Florida Rover's 1997 Discovery XD
It was at this point I decided to install a new hood release cable while I had the access

I was excited to gain a nice pair of vice grips in the process (pic prior to painting)

Turns out you don't need to pull the whole mechanism but I wanted to clean & grease the latch

I can't leave "good enough" alone so a full wire wrap & tuck was in order

Pulled back without breaking a single fastener

Detailed

20 years of buildup

Post pic of the cleanup, once again I got carried away and stopped taking pics

Hood release installed and working properly

Everything wrapped and secured

Sanitary

I had sealed the air filter housing during this process

JB Water Weld seemed like a good choice, hit with a coat of SEM Trim Black after

Going back together

One final replacement while I was working on this side of the engine compartment

Luckily I had pulled this from the donor truck

Home stretch

Not sure if this is intentional but there is a nice hole and grommet available for running the hose

Some slight clearance required

It ended up taking an entire weekend but project complete.

I was excited to gain a nice pair of vice grips in the process (pic prior to painting)

Turns out you don't need to pull the whole mechanism but I wanted to clean & grease the latch

I can't leave "good enough" alone so a full wire wrap & tuck was in order

Pulled back without breaking a single fastener

Detailed

20 years of buildup

Post pic of the cleanup, once again I got carried away and stopped taking pics

Hood release installed and working properly

Everything wrapped and secured

Sanitary

I had sealed the air filter housing during this process

JB Water Weld seemed like a good choice, hit with a coat of SEM Trim Black after

Going back together

One final replacement while I was working on this side of the engine compartment

Luckily I had pulled this from the donor truck

Home stretch

Not sure if this is intentional but there is a nice hole and grommet available for running the hose

Some slight clearance required

It ended up taking an entire weekend but project complete.
Last edited by FloridaRover; Jun 29, 2017 at 10:11 AM.
After months of sitting on the shelf It was time to remount the LED's, bonus points for spotting the bottle opener

Custom offset..

Final mockup, prior to assembly

Rings painted black, yellow parking rules applied

I had replaced the window ECU with the one from the donor, and that failed... so I took the easy route and installed the bypass, works great

Also came up with an ultra clean bike rack design using the PO's non hub centric spacers, more details later

Logging miles

More direct pic of the lights

Custom offset..

Final mockup, prior to assembly

Rings painted black, yellow parking rules applied

I had replaced the window ECU with the one from the donor, and that failed... so I took the easy route and installed the bypass, works great

Also came up with an ultra clean bike rack design using the PO's non hub centric spacers, more details later

Logging miles

More direct pic of the lights
Last edited by FloridaRover; Jun 2, 2017 at 01:19 PM.
Next up was the driver side rocker / slider

Something to be desired

Another area doomed to fail

The worst of it

1st coat

The slider was in good shape, just needed some touchup

Naturally I stopped taking pics, I'm halfway through the other side and will fill in the blanks..

Backing plates and the rocker got two coats, plan to buff the powder coat to a shine

Something to be desired

Another area doomed to fail

The worst of it

1st coat

The slider was in good shape, just needed some touchup

Naturally I stopped taking pics, I'm halfway through the other side and will fill in the blanks..

Backing plates and the rocker got two coats, plan to buff the powder coat to a shine
Last edited by FloridaRover; Jun 5, 2017 at 05:33 AM.
On to the passenger side...

This would also include the area below the washer bottle

And rocker

Thankfully not as bad as the driver side

And easier to access

Step 1

Minor rust treated

A single rubber grommet causes this section to rot...

Painted the inside rocker where the backing plate sits

5.5"

Finished rocker with refreshed slider

Wires got a fresh wrap & top surface painted

Underneath prepped

Skipping ahead slightly

Finished product

What you didn't see was the lock mechanism breaking and my key getting stuck in the door

Was a good excuse to finally adjust the inner door handle and install a new vapor barrier

Then to top it off I fall through the seat... I'm 175lbs on a good day

1 roll of duct tape later

Seat now feels 50X better than it did before!!

This would also include the area below the washer bottle

And rocker

Thankfully not as bad as the driver side

And easier to access

Step 1

Minor rust treated

A single rubber grommet causes this section to rot...

Painted the inside rocker where the backing plate sits

5.5"

Finished rocker with refreshed slider

Wires got a fresh wrap & top surface painted

Underneath prepped

Skipping ahead slightly

Finished product

What you didn't see was the lock mechanism breaking and my key getting stuck in the door

Was a good excuse to finally adjust the inner door handle and install a new vapor barrier

Then to top it off I fall through the seat... I'm 175lbs on a good day

1 roll of duct tape later

Seat now feels 50X better than it did before!!
Last edited by FloridaRover; Jun 28, 2017 at 10:09 PM.


