Discovery 2 sill repair

steve24v · May 1, 2022

Hi all, anyone fully replaced inner and outer sills including body mounts? Currently have the body off the chassis and started hacking the body mounts off as they are rotten but realised the sills need replacing. I can't replace them at the moment as the body is resting on stands under the sills so will need to do it once I've put it back down onto the chassis. Is there enough room to cut the inner sills off once it's fitted to chassis?
Cheers Steve

Stanleysteamer · May 1, 2022

steve24v said:
Hi all, anyone fully replaced inner and outer sills including body mounts? Currently have the body off the chassis and started hacking the body mounts off as they are rotten but realised the sills need replacing. I can't replace them at the moment as the body is resting on stands under the sills so will need to do it once I've put it back down onto the chassis. Is there enough room to cut the inner sills off once it's fitted to chassis?
Cheers Steve

Stupid question maybe, but can't you just change the support points you are using at the moment to get a free run at the sills?

steve24v · May 1, 2022

Thought about that, the only ones I can use are the mounts in the engine bay (on the footwells),. It's a bit wobbly at the moment to be honest, would be worse if I used them. Also unsure if the body would buckle once I've cut the sills off

FlatbedPilot · May 1, 2022

I did this on my project Disco TD5. Both sills completely replaced, inner and outer. All the details of how I did it are in my project thread. A bit different to your case as I'd cut the rear body off but same issues.

steve24v · May 1, 2022

DefenderPilot said:
I did this on my project Disco TD5. Both sills completely replaced, inner and outer. All the details of how I did it are in my project thread. A bit different to your case as I'd cut the rear body off but same issues.

Been following your build, ideally would prefer to do it while the chassis is out, but can't safely support the body whilst doing the repair unless I faff about finding and building a scaffold frame. I don't have a problem with making/welding the sills just unsure if there is adequate space to cut it all out once the chassis is back under it.
Cheers

frostythor · May 1, 2022

I can only assume you will do one side at a time, so if that the case install, a temporary support between the A, B,an C posts, these could be welded or of a clamp design, once installed, start the will removal

FlatbedPilot · May 2, 2022

There's a decent gap between the chassis rail and inner sill. I can measure and take a pic if you like. Plenty of room to work from the outside though if you remove the outer sill first. I took the body off before doing all this work but was advised by my panel supplier that the mounts should have been done before removing the body to ensure they line up properly. I got all the stuff I needed from Froggats and the guy I spoke to on the phone was very helpful with advice on how to fit them.

steve24v · May 2, 2022

DefenderPilot said:
There's a decent gap between the chassis rail and inner sill. I can measure and take a pic if you like. Plenty of room to work from the outside though if you remove the outer sill first. I took the body off before doing all this work but was advised by my panel supplier that the mounts should have been done before removing the body to ensure they line up properly. I got all the stuff I needed from Froggats and the guy I spoke to on the phone was very helpful with advice on how to fit them.

Thanks mate, thats what I needed to know. Plan is to fit the body back on, cut the the sill off and weld new one on. Then bolt the mounts on to chassis then weld to the sill

FlatbedPilot · May 2, 2022

Yeah, that's how I should have done it in the first place. It would have been a lot easier. Never mind, you live and learn.

Discovery 2 sill repair

steve24v

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Stanleysteamer

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steve24v

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FlatbedPilot

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steve24v

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frostythor

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FlatbedPilot

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steve24v

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FlatbedPilot

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