300tdi Sills

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J

JARVO

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Hi all, the time has come to replace my inner and outer sills as my mot:mad: is due next month.ive been putting it off for ages but now have no choice but to do them.Its a rather dawnting task for me as ive never done any sills before.
just wonderd if you guys could give me any tips like the best way to get the old ones off without damaging the floor?
Any info would be very helpfull.:rolleyes:cheers
 
Hi Jarvo, I have Brand new inner & outer sills going spare for Drivers side if your interested? Also rear wheel arch for both sides. (going cheap)
To do the job properly you need to cut a lot of the floor away which means cutting off the seat base outside edge, then the door pillar....... Its a lot of work.
Or sell it and buy a sound disco 300tdi ( I have one for sale full MOT and no rot anywhere 113000 miles)
 
Thanks for the info, with what you say about cutting floor and door pillars and what i read from the link you gave me about body distortion i dont even think i will be atempting it my self.I made a good job of the boot floor but that wasnt structaral and with having my two small chilldren in the disco while towing a caravan its best if i wait till i have the cash to ask a garage to do it.
 
The simplest cheapest and most common method is just to cut away the sills and replace using a length of box section steel. Drill a load of holes on the floor of the disco and puddle weld the floor to the box section thru the holes. There are lots of threads on how to do this. and it doesn't require the cutting of any door pillars.
 
thanks redhand, Do you know how i could support the body before i cut the old sills away?as i dont want door gaps like a bannana.:eek:
 
Perhaps I was lucky. I didn't have any issues with body disstortion after cutting away a large segment of my sills, floor and the drivers side door piller.

Doing the prep work yourself is easy enough. Just remember to wear the goggles and protective overclothing. Having a buring hot metal splinter in your eye whilst another bit of burning metal is melting into your skin is never fun.

I ended up getting door piller, seat belt mounts, sills, and some small floor sections welded up for £180, but that included me doing all the prep beforehand, and the painting afterwards.

Again, painting was easy. grind / sand down the welded areas, treat with a couple of coats of Karust, then a couple of coats of Hammorite.
 
:)Thanks for the extra info chaps.i think i may have a go the weekend weather permiting.
Just one more question for you before i start the job,
If i deside to remove all the sills and replace with box section what do i do about the body mounts? as i need it to pass mot first time.:confused:
 
redhand said:
The simplest cheapest and most common method is just to cut away the sills and replace using a length of box section steel. Drill a load of holes on the floor of the disco and puddle weld the floor to the box section thru the holes. There are lots of threads on how to do this. and it doesn't require the cutting of any door pillars.
Click to expand...

Wot he said....

Done this meself and it works ;)

Plus you get the added bonus of "built in" rock sliders :D

Not at all hard to do even for an inexperienced welder :cool:
 
JARVO said:
:)Thanks for the extra info chaps.i think i may have a go the weekend weather permiting.
Just one more question for you before i start the job,
If i deside to remove all the sills and replace with box section what do i do about the body mounts? as i need it to pass mot first time.:confused:
Click to expand...


Remove them from the old inner sills and clean em up or repair as nessacary and then attach then direct to the box section ;)
 
thanks captain thats very good advice and i now feel confident enough to do the job myself.
Thanks to all you guys for your advice it will save me a fortune.:D
 
reading up info before i start extensive bodywork on my 300 tdi disco.
got it recently by trading in a v6 freelander for it, 'spares or repairs' on both vehicles. ive owned two 300 tdi's and one 200 previously, but moving into the middle of Looe town 3 years ago meant bye bye disco due to stupid narrow access to my allocated parking. not an issue anymore thank God!
the upper bodywork of the disco is spotless, the interior is very good, the engine, gears and transfer etc all in top order, but the underside looks' like its been parked in a rockpool for a decade !:doh:
yep, lots of red rusty stuff and holes you can put yer arm through!
i've had good info on replacing boot floor with summat more permanent and meaty from 'beast o bodmin' (cheers chap-i'll be in touch soon for panel when prepwork done).
what i would like now is detailed info with pics if poss reference to cutting away whats left (VERY little) of the sills and replacing them with stronger box section steel with the option of welding on some tubular steel tree fenders to the sides of new box section sills to act as a step for my other half and to protect doors when ragging it around the farm.
what dimention box section did you guys use?
can i just disc-cut off old sills flush to floor and weld box section straight to it? (is puddle weld alone ok or is it best to seam weld along it also?)
thanks for help guys.
 
Boiler man said:
reading up info before i start extensive bodywork on my 300 tdi disco.
got it recently by trading in a v6 freelander for it, 'spares or repairs' on both vehicles. ive owned two 300 tdi's and one 200 previously, but moving into the middle of Looe town 3 years ago meant bye bye disco due to stupid narrow access to my allocated parking. not an issue anymore thank God!
the upper bodywork of the disco is spotless, the interior is very good, the engine, gears and transfer etc all in top order, but the underside looks' like its been parked in a rockpool for a decade !:doh:
yep, lots of red rusty stuff and holes you can put yer arm through!
i've had good info on replacing boot floor with summat more permanent and meaty from 'beast o bodmin' (cheers chap-i'll be in touch soon for panel when prepwork done).
what i would like now is detailed info with pics if poss reference to cutting away whats left (VERY little) of the sills and replacing them with stronger box section steel with the option of welding on some tubular steel tree fenders to the sides of new box section sills to act as a step for my other half and to protect doors when ragging it around the farm.
what dimention box section did you guys use?
can i just disc-cut off old sills flush to floor and weld box section straight to it? (is puddle weld alone ok or is it best to seam weld along it also?)
thanks for help guys.
Click to expand...

My thread has photos on the sills, I took pictures when doing both sides. Check out post 77
http://www.landyzone.co.uk/lz/f8/discovery-rust-boot-sills-wings-161843-8.html
 
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