Discovery sill replacement, what's the rebuild order?

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mcmoonter

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'95 300tdi four door

I should rephrase the title. I've cut out the floor section just leaving what remains of the outer sill to maintain the door gaps. I bought some replacement inner and outer sills from GDI Products on ebay.

Before I do the final cuts I have a couple of questions. When I replace the sills do I weld the outer first to the body and then weld the inner to it. Or can I weld both the inner to the outer off the car then offer them up to the body.

It looks like I will have to drill a hole through the original floor to remove the rear inner body mount bolt. Is that the case?

Thanks in advance. Peter
 
outer then inner.
once nut is removed, bolt will normally move enough to remove it past bodywork, plenty of wd40 or similar. or cut bolt head off and remove from below.

dont forget closing piece at rear and floor supports at front.
 
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Thanks for that. I've wire brushed the threads and soaked them in WD40, hopefully by morning they'll be good to go.
 
dont forget - if yu are replacing the inner sill, the old one can be cut to buggery - yu wont need it again :). fitting the new inner sill is a bit fiddly to get it past the outriggers n bits, i had to rotate and slide mine forwards, rotate it back in line, then slide it back onto rear body mount. sounds complicated, but not too difficult when yu try it :).
 
mcmoonter said:
'95 300tdi four door

I should rephrase the title. I've cut out the floor section just leaving what remains of the outer sill to maintain the door gaps. I bought some replacement inner and outer sills from GDI Products on ebay.

Before I do the final cuts I have a couple of questions. When I replace the sills do I weld the outer first to the body and then weld the inner to it. Or can I weld both the inner to the outer off the car then offer them up to the body.

It looks like I will have to drill a hole through the original floor to remove the rear inner body mount bolt. Is that the case?

Thanks in advance. Peter
Click to expand...
Inner body mount, I dream of having an inner body mount :doh:
 

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No you don't have to drill a hole it is open enough above to get a spanner on it and a deep socket from beneath.

Better to test fit and weld on gusset and new body mounts then fit inner part then weld outer part on once on the car as width can be very variable by LR build specs and tolerances!!!

Did you brace your pillars sufficiently??? Speaking from the seat of a guy who spent a day undoing a mates balls up a couple of weeks ago it is well worth bracing OTT IMHO!!
 
I've now got all the cutting out done. I had to use the hole saw to get the rear sill mount bolt out. It will make it easier to put it back.
 
Progress report.

I welded in the outer sill first. I found it impossible to then fit the inner sill complete with the body mounts. I ended up drilling out the spot welds on the rear mount. It should be easier to put it in place and weld it up. My welding isn't especially pretty but it is strong.

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