Disco 2 Feel Like I'm Losing The Battle

meego · Aug 10, 2018

Finally bit the bullet and got on with welding up the Disco today. Cut out the rot. Bit that was worrying me the most was where the loom goes through the bulkhead. The bottom of the opening was completely gone. I made this plate and welded it on. Still to do a bit of tidying up but happy with the result.

I also had a bit of rot in the footwell where the body mount is

I made up this plate and welded it in.

Just got the rest of the floor to weld up and then I will start on the inner wheel arch.
The floor is a bugger as it’s not flat and has more joints in it than a Junkies hoose.

meego · Aug 10, 2018

meego said:
Finally bit the bullet and got on with welding up the Disco today. Cut out the rot. Bit that was worrying me the most was where the loom goes through the bulkhead. The bottom of the opening was completely gone. I made this plate and welded it on. Still to do a bit of tidying up but happy with the result. View attachment 155329
I also had a bit of rot in the footwell where the body mount is
View attachment 155330
I made up this plate and welded it in.
View attachment 155331
View attachment 155332 View attachment 155333
Just got the rest of the floor to weld up and then I will start on the inner wheel arch.
The floor is a bugger as it’s not flat and has more joints in it than a Junkies hoose.

meego · Aug 10, 2018

Don’t know why that went up twice.

I also cut the flange off as it was easier to get in to clean up the rust and fully weld this corner up

I’ll need to fabricate a new piece and weld it on. I’ll need to remember and put the lugs on it that the plastic arch fastens to.

Colthebrummie · Aug 11, 2018

Some nice welding there, wish I could do it that well.

Col

andy85 · Aug 11, 2018

Nice job,it’s a pain that area

meego · Aug 11, 2018

Colthebrummie said:
Some nice welding there, wish I could do it that well.

Col

andy85 said:
Nice job,it’s a pain that area

Cheers guys. I'm not overly happy with the welding on the inside, but it was awkward as hell as I had wet towels stuffed everywhere to stop spatter hitting wires etc

meego · Aug 22, 2018

Feel like I’m winning the battle now. Got the floor complete and sound deadening down tonight

meego · Sep 15, 2018

Round 2 with the off side. Not as bad but bad enough.

And the side step needs some attention too

meego · Sep 27, 2018

Not getting much interest but I’ll keep it going anyway in case it helps someone down the line.Here’s a before and after on the drivers footwell repair.

iansoady · Sep 28, 2018

I'm interested (well slightly alarmed...) Looks like an excellent job you're doing.

meego · Sep 28, 2018

iansoady said:
I'm interested (well slightly alarmed...) Looks like an excellent job you're doing.

Cheers. Reason I am posting is to show that D2's are old and developing issues and to make owners on here aware of the possibility theirs might have the same. Some unseen and hidden like mine.

meego · Sep 28, 2018

Here’s the holes behind the offside rear wheel arch trim. These are due to the mild steel inner part touching the inside of the aluminium body.

That’s them ground back to good metal ready for repair. It will be hidden once the trim is back on.

Feathers McGraw · Sep 28, 2018

meego said:
Cheers. Reason I am posting is to show that D2's are old and developing issues and to make owners on here aware of the possibility theirs might have the same. Some unseen and hidden like mine.

But still fixable! Looking good

Royston 90 · Sep 28, 2018

Keep the good work up meego. I`m still doing bits to my disco 2 as & when I get time. I quite like looking at these threads. This weekend I`ll be welding the mounting up that the nearside rear sidestep attaches too. Luckily for me that is the only bit that needs welding that I have found. I even dropped the tank & treated all the inside of the chassis there too. I do have some corrosion on the nearside front wing at the corner & also on the front door next to it, that needs some preventative treatment. I have removed the lower plastic trim both sides and they only need a clean up underneath. After that I will need to put on the galvanized mud flaps.

meego · Sep 28, 2018

Feathers McGraw said:
But still fixable! Looking good

Exactly. Any other car and it would have been gone a long time ago. It's mechanically sound, and still drives great. I'm hoping for a good few years out of it yet.

Interceptorxj · Sep 28, 2018

Nice work, luckily had all the carpets out of mine at the begging of the year just in time to prevent any major fabrication. All kurusted , painted and waxoiled now with all sunroof and windscreen leaks fixed so hopefully good from inside for another few years.

Disco1BFG · Sep 28, 2018

I've done similar repairs to both our D1's - Keep telling yourself it is worth it, because it is ! If LR's original p*ss poor paint work got the original steel to last this long, then your repairs will last 30 years

And hopefully, so will ours!

Of course, modern "paint" ( I.E. Corrosion protection like Dinitrol / bilt hamber ) is far better, so I for one am hoping that I never have to do extensive welding again

IMHO, it's worth getting any vehicle this well looked after on agreed value insurance, because if the worst comes to the worst .... well you know what'll happen

meego · Sep 28, 2018

Royston 90 said:
Keep the good work up meego. I`m still doing bits to my disco 2 as & when I get time. I quite like looking at these threads. This weekend I`ll be welding the mounting up that the nearside rear sidestep attaches too. Luckily for me that is the only bit that needs welding that I have found. I even dropped the tank & treated all the inside of the chassis there too. I do have some corrosion on the nearside front wing at the corner & also on the front door next to it, that needs some preventative treatment. I have removed the lower plastic trim both sides and they only need a clean up underneath. After that I will need to put on the galvanized mud flaps.

Cheers. I’ve done quite a bit lately, so give me a shout if I can help with any advice on how I went about things. I’m not sayin it’s done the right way though...but it’s done

1988smithy · Sep 28, 2018

Very tidy work mate, keep it up you're winning now

Disco 2 Feel Like I'm Losing The Battle

meego

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