Not so sure I’d go as far as to say “Expertise”

There are a lot of people who could have done the work a lot quicker then I have but it’s quite satisfying to say I’ve done it myself I must admit.

I’m really looking forward to driving it when it’s finished now but I’m not driving it until it’s been tracked properly so I’ll be taking it to the local specialist to get done on the trailer.

Today saw the air receiver refitted into the inner cill. I then started reassembly of the subframe.

I'm looking at doing some similar rustproofing whilst I've got some stuff removed (and on my P38).

I'm interested in knowing the procedure and what products you are using here. From what I can see you're using Hydrate 80 on the bare metal, then zinc primer (Electrox?), followed by Epoxy Mastic?

I don't have much experience with anti-corrosion products so I'm just looking for suggestions really. Thanks. 1995 4.6 P38
2003 L322 4.4 - Sold
2010 L322 5.0 S/C

That's right.

I've got most things from Bilt Hamber.

Deox C - Mix it with water, submerse things and the rust is treated whilst submersed.
Deox Gel - Plaster it on thick with a brush, cover things in clingfilm and wash off with soapy water.
Hydrate 80 - Paint on metal once you've removed the loose rust and it cures the rust.
Zinc Corrosion Paint - Spray onto the rust treated surfaces. (Screwfix)
Epoxy Mastic - Mix the tin incredibly well, I used a bent wire in the drill, add the hardener and mix again, then paint on.

On the subframe and wishbones I applied the epoxy direct to bare metal as they'd been blasted. On the underside of the car I used the zinc paint before applying the mastic.

Until starting this I was very much in the same boat as you. This is the first thing I've really spent any time on doing rust work.

Thankfully, none of our P38's have had anything more then surface rust so I've never had to do similar works to them.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

If you are going to use epoxy or something to paint your subframe, make sure you’ve got a decent tap set as the bolt holes in the subframe will need cleaning out once it’s dried off.

I painted the final piece of my puzzle tonight - the fuel tank guards. The diff should be on it’s way home tomorrow so we can then crack on with reassembly this weekend!

A pallet left Birmingham at 3pm yesterday and I was told to expect it Thursday or Friday. At 10.15 this morning I got a call from a delivery guy asking how to find us…

At 10:30 this turned up…

Last weekend when I was trying to change a CV gator on the rear shaft as it was torn I could not for the life of me get the CV joint off the shaft.

In the end the CV joint chipped and cracked. I cleaned everything up and then noticed that the CV joint had gone incredibly blue. Presumably due to a lack of grease.

Worth while popping the gaiters off and checking for grease if your old ones were dry?

My old shaft had a blob of epoxy over a tear in the gator which is why it was short.

These ones don’t look as if they’ve been touched thankfully so I’m just going to fit them and see what happens.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

Tonight I’ve reassembled the diff with the locking motor.

All looking good - you may have done it but take the inner lower cover up the upper boot lid and load it up with bilthammer - apparently they rust from the inside out. When I got my new lid painted that’s the first thing I did Current stable:
2006 BMW M6
2007 4.2 V8 S/C FF
Gone:
2002 4.4 V8 FF

Are you talking about the cup that sits over the diff seals on the shafts?

Edit - Just realised what you mean. The can of chassis wax I had for doing the subframe and wishbones I’m planning on emptying into the tailgate once I’ve got the battery back on the car.

I’m going to be sending the car in for some paint at some point on the rear door that was scratched when I got it and am going to be having the tailgate painted at the same time. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

Tonight saw the rear diff motor cleaned up - good job I gave it a proper look over as it had little shiny metal particles in it. This makes sense as the lad I spoke to today was the lad who stripped my diff down - he said the bearings in it were worn.

Instant Gasket applied to the top of the diff flange. Not my neatest job… it took one hell of a lot of squeezing to get it out of the tube and my hands were sore doing it!

Tell you what David i am so excited for you when this is all back together and on the road again what a journey!! also i am super envious of the facilities you have to work from.  2012 Vogue 4.4 TDV8 - Current
2014 Navara V6 - Gone
2004 Vogue TD6 - Gone
Grand Cherokee - Gone
Discovery V8 (LPG) - Gone
Discovery TD5 - Gone

Thank you

I must admit I'm really looking forward to driving it once it's all done too!

I don't want to drive it until it's 100% sorted either though so I'm going to take it to get a full alignment set up on the trailer That way the first drive home from the specialist will be 100%... or so I hope!

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

Argggggghhh!

The torx screws holding my height sensors to the metal bracket look like they've lived in the sea and would never come off when on the car so I ordered 2 new brackets and 4 new screws to replace them before fitting the subframe back to the car.

DPD have routed my parcel from Duckworths to Southampton rather then Glasgow and are now telling me I won't see it before Monday 😫

Not happy is a bit of an understatement.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior