2oolander's 2003 Land Rover Discovery II Light Build
2003 Disco Build Light
Photo: 2003 Disco Build LightA 2003 Land Rover Discovery II upgraded for light off-road and daily use
2oolander bought a high-mileage but mechanically solid Discovery II from its original owner and set about cosmetic fixes plus a series of practical off-road and lighting upgrades. The thread documents cleaning and cosmetic repairs, then bumpers, fenders, armor, a winch, and lighting added over about a year, with trail outings along the way.
Specs
As stated in the original write-up.
- Engine
- Head gasket replaced 25-35K miles before purchase
- Transfer case
- 2004 Rover-tym unit with CDL installed by prior owner, lever later added by owner
- Brakes
- New brakes and rotors all around (done prior to purchase)
- Wheels
- 16" Kalahari wheels, later plasti-dipped black, with BORA 1.75" wheel spacers
- Tyres
- 265/75/R16 Cooper Discoverer STT
- Front bumper
- Rover-tym front bumper fitted with Warn Hawse fairlead
- Rear bumper
- Atlantic British rear bumper replacing broken original
- Body
- Chawton white, TerraFirma extra-wide fender flares, 3M vinyl hood blackout
- Underbody protection
- TerraFirma diff guards front and rear, TerraFirma gas tank skid plate, TerraFirma rock sliders with tree bars
- Winch
- Warn VR8-S 4-ton synthetic winch with Warn 9T shackles
- Lighting
- Hella black Magic 6" driving lights wired to high beams, TerraFirma light bar, 4 Nilight 51w LED roof lights
- Communications
- CB radio built in, repaired wiring
- Trim
- External plastics sealed with 3M rubberized under body sealant, painted grill
Parts used
Parts named as used in the original write-up, grouped the way the Parts page groups them. Where one of the shops we index lists the same thing for this car, it is shown underneath with a link to the shop.
Gearbox & Drivetrain 1
- Central diff lock lever
Added to activate CDL on the previously installed transfer case
Suspension & Steering 3
- Warn Hawse FairleadWarn
Installed in front bumper opening ahead of winch fitment
In the shops
Hawse Fairlead - Black ↗
Land Rover Parts, Spares & Accessories· £34.57 GBPHawse Fairlead Center - Black ↗Land Rover Parts, Spares & Accessories· £34.57 GBPStainless Steel Hawse Fairlead ↗Land Rover Parts, Spares & Accessories· £78.79 GBP - TerraFirma rock sliders with tree barsTerraFirma
Fitted for underbody and recovery protection
In the shops
Steering Damper (Terrafirma) ↗
Moss Motors – Triumph TR6/TR250· $72.00 USD
Steering Damper Assembly (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $73.75 USD
Shock Absorber Rear | Terrafirma STC3671TFAT ↗Moss Motors – Triumph TR6/TR250· $58.50 USD - TerraFirma diff guardsTerraFirma
Front and rear differential protection fitted
In the shopsSteering Damper (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $72.00 USDSteering Damper Assembly (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $73.75 USDShock Absorber Rear | Terrafirma STC3671TFAT ↗Moss Motors – Triumph TR6/TR250· $58.50 USD
Wheels & Tyres 2
- Plasti-dip wheel coating
Applied to Kalahari wheels to trial a black finish before permanent paint
- BORA 1.75 inch wheel spacersBORA
Installed with red loctite for stance and stability, though caused minor tyre rub at full articulation
Body & Trim 9
- 3M rubberized under body sealant3M
Sprayed on exterior plastic trim to restore a new look
In the shops
Under Body Panels & Fittings, XK120 ↗Moss Motors – Triumph TR6/TR250· $0.00 USD
Under Body Panels & Fittings, XK150 ↗Moss Motors – Triumph TR6/TR250· $0.00 USD
Under Body Panels & Fittings, XK140 ↗Moss Motors – Triumph TR6/TR250· $0.00 USD - Grill paint
Grill painted for appearance
- Windshield pillar paint
Painted damaged pillar area instead of replacing missing plastic cover
In the shopsWindshield Center Pillar ↗Moss Motors – Triumph TR6/TR250· $0.00 USD
Windshield Pillar Pad Pair ↗Moss Motors – Triumph TR6/TR250· $26.99 USDHook, Windshield Side Pillars ↗Moss Motors – Triumph TR6/TR250· $37.95 USD - Atlantic British rear bumperAtlantic British
Replaced broken rear bumper, fitted in about 45 minutes
In the shops
Rear Fender, Left (British Motor Heritage) ↗Moss Motors – Triumph TR6/TR250· $525.99 USD
British Motor Heritage Hood ↗Moss Motors – Triumph TR6/TR250· $1,787.35 USD
Hood, British Motor Heritage ↗Moss Motors – Triumph TR6/TR250· $1,179.75 USD - TerraFirma fender flaresTerraFirma
Extra-wide flares fitted in place of old fenders, required drilling
In the shopsSteering Damper (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $72.00 USDSteering Damper Assembly (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $73.75 USDShock Absorber Rear | Terrafirma STC3671TFAT ↗Moss Motors – Triumph TR6/TR250· $58.50 USD - 3M vinyl hood wrap3M
Blackout vinyl applied to the hood
- TerraFirma gas tank skid plateTerraFirma
Fitted to protect the fuel tank underneath
In the shopsSteering Damper (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $72.00 USDSteering Damper Assembly (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $73.75 USDShock Absorber Rear | Terrafirma STC3671TFAT ↗Moss Motors – Triumph TR6/TR250· $58.50 USD - Land Rover OEM ladderLand Rover
Fitted to the rear of the vehicle
In the shops
Land Rover Mid Silver Decal ↗Moss Motors – Triumph TR6/TR250· $78.50 USD
P Gasket (Genuine Land Rover) ↗Moss Motors – Triumph TR6/TR250· $10.50 USD
Input Oil Seal (Genuine Land Rover) ↗Moss Motors – Triumph TR6/TR250· $18.75 USD - Land Rover G4 tail light guardsLand Rover
Fitted to protect tail lights
In the shopsLand Rover Mid Silver Decal ↗Moss Motors – Triumph TR6/TR250· $78.50 USDP Gasket (Genuine Land Rover) ↗Moss Motors – Triumph TR6/TR250· $10.50 USDInput Oil Seal (Genuine Land Rover) ↗Moss Motors – Triumph TR6/TR250· $18.75 USD
Electrical 4
- Hella black Magic 6 inch driving lightsHella
Installed and wired to activate with high beams
In the shops
Hella 500 Driving Light Kit ↗Moss Motors – Triumph TR6/TR250· $156.00 USD
Radiator, Hella ↗Moss Europe (UK)· £387.25 GBP
Radiator, Hella ↗Moss Europe (UK)· £291.25 GBP - CB radio
Repaired broken negative cable and rewired positive lead directly to battery input at fuse box
- TerraFirma light barTerraFirma
Mounted though owner had mixed feelings about mounting height and strength
In the shopsSteering Damper (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $72.00 USDSteering Damper Assembly (Terrafirma) ↗Moss Motors – Triumph TR6/TR250· $73.75 USDShock Absorber Rear | Terrafirma STC3671TFAT ↗Moss Motors – Triumph TR6/TR250· $58.50 USD - Nilight 51w LED roof lightsNilight
Four lights, two spot and two flood, with switches professionally wired into unused heated-seat switch locations
Other 2
- Warn 9T shacklesWarn
Fitted as recovery points
- Warn VR8-S 4-ton synthetic winchWarn
Installed in front bumper with fairlead already mounted
In the shops
Warn Zeon Winch Rope Cover ↗Land Rover Parts, Spares & Accessories· £39.38 GBPWarn Zeon Winch Rope Cover ↗Land Rover Parts, Spares & Accessories· £39.38 GBP
Synthetic Winch Rope (TF3323) ↗
Paddock Spares· £145.03 GBP
Photos
68 pictures collected from the write-up, in the order they were posted, shown from 2003 Disco Build Light. A picture opens larger here, with the way through to the page it is on.
2003 Disco Build Light - Land Rover Forums - Land Rover Enthusiast Forum 39this post at 2003 Disco Build Light ↗
2003 Disco Build Light - Land Rover Forums - Land Rover Enthusiast Forum 29this post at 2003 Disco Build Light ↗
How it was done
Starting condition
Bought from the original owner at 145K miles with a Chawton white body, Kalahari wheels, a prior transfer case upgrade with CDL, new brakes, and recently replaced head gasket. Problems included a broken rear bumper, damaged rear quarter panels, worn interior, broken mirror, missing windscreen cover, sun-damaged plastics, and stuck door lock actuators.
Cosmetic cleanup
Had the interior professionally detailed and did exterior cleaning and light waxing himself. Planned further cosmetic work including new lights, CB repair, plastic trim treatment, and grill paint.
Lighting and small fixes
Installed Hella black Magic driving lights wired to the high beam circuit, repaired a broken CB radio cable, sprayed exterior plastic trim with 3M rubberized under body sealant, painted the grill and a damaged windshield pillar, and fitted a Warn Hawse fairlead and Warn 9T shackles ahead of a winch.
Bumpers and fenders
Fitted an Atlantic British rear bumper in about 45 minutes and installed TerraFirma extra-wide fender flares, along with a 3M vinyl hood blackout.
First trail run
Took the Discovery on its first off-road outing at Table Mesa near Phoenix alongside an IH Scout and an FJ, noting the hill descent control worked well; tyres were not aired down and sway bars not disconnected that trip.
Off-road and appearance upgrades
Plasti-dipped the wheels black to trial the look before considering paint. Later added a central diff lock lever, TerraFirma rock sliders with tree bars, BORA 1.75 inch wheel spacers, TerraFirma front and rear diff guards, a TerraFirma gas tank skid plate, a Warn VR8-S winch, a TerraFirma light bar, four Nilight LED roof lights with professionally wired switches, an OEM ladder, G4 tail light guards, and custom plates.
A summary in our own words. The full account, with all its detail, is in the original write-up: read it at 2003 Disco Build Light ↗
Worth knowing
- 1.75 inch wheel spacers were more than needed, 1.25 inch would have been better
- BORA spacers held securely with red loctite
- TerraFirma light bar mounting could be stronger and lower