgmt, also upgrade your headlight harness to the ARB.

Lots of info on Dweb for the technical aspects, lots of build threads on ExpO for D1's. Best to keep your mods simple and clean; the 10 commandments of things not to do to an ExpO rig" is worth looking at.
r-
Ray
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