27" TV CONVERSION
This webpage describes how to replace the 20" TV in your pre-2000 Discovery with a 27" TV. This is a relatively straightforward project and can be accomplished with a minimum of tools and skills.
Thanks to Bob Procell for this great project and also the accompanying pictures.
This project does not require the removal or modification of the storage compartments above the pilot or co-pilot seats. However, this limits your TV choices to those with a width of 25.5" or less. After some searching, Bob found that the RCA FD2744 27" TV fit the bill nicely.
The existing TV enclosure (box) is removed, reinforced, and lowered approx 2". The new TV will protrude approx 4.5" from the front of the box, necessitating that a base be made for the new TV from 3/4" plywood. The box is reinforced and reattached approx 2" lower, and the new TV is slid into place and secured.
Since the new TV is approx 20 lbs heavier, it is IMPORTANT that the box be reinforced. This can be done by using L joist hanger brackets on the bottom left and right sides.
Since the TV will extend forward from the box by approx 4.5", a new base must be made using 3/4" plywood. I used a 2' x 2" piece of 3/4" plywood for the base. First, measure and cut one end of this plywood so that it fits in the box, with the other end flush with the front. (You will have approx 8" of the original plywood sticking out the front of the box).
At this point, I will describe how Bob Procell completed his installation and another alternative will be discussed later
With the new base positioned in the box, set position the new TV in the box. Approx 4.5" of the TV will stick out in front as it is too wide for the box. Using a pencil, scribe a line along the contour of the front base of the TV. Remove the base and cut along this line.
After your base is cut, securely attach the base to the bottom of the TV. As an added measure, use L brackets to secure the rear of the TV to the base. Attach a flat "extender" bracket to the floor of the box. This "extender" bracket will be used to attach the TV/base to the box.
With the TV in the box, carefully measure how much taller the TV is than the top edge of the box (approx 2"). This is the distance that must be "lowered" when it is reattached to the coach. Remove the TV/base from the box and securely attach the box to the coach ensuring you have the approx 2" drop from the ceiling. Ensure that your screws are attached to solid wood on the frame of the compartments - not just screwed to the flimsy panelling that is the sides of the compartments. You can want to add extra screws, just to make sure the box is securely attached. Also, I recommend that you add a strap at the rear of the box that is secured to the wood header above the windshield.
After the box is securely attached, you can slide the new TV/base into the box. Check for proper positioning so that the left and right compartment doors can open freely. Secure the base to the box with the flat extender.
At this point, you are basically done, but you are left with an unfinished front and bottom at the TV set. Bob crafted a really beautiful shelf that attaches to the front of the TV/base.
Thanks to Bob Procell for this great modification and also for his help with making the modification in my 98 D.