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AusCam
Member Since: 11 Dec 2009
Location: Warrnambool
Posts: 27
  
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Need some advice
We opened the tail gate this afternoon to find the strut holder at the top had come un wound. trying to put the ball head/screw mount back into position and the nut that was ment to be captive fell down into the the rear pillar.
The issue i have now is how to put a new one in? Nutsert ? Weld ? De skin the disco?
Thank you in advance
Ian Java Black
2005 V8 SE
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 Mon May 02 2011 10:31am |
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AusCam
Member Since: 11 Dec 2009
Location: Warrnambool
Posts: 27
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Thanks
Gedaso
Too old for waranty, looks like i will have to go the technical solution ( cut holes in everything and weld it all back up )
Not likely, wiill try another way and if suitable will put out there for people who have bought the most awesome and complicated vehicle in the world. ( some days i wish i had grabbed a masses/common tojo )
Cheers Java Black
2005 V8 SE
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| Mon May 02 2011 12:47pm |
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nikademus
Member Since: 08 Sep 2006
Location: Geelong
Posts: 61
 
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Never fear!
I too, have had the unpleasant sensation of hearing the caged nut rattle its way down the inside of the pillar just before the tailgate hit me in the back of the head. I too read all the posts about cutting and welding. Then there were suggestions about bronzing nuts on to rods.... a bit above my technical expertise...
Sooo, I invented the nikademus-latch-fast-ezy-swing approach:
1. Take a bog standard coat hangar and straighten it out. Mix up some araldite and glue a nut (I think it was an M8, but check before) on the the coat hangar with  of araldite on some wax paper. Allow to go hard overnight.
2. rip the trim panel off immediately inside the pillar. there's a bunch of access holes. choose the one that best suits (I think it has a grommet cover) and feed the nut up inside the pillar. A bit of bending and refeeding later, you should be able to line up the nut. When you're close, cover the bolt with a of loctite and screw it up.
It worked for me.
I was shocked too. Disco 2 TD5 "Good"
Disco 3 TDV6 "Better"
Disco 4 HSE SDV6 "Best"
The older I get, the better I was.
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| Thu May 05 2011 7:23am |
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AusCam
Member Since: 11 Dec 2009
Location: Warrnambool
Posts: 27
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Nikademus
Absolute legend  , would rather spend the weekend trying your way than go the horror stories route.
Will keep ye all informed of progress.
Regards
Ian Java Black
2005 V8 SE
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| Fri May 06 2011 9:36am |
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mrandmrsh
Member Since: 25 Sep 2008
Location: Holmfirth
Posts: 481
 
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nikademus wrote:
Sooo, I invented the nikademus-latch-fast-ezy-swing approach:
You, Sir, are a genius
I have reposted this onto the long thread mentioned above.
Cheers
Craig 2012 Defender 110 XS Utility 2.2
2012 D4 Commercial 255 8-speed, Active diff, lots of extras on order, comes Sept - ORDER CANCELLED (isn't divorce expensive....?)
2008/08 D3 HSE G4 - part exchanged for the 110
1987 110 CSW with 200 Tdi (now gone)
2007/57 D3 TDV6 HSE - NOW GONE owned 1/oct/08 to 31/dec/09
2007 Seat Altea Freetrack4 170 tdi (wife's car, wife now gone!)
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| Fri May 06 2011 9:58am |
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AusCam
Member Since: 11 Dec 2009
Location: Warrnambool
Posts: 27
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Well, have finally fixed back door, I glued a washer to the nut to re-inforce the inside. Cut a small holesaw hole in area behind trim and with said cOat hanger sorted it out  .
Thanks for all input
Ian Java Black
2005 V8 SE
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| Sun May 29 2011 12:50pm |
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pierrepressure
Member Since: 28 Apr 2011
Location: Cape Town
Posts: 1
 
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| 2 more tips on nikademus-latch-fast-ezy-swing approach |
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This has just happened to me guys and Sir Nikademus, Legend, Master of the Universe, if you're ever in Cape Town, South Africa - I owe you a good pub lunch!! Just a couple of things to note for the DIY novices like me:
1. The hole with the grommet cover is the only one you'll fit the nut-on-wire through but you also need to feed it through a second hole on the inner skin slightly up from the 1st hole, otherwise you'll be fiddling about in the wrong area.
2. As a tip , bend a 5-10mm section at the tip of the coat hanger to 90° to"wrap" around the nut before you metal glue it - it'll hold better. Also, get your nut-on-wire length pre-bent outside the work area to get the angles correct, i.e. measure up & test just outside the insert & bolt holes before you go in.
What I found was that when I had the nut-on-wire lined up & the bolt inserted & tightened, the metal glue joint broke as I was doing the last bit of tightening, which was perfect to haul the wire out - job done!
Pierre - Bloubergstrand, Cape Town, South Africa.
2006 Disco V6S
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| Sun Nov 20 2011 2:40pm |
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