Hello from Cornwall.. Disco project..

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Tigger said:
Can I suggest that you read this thread before you go any further:

http://www.landyzone.co.uk/lz/f8/discovery-rust-boot-sills-wings-161843.html
Click to expand...

Been reading that and getting inspiration from the guys :)..

Can anyone please tell me how I am to repair this (and other) inner panels..? They are paper thin..
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I am getting on well removing everything inside the disco and have cleaned and red oxide'd the rear chassis. There is a lot of work to all this, isn';t there.. I would never had started the project if I had not found this forum.. Big thank you to all you guys who stick up progress photos and videos.

This was how the back looked before I got the fuel tank out.. Will get some more shots soon..
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The Cornish Winter weather has meant I have not been able to get on with this as much as I would of liked, but here is an update..
The rear end of the car is coming on well now. I have welded (not pretty) new side strips in to take the boot floor. I have sorted out the rear chassis crossmember. I have welded in new rear body mounts, and patched up bit here and there..
I red oxided all the chassis and underneath, and painted on the black waxoyl paint.
I have sprayed waxoyl into every hole I could find in the chassis.

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When you're ready to get it MOT'd, take it to Simon at Barbican MOTs and tell him I sent you.
He understands Landys, cos he's my Son.
 
I got a bit more done on the Landy today. I finished off a bit more welding that needed doing and I got the rear part of the chassis, and the mounts etc completely painted up in chassis paint. I will be able to get the fuel tank in now, and put the boot floor in.

Here are some pics of some of the things I need to sort out still..
The sills need a lot of welding..
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Also the inner front wheel arches and headlight surrounds need a lot of attention
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I had a good result on a front bumper off ebay for £5.50, so I went and picked that up this evening. I need to find a rear bumper as I had to cut the old rotten one off..
 
JonnyP,

Great thread and thanks for adding another project to the forum. Whilst I like reading some of the questions, most can be answered by the pee themselves if they search and google. To get interesting threads of people getting stuck into stuff outside of their comfort zones is inspiring.

Firstly I feel your pain. Working outside is an absolute nightmare this time of year. All mine was done on a gravel driveway so I didn't even have concrete and a level surface. Moan moan moan (yeah and me and me brovers had to take it in turn to go to school cos we only had one pair of shoes between the three of us).

Anyhow all is not lost because you look like you're doing well. The boot floor sides are coming along nicely mate. Just one step at a time. I found that starting at one corner of the car and the slowly moving around was the best way for me. That way I didn't immediately end up with a stripped shell and a view of a whole mountain of work.

I started at the drivers door sill area and then slowly moved around and finished at the front. When I got down and disappointed I just looked at what I had done and it cheered me on.

Always go back to clean metal. Many stories on here state that the owner started with a small hole and then ended up with it the size of a football. This is because you just have to get rid of the crap. There is no point trying to weld to rust and pitted steel.

Keep the photos coming. People like these and the interest will keep you inspired as people offer advice.

Good luck
 
Thanks GH :0)
We have a few buildings here where I might be able to get some of the car under cover (when the fuel tank goes back), but its mostly around wood stacks and I cannot risk welding and grinding sparks setting it all on fire.. I might get me a big tarp and rig up a shelter, but the wind we have had lately has put me off that idea a bit..
Thanks for the advice.. I am out of my comfort zone with much of the work, but its getting easier as I progress and gain confidence.. My welding is still crap though.. :eek:
 
Got a good day in on the landy today. I got the rear inner side panels all welded up which took me most of the day. And I got the fuel tank back in and all connected up..

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Got the new boot floor in..

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I used roof n gutter sealant between the floor and the supports and pop riveted the floor down.
I waxed up the under side of the floor before it went in.

The rear end of the car is almost complete now.
 
Got some more done today.. I cut out sections of the floor soundproofing for access and treated up and primed both footwells.
The sound proofing holds moisture and if it ever gets wet again I don't want the floor rotting, so I am going to get a few layers of paint on there and wax it up. The under side of the floor all seems ok, so it seems to prove its the wet soundproofing that causes the rust.
I also made a start on both sills. I cut out all the old rot and treated any rust with krust and primed it all with red oxide. I am going to use 100x60mm box section and weld it in place.

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Got to say, I am loving doing this old Disco up. I am so out of my comfort zone on a lot of the work and the thoughts of what needs to be done, but its all a doddle really (so far).
I never would of started it if I had not seen threads by others doing up Disco's on this site..
 
I had to put on a new wheel stud as the previous owners had a little accident.. Their mechanic started taking off the n/s front wheel to do some work. Then he realised he was on the wrong side and put the wheel back on, but he only put back one wheel nut. The Landy got taken away and a few days later the wheel came off while they were driving round a bend. It had snapped the stud and knackered up the wheel.
I had to take off the hub to get the new stud in, which was a bigger job than I thought it would be. I had bought me a special socket for undoing the inner nut, but found it was loose and easy to undo anyway.

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While I am waiting for the sills I carried on rust treating and making up patches to weld on over the holes. Any holes are given a rust treatment and then red oxided. The patches are being red oxided too. When I am ready to weld, I pencil mark around where the patch goes and then grind back to bare metal where the weld will go. This way most of the metal inside the patch will be red oxided. I will also be painting over the red oxide with under seal too..

New wheel stud on, and rust treatment done around the n/s front..
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The more you look, the more you find.. This car really should of been scrapped. I keep finding more work to do..

This was what I found underneath the battery..
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And behind the front light..
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Underneath the air filter..
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And an MOT fail with rust 30 cm away from the brake master cylinder..
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I took the o/s front wing off today and found some more holes and a load of dirt..
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I also got the n/s front arch welded up.. I took the photo from back a bit, so my welding doesn't show up too much.. Its holding ok, but its not pretty.. I cannot seem to weld in a straight line..
009-1.jpg
 
Just to the right of the headlight in this pic, is a body mount. You can see all the rust and holes around it.
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This is another MoT fail, so I started work on this today..
I had the sheet metal to do the sides, but I had trouble finding something thick enough to do the base of the mount. I eventually found an old RSJ off cut, so I cut that up. I don't know how I am going to drill the holes needed in it yet. One is a big 30mm ish hole. I have some hole cutters, but I dont think they will do steel this thick..
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I had to bend the sheet steel sides, so I did this by holding the steel over the open jaws of an old vice, and wacking it with a bolster.. Like this..
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It will go together like this, with the sides being welded in place..
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I am not too sure how I am going to get on welding the thin sheet to the thick base.. Any advice..?
 
I got on well today.. I welded up the front body mount supports and got one of them fitted in..
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I got both sills welded up.. This took most of the day..
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I had got all the dash back in last week too..
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And the n/s front wing can now go back on.
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Its all starting to come together..
 
looking good comeing along v nice i cant weld stright does my head in no matter what i try i end up going off a bit keep up the good work and the up dates :D
 
keiron said:
looking good comeing along v nice i cant weld stright does my head in no matter what i try i end up going off a bit keep up the good work and the up dates :D
Click to expand...

Cheers chap.. I am getting on better by welding in short bursts now, so I can keep an eye on what I am doing more often. The visor I have is a solar one, so the visibility is good when you stop welding.
 
Not posted any updates for a while, but I have been busy on the disco..
The second hand 300tdi bumper had to be washed, de-rusted, primed and painted, but I am happy with the result..
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All the welding has been done now (at last). All the exterior panels are back on (but need tidying) except the sill trims. I still have a load of interior panels to put back, plus seat belts.
I found that the heavy duty tubular front bumper from a 300tdi, that I won on ebay and spent ages doing up, does not fit my 200tdi without hacking off a lot off the front end of my car, so I ended up putting all the old bumper back on.
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I won a set of steel rims and ok ish tyres on ebay for £3.20 (result), and I will be doing them up and sticking them on, as my alloys are two different types.
Gonna just concentrate on getting the car on the road for now, and work on the small stuff as and when.
 
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