Disco 3 (LR3) Mot fail

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Found a picture of the sill construction

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What are they? some sort of plastic plugs? If said welder is going to need to get inside won't you need to get them out anyway?

Funny enough just found a picture of the sill construction, there rubber grommets

It just looks like the outer plate as either been bolted on or glued ?? , as can see the lip at the top where the red line is

I’ll do some further checking in case it can come off, as wonder if the sills have been covered with a plate in the past
 
Funny enough just found a picture of the sill construction, there rubber grommets

It just looks like the outer plate as either been bolted on or glued ?? , as can see the lip at the top where the red line is

I’ll do some further checking in case it can come off, as wonder if the sills have been covered with a plate in the past
Being relatively modern I daresay it could be glued. What a state of affairs. If you can't find any spot welds or bolts I guess it must be. Nowt to stop you drilling and plug welding it once you have taken it off.
 
Being relatively modern I daresay it could be glued. What a state of affairs. If you can't find any spot welds or bolts I guess it must be. Nowt to stop you drilling and plug welding it once you have taken it off.

Many thks as Ur right mate , it’s tack welded as can see them along the top, wonder if a dremel will zip through the welds ?

Have got a 2” disc cutter as well in case the dremel isn’t powerful enough

If it is to be the case of overlapping it I assume it become a water trap and simply allowed the sill behind to rust out as it has

Also can’t see any drain holes

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Many thks as Ur right mate , it’s tack welded as can see them along the top, wonder if a dremel will zip through the welds ?

Have got a 2” disc cutter as well in case the dremel isn’t powerful enough

If it is to be the case of overlapping it I assume it become a water trap and simply allowed the sill behind to rust out as it has

Also can’t see any drain holes

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I cannot see any evidence of seam sealer either. :(
 
I cannot see any evidence of seam sealer either. :(
Likewise mate , looks like they’ve tack welded it

Maybe there’s sealer behind but going to try and see if my dremel will zip through the top one,

Then will attempt to try and bend the plate down to snap the bottom tack welds off

As u say no sealer if u zoom into this picture

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If you can't get a mic on it directly, then measure a spacer, like a ball bearing then put that in with the thin sheet of steel. Measure both then do a "take away".
I've done that with bearing shells to prove to a Ford garage that their whole stock was undersize! 🤣

Many thks as that’s a good idea
 
Looking at this picture in more detail can see the outer sill plate, wraps round, I’m wondering on mine if they trimmed the top part off an original sill plate and tack welded it on over my original sills

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Hi mate bless you it is a bit of a mess, try cleaning areas you suspect there may be spot welds with blowtorch and wire brush they become more visible it's a case of removing available panels inner and outer sill? and cutting out rust from other affected areas, I do have a 06 I have been robbing of parts, could cut out anything you need body wise for your welder Foc
Can be posted, have posted motors before
Don't worry about brakes we can sort that for peanuts arms too mate
Just take it easy take your time speak to you soon
 
Hi mate bless you it is a bit of a mess, try cleaning areas you suspect there may be spot welds with blowtorch and wire brush they become more visible it's a case of removing available panels inner and outer sill? and cutting out rust from other affected areas, I do have a 06 I have been robbing of parts, could cut out anything you need body wise for your welder Foc
Can be posted, have posted motors before
Don't worry about brakes we can sort that for peanuts arms too mate
Just take it easy take your time speak to you soon

Many thks as always mate

Apart from the dremel have a larger 50mm disc cutter which also accepts flapper sanding discs , have the finger belt sander too

If they have cut the top off and just tacked welded over the original sills that will do me a favour as will allow a lot more access if they come off

That’s amazing , thk u so much as that may come in very useful ref the panels etc and very kind offer ref the brakes , talking of them , have 2 x rolls of 25’ kunifer plus fittings , a lot cheaper than the quoted £400 🤣,

Suppose if I can try and open it up the best I can it will allow the welder to at least then get a better look

Have an endoscope if needs be , as always just so grateful being able to chat about it and get great feedback

Will of course update as soon as I’m able to have a closer look

Thks again

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No problem mate, as said will find out what panels are made for D3 from local dealer
Going to break a 06 D3 so are welcome to any parts foc.
Dont hesitate to ask, will have a poke around underneath mine see if I can offer any ideas
Keep the faith mate all the best
 
No problem mate, as said will find out what panels are made for D3 from local dealer
Going to break a 06 D3 so are welcome to any parts foc.
Dont hesitate to ask, will have a poke around underneath mine see if I can offer any ideas
Keep the faith mate all the best

Bless u as that’s very handy to know mate along with parts being available and saving money along the way

Would of course give the interior part of the sills with a coat of dinitrol but that’s a long way off yet

Thk u as That’s also very handy with u breaking one as will be good to see if they’ve done the same on that outer sill panel as I compared it to a new one and indeed looks like they’ve cut the top off to save them having to plug weld

Need to get the full rear inner wheel arch liner out, shouldn’t be too bad seeing I’ve got to pull offf the wheel arch spats and then the inner liner

At the end of the day think the more I can strip off the better to allow a really good look , along with then being able to treat rust areas that are just surface , will just sand it off to see how far patches have gone

So think that file sander will come in very useful and these 50mm flapper discs as just got a grit mixture

Thks again and will of course update the thread as I get bits done
 

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Will need a continual weld Gary not spot welding you cannot glue new sills or metal on there.
One of my friends lives 10 mins from you and for the last 10 years been restoring classic ford's he was there metal guy doing all the welding and fabricating I can ask him if you want to take it on getting it repaired.
He has just this week changed career but I can ask him no harm asking.
 
Will need a continual weld Gary not spot welding you cannot glue new sills or metal on there.
One of my friends lives 10 mins from you and for the last 10 years been restoring classic ford's he was there metal guy doing all the welding and fabricating I can ask him if you want to take it on getting it repaired.
He has just this week changed career but I can ask him no harm asking.

Yes plse as would be good for such an expert to have a look

Will send u a pm mate and bless u as very grateful

Funny enough I did wonder that about the weld , seeing these tack welds makes me believe of them just putting a narrower sill plate on

Thks again mate
 
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