Here is my N.C.F. Sahara, after four months hard work. It is based on the standard chassis and running gear from a Mk.1 Discovery. In my case a 1990 200tdi model, but more about that later.
The kit comprises a replacement body consisting of a steel roll cage, to which galvanised steel panels are fitted and the bonnet / wings assembly that hinges complete, from the original front bumper mountings. The lift off doors are an option and the car can be legally driven with or without them in place.
Due to the design of the body, 33/1250/15 tyres can be fitted whilst still retaining the original suspension (I suspect that 35/1250 tyres would also fit). As a result, it can still be driven safely at motorway speeds without stability problems, but has extra ground clearance for off road performance.
On the following pages are the details of the build, I tried to take as many photographs as possible during the build. I had never undertaken a project as big as this before, and I must say that I found the build a thoroughly enjoyable experience.
The donor vehicle:
My choice of donor vehicle was due to the fact that I already owned it!, The chassis and drive train were in excelent condition, but the bodyshell was badly rusted in all the usual places and beyond economical repair.
After a trip to see Nick (N.C.F. Motors himself), and having had a good look round the prototype, I decided to place my order. At the time I placed my order there was about a 10 week wait for delivery, which would give me plenty of time to prepare the donor.
The first job, before the arrival of the new shell, was to remove the old body. I decided that due to a lack of space, the best option for me was to remove th body in sections. This turned out to be much easier than I first thought. First, all the bolt on bits were removed, trim, doors, bonnet wings etc. Next all the glass was removed, then using a 9" grinder the body was carefully removed in sections. The whole operation took a day and a half.
As you can see from the photograph, the front section of the floor, bulkhead and seats remain in place. Great care was taken not to damage any of the wiring or pipework beneath the body.
N.C.F. SAHARA
Build. (1)
